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TROUBLESHOOTING

9-1

EAS20090

TROUBLESHOOTING

EAS30599

GENERAL INFORMATION

TIP

The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic trouble-
shooting. Refer to the relative procedure in this
manual for checks, adjustments, and replace-
ment of parts.

EAS31258

STARTING FAILURE/HARD STARTING

Engine

1. Cylinder and cylinder head

• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve

2. Piston and piston ring(s)

• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston

3. Air filter

• Improperly installed air filter
• Clogged air filter element

4. Crankcase and crankshaft

• Improperly assembled crankcase
• Seized crankshaft

Fuel system

1. Fuel tank

• Empty fuel tank
• Clogged fuel tank cap breather hole
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose

2. Fuel pump

• Faulty fuel pump
• Clogged fuel pump filter

3. Throttle body

• Deteriorated or contaminated fuel
• Sucked-in air

Electrical system

1. Battery

• Discharged battery
• Faulty battery

2. Fuse(s)

• Blown, damaged or incorrect fuse
• Improperly installed fuse

3. Spark plug

• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap

4. Ignition coil

• Cracked or broken ignition coil body
• Broken or shorted primary or secondary coils
• Faulty spark plug lead

5. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key

6. Switches and wiring

• Faulty main switch
• Broken or shorted wiring
• Faulty front, rear or both brake light switches
• Faulty start switch
• Faulty sidestand switch
• Improperly grounded circuit
• Loose connections

7. Starting system

• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch

EAS30601

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder and cylinder head

• Incorrect valve clearance
• Damaged valve train components

2. Air filter

• Clogged air filter element

Fuel system

1. Throttle body

• Damaged or loose throttle body joint
• Faulty ISC (idle speed control) valve
• Improper throttle grip free play

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Содержание MBK MW125 2014

Страница 1: ...SERVICE MANUAL MW125 2014 MW125F 2015 2CM F8197 E0...

Страница 2: ...W125F 2015 SERVICE MANUAL 2014 by Thai Yamaha Motor Co Ltd First edition May 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Thai Yamaha Motor Co Ltd is...

Страница 3: ...g nificant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable TIP Designs and specifi...

Страница 4: ...int than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the...

Страница 5: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Страница 6: ......

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

Страница 8: ......

Страница 9: ...1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARI...

Страница 10: ...EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS30003 MODEL LABEL The model label 1 is affixed to the inside of the stor...

Страница 11: ...ns of the en gine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tune...

Страница 12: ...ration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air p...

Страница 13: ...he battery charged by a Yamaha dealer Speedometer The speedometer shows the vehicle s traveling speed Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of th...

Страница 14: ...DO the tripme ter modes TRIP 1 and TRIP 2 the oil change tripmeter mode OIL TRIP and the V belt re placement tripmeter mode BELT TRIP in the following order ODO TRIP 1 TRIP 2 OIL TRIP BELT TRIP ODO Wh...

Страница 15: ...km 600 mi the next periodic oil change interval will be at every 4000 km 2500 mi thereafter V belt replacement indicator V BELT This indicator come on at every 20000 km 12500 mi to indicate that the...

Страница 16: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Страница 17: ...air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after on...

Страница 18: ...ener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the faste...

Страница 19: ...a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Re...

Страница 20: ...5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never i...

Страница 21: ...refore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely an...

Страница 22: ...k Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be s...

Страница 23: ...er to the list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration...

Страница 24: ...90890 01275 Bolt YU 90060 5 65 5 66 Adapter M12 90890 01278 Adapter 3 YU 90063 5 65 5 66 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 29 Tappet adjusting tool 90890 01311 Six piece t...

Страница 25: ...3 8 drive 60 cm long YM 01326 4 71 4 72 Clutch spring holder 90890 01337 Universal clutch compressor holder YM 33285 5 39 5 42 Locknut wrench 90890 01348 Locknut wrench YM 01348 5 39 5 43 Radiator ca...

Страница 26: ...0 01372 Replacement 38 mm YM A5142 1 4 73 Oil seal guide 90890 01384 Oil seal guide YM 33299 5 42 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 16 3 17 4 85 Sheave holder 90890...

Страница 27: ...re adapter 90890 03181 Fuel pressure adapter YM 03181 7 3 Compression gauge extension S 90890 03195 5 1 Yamaha diagnostic tool 90890 03231 3 7 3 8 7 11 7 11 7 11 7 12 8 29 Test harness lean angle sens...

Страница 28: ...guide reamer 5 0 mm YM 04099 5 23 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 22 5 27 Mechanical seal installer 90890 04145 6 9 Crankshaft installer...

Страница 29: ...NING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 LUBRICATION SYSTE...

Страница 30: ...2CM5 GBR 2CM7 AUS NZL Dimensions Overall length 1905 mm 75 0 in Overall width 735 mm 28 9 in Overall height 1215 mm 47 8 in Seat height 780 mm 30 7 in Wheelbase 1310 mm 51 6 in Ground clearance 120 mm...

Страница 31: ...50 Recommended engine oil grade API service SG type or higher JASO standard MA or MB Engine oil quantity Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Periodic oil change 0 80 L 0 85 US qt 0 70...

Страница 32: ...mm 0 0032 in Valve valve seat valve guide Valve clearance cold Intake 0 08 0 12 mm 0 0032 0 0047 in Exhaust 0 16 0 20 mm 0 0063 0 0079 in Valve dimensions Valve head diameter intake 25 90 26 10 mm 1 0...

Страница 33: ...31 0 048 mm 0 0012 0 0019 in Diameter 52 362 52 385 mm 2 0615 2 0624 in Measuring point from piston skirt bottom 7 0 mm 0 28 in Piston pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in Limit...

Страница 34: ...on ratio 1 000 Secondary reduction ratio 9 533 44 15 x 39 12 Gear ratio 2 361 0 794 1 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Air filter Air filter element O...

Страница 35: ...04 in Lateral wheel runout limit 0 5 mm 0 02 in Front tire Type Tubeless Size 90 80 14M C 43P Manufacturer model CHENG SHIN M6231 Wear limit front 1 5 mm 0 06 in AUS NZL 1 6 mm 0 06 in CYP FIN GBR GRC...

Страница 36: ...0 28 in Limit 1 5 mm 0 06 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Specified brake fluid YAMAHA GENUINE BRAKE FLUID DOT 4 Steering Steering...

Страница 37: ...pe Coil spring oil damper Rear shock absorber assembly travel 97 0 mm 3 82 in Spring free length 209 6 mm 8 25 in CYP FIN GBR GRC IRL POL SVK SVN TUR Spring installed length 199 6 mm 7 86 in Spring ra...

Страница 38: ...coil resistance 0 400 0 600 W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 0 15 0 V Battery Model YTZ7V Voltage capacity 12 V 6 0 Ah Manufacturer YUASA Hea...

Страница 39: ...83 in Mica undercut depth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal relay Relay type Condenser Built...

Страница 40: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Страница 41: ...lbf Coolant reservoir nut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Radiator cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Radiator bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M12 1 2 5 Nm 0 25 m kgf 1...

Страница 42: ...m kgf 7 2 ft lbf Cylinder head stud bolt M8 2 15 Nm 1 5 m kgf 11 ft lbf Cylinder head plug M12 1 28 Nm 2 8 m kgf 20 ft lbf Oil check bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Spark plug M10 1 13 Nm 1 3 m k...

Страница 43: ...TIGHTENING TORQUES 2 14 Cylinder head tightening sequence Radiator fan case tightening sequence 6 5 2 3 4 1 1 3 5 4 1 2...

Страница 44: ...1 ft lbf Rear fender screw M5 4 1 5 Nm 0 15 m kgf 1 1 ft lbf Tail brake light assembly bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear reflector screw M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Wire harness holder...

Страница 45: ...7 m kgf 5 1 ft lbf Handlebar switch screw right side M5 2 2 4 Nm 0 24 m kgf 1 7 ft lbf Handlebar switch screw left side M5 2 2 4 Nm 0 24 m kgf 1 7 ft lbf Front brake master cylinder holder bolt M6 2...

Страница 46: ...cket bolt M6 6 13 Nm 1 3 m kgf 9 4 ft lbf Front fender bracket screw M4 4 1 0 Nm 0 10 m kgf 0 72 ft lbf Front brake hose holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Front fork leg bolt M10 4 50 Nm 5 0...

Страница 47: ...heel axle nut 1 2 Temporarily install the swingarm mounting bolt upper side 2 then the swingarm mounting bolt lower side 3 3 Tighten the rear wheel axle nut to 125 Nm 12 5 m kgf 90 ft lbf 4 Tighten th...

Страница 48: ...nd Piston piston rings and cylinder inner surface O rings crankshaft assembly bearing Oil pump drive gear Cam chain sprocket Oil pump driven gear shaft O rings fuel injector Starter clutch one way pin...

Страница 49: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 20...

Страница 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 7 6 5 4 3 2 1...

Страница 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Oil nozzle 5 Camshaft 6 Valve stem end 7 Rocker arm...

Страница 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS30021 LUBRICATION DIAGRAMS 1 3 2...

Страница 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Oil strainer 2 Oil pump assembly 3 Camshaft...

Страница 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 2 3 4 5 1...

Страница 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Camshaft 5 Rocker arm Valve stem end...

Страница 56: ...COOLING SYSTEM DIAGRAMS 2 27 EAS20020 COOLING SYSTEM DIAGRAMS 1 2 4 3 5 6 9 8 3 4 5 7...

Страница 57: ...DIAGRAMS 2 28 1 Radiator cap 2 Coolant reservoir hose 3 Cooling system air bleed hose 4 Radiator inlet hose 5 Radiator outlet hose 6 Radiator 7 Water pump assembly 8 Water pump outlet hose 9 Water pu...

Страница 58: ...CABLE ROUTING 2 29 EAS20021 CABLE ROUTING Handlebar front and rear view A C B 11 1 2 2 4 4 7 10 10 1 1 10 8 9 5 6 5 6 10 8 9 1 2 3 4 7...

Страница 59: ...6 Left handlebar switch lead 7 Wire harness 8 Right handlebar switch lead 9 Front brake light switch lead 10 Throttle cable decelerator cable 11 Wire harness strap A Make sure that the wire harness st...

Страница 60: ...CABLE ROUTING 2 31 Steering head left side view A A A A 1 2 2 2 1 1 2 1 2 1 2 B...

Страница 61: ...d sensor lead 2 Front brake hose A Fasten the speed sensor lead to the front brake hose with the holder Align the holder with the white paint marks on the speed sensor lead and front brake hose B Inne...

Страница 62: ...CABLE ROUTING 2 33 Front wheel left side view 1 2 1 1 1...

Страница 63: ...CABLE ROUTING 2 34 1 Speed sensor lead 2 Front brake hose...

Страница 64: ...CABLE ROUTING 2 35 Throttle body and rear wheel left and right side view 2 2 1 1 A B A C D D E E F G H D E 3...

Страница 65: ...white paint mark on the cylinder head breather hose C Install the breather hose throttle body to cylinder with its yellow paint mark facing upward D Point the ends of the hose clamp in the direction...

Страница 66: ...CABLE ROUTING 2 37 Front frame right side view...

Страница 67: ...Sidestand switch lead 4 Main switch lead 5 Throttle cable accelerator cable 6 Throttle cable decelerator cable 7 Horn receiver unit lead 8 Seat lock cable A Connect the horn connectors to the horn ma...

Страница 68: ...CABLE ROUTING 2 39 Rear frame right side view 1 2 3 4 5 5 5 6 7 8 8 9 10 11 12 13 A 8 8 8 14 15 15 15 16 17 19 18 23 22 18 17 15 24 19 B K J 21 8 15 H G I 8 8 5 5 15 15 20 F 11 E D C...

Страница 69: ...gative battery lead with the plastic band B Fasten the crankshaft position sensor stator coil assembly lead with the holder on the air filter case joint C When fastening the wire harness and leads wit...

Страница 70: ...CABLE ROUTING 2 41 Front frame left side view 1 2 3 4 5 6 7 8 9 10 A 4 7 5 6 11 13 12...

Страница 71: ...ake hose 4 Rear brake hose 5 Throttle cable decelerator cable 6 Throttle cable accelerator cable 7 Seat lock cable 8 Sidestand switch lead 9 Headlight coupler 10 Front turn signal light coupler 11 Aux...

Страница 72: ...CABLE ROUTING 2 43 Rear frame left side view 7 8 7 6 5 9 10 11 12 13 14 15 16 18 17 1 2 3 4 5 6 7 B G I H A 13 19 20 14 5 D C E F...

Страница 73: ...ed between the storage box and the frame B Align the white tape on the seat lock cable with the center of the holder C Route the throttle cable decelerator cable which is identified by white tape on t...

Страница 74: ...CABLE ROUTING 2 45 Front frame top view 1 2 3 4 2 3 4 5 6 12 10 11 13 7 8 8 9 A 2 3 5 4 6...

Страница 75: ...ignal light lead 6 Wire harness 7 Seat lock cable 8 Rear brake hose 9 Sidestand switch lead 10 Throttle cable accelerator cable 11 Throttle cable decelerator cable 12 Front left turn signal light lead...

Страница 76: ...CABLE ROUTING 2 47 Rear frame top view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A B...

Страница 77: ...regulator lead 9 Rear right turn signal light lead 10 Tail brake light lead 11 Rear left turn signal light lead 12 Seat lock cable 13 Fuel hose 14 Fuse box A Route the rectifier regulator lead and fr...

Страница 78: ...CABLE ROUTING 2 49...

Страница 79: ...CHECKING THE REAR BRAKE HOSE 3 11 CHECKING THE BRAKE FLUID LEVEL 3 11 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 12 CHECKING THE WHEELS 3 13 CHECKING THE TIRES 3 14 CHECKING THE WHEEL BEARINGS 3 15 CHECKI...

Страница 80: ...CHECKING THE THROTTLE GRIP OPERATION 3 24 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 24 ADJUSTING THE HEADLIGHT BEAM 3 25 REPLACING THE HEADLIGHT BULB 3 25...

Страница 81: ......

Страница 82: ...The annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 20000 km 12000 mi repeat the maintenance inte...

Страница 83: ...screws are properly tight ened Every 12000 km 7200 mi 14 Front brake lever pivot shaft Lubricate with silicone grease 15 Rear brake lever pivot shaft Lubricate with silicone grease 16 Unified brake sy...

Страница 84: ...calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers...

Страница 85: ...well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replac...

Страница 86: ...ttle cable guide Spark plug cap Spark plug 2 Cylinder head cover 3 Cylinder head cover gasket 3 Remove Radiator cover 1 4 Move Radiator 1 TIP Move the rear of the radiator outward 5 Measure Valve clea...

Страница 87: ...ylinder head cover gasket Cylinder head cover Spark plug Spark plug cap Cylinder head breather hose 10 Install Center side covers Storage box Center cover Refer to GENERAL CHASSIS 1 on page 4 1 GENERA...

Страница 88: ...t it warm up for several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the ISC idle s...

Страница 89: ...ool For more information refer to the opera tion manual of the Yamaha diagnostic tool 1 Connect the Yamaha diagnostic tool to the connector For information about connecting the Yamaha diagnostic tool...

Страница 90: ...air filter element into the air filter case make sure that the sealing surfaces are aligned to prevent any air leaks EAS31181 CLEANING THE V BELT CASE AIR FILTER ELEMENT TIP Check the V belt case air...

Страница 91: ...633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves a almost disap peared Replace the brake pa...

Страница 92: ...hose 1 Cracks damage wear Replace 2 Check Brake hose holder Loose Tighten the holder bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Repla...

Страница 93: ...to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake syste...

Страница 94: ...imes h Fully pull the brake lever and hold it in posi tion i Loosen the bleed screw TIP Loosening the bleed screw will release the pres sure and cause the brake lever to contact the handlebar grip j T...

Страница 95: ...the tire immediately 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury...

Страница 96: ...ECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEELS on page 4 28 and CHECKING THE REAR WHEEL on page 4 33 E...

Страница 97: ...directions If any bind ing is felt remove the steering column or lower brackets and check the upper and low er bearings Refer to STEERING HEAD on page 4 81 Refer to FRONT ARMS AND LOWER BRACKETS on p...

Страница 98: ...LINK ARM BEARINGS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Elevate Front wheels Refer to REMOVING THE FRONT...

Страница 99: ...ment Repair Refer to FRONT FORKS on page 4 65 EAS30654 CHECKING THE REAR SUSPENSION 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of i...

Страница 100: ...engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Dipstick 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil co...

Страница 101: ...ange indicator Refer to INSTRUMENT FUNCTIONS on page 1 4 EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is up...

Страница 102: ...ant reservoir hose 1 2 Drain Coolant from the coolant reservoir 3 Remove Radiator cover 1 4 Remove Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator...

Страница 103: ...0 Bleed Air bleed a Tighten the radiator cap start the engine and warm it up for several minutes b Touch the radiator inlet hose and make sure that it is warm make sure the thermostat is opened c Rev...

Страница 104: ...and second ary pulleys Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 TIP Replace the V belt every 20000 km 12500 mi of operation 3 Install V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on...

Страница 105: ...peed should be adjusted properly a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighte...

Страница 106: ...il it has cooled down 4 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from o...

Страница 107: ...BLY COVER 4 10 REMOVING THE UPPER LEG SHIELD 4 11 INSTALLING THE UPPER LEG SHIELD 4 11 GENERAL CHASSIS 6 4 12 REMOVING THE UPPER HANDLEBAR COVER 4 13 INSTALLING THE UPPER HANDLBAR COVER 4 13 GENERAL C...

Страница 108: ...41 REMOVING THE FRONT BRAKE CALIPERS 4 42 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 42 CHECKING THE FRONT BRAKE CALIPERS 4 42 ASSEMBLING THE FRONT BRAKE CALIPERS 4 43 INSTALLING THE FRONT BRAKE CALIPER...

Страница 109: ...LOWER BRACKETS 4 79 CHECKING THE FRONT ARMS TIE ROD AND LOWER BRACKETS 4 79 INSTALLING THE LOWER BRACKETS 4 79 INSTALLING THE FRONT ARMS 4 79 STEERING HEAD 4 81 REMOVING THE STEERING COLUMN 4 85 CHECK...

Страница 110: ...CHASSIS 1 Removing the battery and seat Order Job Parts to remove Q ty Remarks 1 Center cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Seat 1 1 5 Nm 0...

Страница 111: ...er side covers and rear side cov ers e Slide the center cover forward and remove it EAS31190 INSTALLING THE CENTER COVER 1 Install Center cover a Close the seat b Slide the center cover rearward and i...

Страница 112: ...to remove Q ty Remarks 1 Fuse box cover 1 2 Fuse box 1 3 Starter relay coupler 1 Disconnect 4 Starter relay 1 5 Fuel tank overflow hose 1 6 Storage box 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf...

Страница 113: ...rom the projections on the stor age box b Unhook the slots in the fuse box cover from the projections on the storage box EAS31261 INSTALLING THE FUSE BOX COVER 1 Install Fuse box cover a Fit the slots...

Страница 114: ...at Storage box Refer to Removing the storage box 1 Rear cover 1 2 Grab bar bracket rear side 1 3 Grab bar bracket front side 1 4 Grab bar 2 5 Rear side cover 2 6 Center side cover 2 1 5 Nm 0 15 m kgf...

Страница 115: ...AS31264 REMOVING THE SIDE COVERS The following procedure applies to both of the side covers 1 Remove Side cover a Remove the screws and quick fastener screws b Unhook the projections on the side cover...

Страница 116: ...l brake light assembly b Fit the projections on the side cover into the slots in the rear fender c Install the screws and quick fastener screws T R Rear side cover screw front side 7 Nm 0 7 m kgf 5 1...

Страница 117: ...Removing the side covers 1 Tail brake light coupler 1 Disconnect 2 Rear turn signal light coupler 1 Disconnect 3 Tail brake light assembly 1 4 Rear reflector 1 5 Rear fender 1 6 Flap 1 10 Nm 1 0 m kg...

Страница 118: ...2 Windshield bracket 2 3 Front upper panel 1 4 Meter assembly cover 1 5 Meter assembly coupler 1 Disconnect 6 Meter assembly 1 7 Upper leg shield 1 2 1 3 4 4 4 5 6 4 7 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R...

Страница 119: ...PANEL 1 Install Front upper panel a Push the front upper panel rearward to fit the projection into the grommet in the headlight unit b Fit the projections on the front upper panel into the slots in t...

Страница 120: ...1 Remove Upper leg shield a Pull the upper leg shield rearward to unhook the projections from the slots in the lower leg shield EAS31271 INSTALLING THE UPPER LEG SHIELD 1 Install Upper leg shield a Fi...

Страница 121: ...ve Q ty Remarks Upper leg shield Refer to Removing the meter assembly 1 Rearview mirror 2 TIP The rearview mirror right side has left hand threads 2 Upper handlebar cover 1 3 Lower handlebar cover 1 1...

Страница 122: ...ctions on the upper handle bar cover from the slots in the lower handle bar cover EAS31273 INSTALLING THE UPPER HANDLBAR COVER 1 Install Upper handlebar cover a Fit the projections on the upper handle...

Страница 123: ...Lower leg shield cover 2 3 Headlight coupler 1 Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Front turn signal light coupler 1 Disconnect 6 Front cowling assembly 1 7 Lower leg shield 1 12 1 3 5...

Страница 124: ...into the slots in the front side panels and front cowling assembly b Install the screws EAS31276 REMOVING THE LOWER LEG SHIELD COVERS The following procedure applies to both of the lower leg shield co...

Страница 125: ...orward to re move the grommets from the projections on the windshield bracket EAS31279 INSTALLING THE FRONT COWLING ASSEMBLY 1 Install Front cowling assembly a Fit the grommets in the front cowling as...

Страница 126: ...ard and remove it EAS31281 INSTALLING THE LOWER LEG SHIELD 1 Install Lower leg shield a Slide the lower leg shield downward and in stall it b Install the screws T R Lower leg shield screw center 4 0 N...

Страница 127: ...ignal light bulb 2 6 Headlight bracket 2 7 Side cowling 2 8 Front side panel 2 9 Turn signal light 2 10 Headlight coupler 1 Disconnect 11 Headlight bulb cover 1 12 Headlight bulb 1 13 Headlight unit 1...

Страница 128: ...dure applies to both of the front center panels 1 Install Front center panel a Fit the projections on the front center panel into the slots in the side cowling EAS31284 REMOVING THE FRONT SIDE PANELS...

Страница 129: ...GENERAL CHASSIS 8 4 20 a Fit the projections on the front side panel into the slots in the side cowling...

Страница 130: ...om cover 2 2 Front cowling upper inner panel 2 3 Front cowling lower inner panel 1 4 Footrest board 1 5 Footrest board bracket 2 New New 4 4 3 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1...

Страница 131: ...ottom cover from the grommet in the front cowling lower inner pan el EAS31287 INSTALLING THE BOTTOM COVERS The following procedure applies to both of the bottom covers 1 Install Bottom cover a Fit the...

Страница 132: ...cover Air filter case duct Air filter case duct cover 1 1 1 2 Air filter element 1 3 Cylinder head breather hose 1 Disconnect 4 Air filter case joint clamp screw 1 Loosen 5 Air filter case Air filter...

Страница 133: ...ction a on the air filter case joint between the projections b on the air filter case 2 Install Air filter case joint clamp 1 to the air filter case joint 2 TIP Align the projection a on the air filte...

Страница 134: ...and so that the front wheel is elevated 1 Mudguard 1 2 Speed sensor 1 Right side only 3 Speed sensor lead guide 1 Right side only 4 Front brake caliper 1 5 Wheel cap 1 6 Clip 1 7 Front wheel axle nut...

Страница 135: ...1 Right side 11 Collar 1 Left side 12 Speed sensor rotor 1 Right side only 13 Front brake disc 1 14 Fitting plate 1 15 Front wheel assembly 1 LS New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 f...

Страница 136: ...sassembling the front wheels Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front wheels 1 Oil seal 2 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 New New New...

Страница 137: ...of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings...

Страница 138: ...n powder dust solvent Clean TIP The speed sensor rotor is installed on the inner side of the wheel hub When cleaning the speed sensor rotor be careful not to damage the surface of the rotor EAS30151 A...

Страница 139: ...that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to...

Страница 140: ...or with the stamped mark a facing away from the wheel Install the brake disc with the stamped mark b facing toward the wheel Tighten the bolts in stages 2 Check Front brake disc Refer to CHECKING THE...

Страница 141: ...he rear wheel and brake disc Order Job Parts to remove Q ty Remarks Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 88 1 Rear wheel 1 2 Washer 1 3 Rear brake disc 1 LT LT LT L...

Страница 142: ...TIRES on page 3 14 and CHECKING THE WHEELS on page 3 13 2 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEELS on page 4 28 EAS30165 INSTALLING THE REAR WHEEL REAR BRAK...

Страница 143: ...ing procedure applies to both of the front brake calipers 1 Front brake caliper bolt 2 2 Speed sensor lead guide 1 Right side only 3 Front brake caliper 1 4 Brake pad pin 1 5 Front brake pad 2 6 Brake...

Страница 144: ...ylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever cover 1 5 Front brake light switch connector 2 Disconnec...

Страница 145: ...ring 1 12 Front brake lever knocker 1 13 Brake lever cable joint 1 14 Brake hose union bolt 1 15 Copper washer 2 16 Front brake hose 1 17 Front brake master cylinder holder 1 18 Front brake master cyl...

Страница 146: ...FRONT BRAKE 4 37 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 New BF 1 BF S 2 S...

Страница 147: ...front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Speed s...

Страница 148: ...rake pad pin 1 2 Front brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 1 6 Brake caliper piston dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 9 Brake cali...

Страница 149: ...er to FRONT WHEELS on page 4 25 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle o...

Страница 150: ...an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad spring and new brake pads TIP Ins...

Страница 151: ...aliper piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper...

Страница 152: ...brake caliper piston dust seals and brake caliper piston seals EAS30175 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper...

Страница 153: ...DING THE HYDRAULIC BRAKE SYSTEM on page 3 12 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 EAS30179 REMOVING TH...

Страница 154: ...tial to in sure safe vehicle operation NOTICE ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown TIP Turn the handlebar t...

Страница 155: ...nt of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 6 Bleed Brake sys...

Страница 156: ...1 2 Rear brake caliper bolt 2 3 Rear brake caliper 1 4 Brake pad pin cap 1 5 Brake pad pin 1 6 Rear brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 5 Nm 0 25 m...

Страница 157: ...Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever cover 1 5 Rear brake light switch connector...

Страница 158: ...ds 10 Rear brake lever 1 11 Rear brake lever knocker 1 12 Brake hose union bolt 1 13 Copper washer 2 14 Rear brake hose 1 15 Rear brake master cylinder holder 1 16 Rear brake master cylinder 1 1 0 Nm...

Страница 159: ...REAR BRAKE 4 50 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 New 1 2 S BF S BF...

Страница 160: ...fer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Rear brake hose holder 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Rear brake hose 1 5 Rear brake caliper bolt 2 6 Rear brake caliper 1 10...

Страница 161: ...5 Brake pad support 1 6 Brake caliper bracket 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 11 Brake caliper body 1 2 5 Nm 0 25 m kgf 1...

Страница 162: ...ake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 40 4 Measure...

Страница 163: ...mum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Ref...

Страница 164: ...on Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obs...

Страница 165: ...Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may r...

Страница 166: ...ster cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap Brake master cylinder reservoir...

Страница 167: ...r over the end of the bolt b 5 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may c...

Страница 168: ...ake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 8 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SY...

Страница 169: ...brake master cylinder holder 1 5 Front brake master cylinder 1 6 Right handlebar switch coupler 1 Disconnect 7 Right handlebar switch 1 8 Throttle cable 2 Disconnect 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 7...

Страница 170: ...ler 1 Disconnect 15 Rear brake light switch coupler 1 Disconnect 16 Left handlebar switch 1 17 Handlebar grip 1 18 Brake hose holder 2 19 Handlebar bolt nut 1 1 20 Handlebar 1 2 0 Nm 0 20 m kgf 1 4 ft...

Страница 171: ...TALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar TIP Align the slots a in th...

Страница 172: ...ower bolt 6 Install Throttle grip 1 Throttle cables 2 Right handlebar switch 3 TIP Lubricate the end of the throttle cables and the inside of the throttle grip with a thin coat of lith ium soap based...

Страница 173: ...to CHECKING THE THROTTLE GRIP OPERATION on page 3 24 9 Adjust Rear brake lever free play Refer to ADJUSTING THE REAR BRAKE LEVER FREE PLAY on page 3 10 Throttle grip free play 3 0 7 0 mm 0 12 0 28 in...

Страница 174: ...eft front fender side 2 Front brake hose speed sensor lead holder 1 Right front fender side 3 Front arm cover 1 4 Front fender 1 5 Front fender panel 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 3 Nm 0 13 m kgf...

Страница 175: ...essary to replace the outer tubes 8 Cap bolt 2 Loosen 9 Lower bracket pinch bolt 4 10 Front fork leg 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T...

Страница 176: ...to both of the front fork legs 1 Front fork leg bolt 2 NOTICE ECA21660 Do not remove the front fork leg bolts un less it is necessary to replace the outer tubes 2 Dowel pin 1 3 Front fork cap bolt 2...

Страница 177: ...ont fork damper rod bolt 1 Main tube side only 9 Front fork outer tube bolt 1 Guide tube side only 10 Copper washer 2 11 Damper rod 1 Main tube side only 12 Damper rod ring 1 Main tube side only 13 Re...

Страница 178: ...15 Oil seal 2 16 Washer 2 17 Outer tube bushing 2 18 Inner tube bushing 2 19 Spring 1 Main tube side only 20 Oil flow stopper 1 Main tube side only 21 Outer tube 2 18 Nm 1 8 m kgf 13 ft Ibf T R LT LT...

Страница 179: ...fore loosening the lower bracket pinch bolts support the front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTICE ECA19110 The fr...

Страница 180: ...nner tube as this may dangerously weaken it 2 Measure main tube side only Fork spring free length a Out of specification Replace 3 Check main tube side only Damper rod Damage wear Replace Obstruction...

Страница 181: ...ing the damper rod assembly with the hexagon bit socket 15 mm 2 and T handle 3 tighten the front fork damper rod bolt 6 Install Outer tube bushing 1 Washer with the fork seal driver attachment 2 and f...

Страница 182: ...e an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork Fork seal driver weight 90890 01367 Replac...

Страница 183: ...up and down to distribute the fork oil EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg 1 Temporarily tighten the lower...

Страница 184: ...the front fork leg bolts stroke the front forks several times First tighten the lower front fork leg bolt then the upper bolt 5 Tighten Cap bolts TIP If the cap bolts are difficult to tighten slightly...

Страница 185: ...brake hose joint holder 1 3 Front brake hose joint 1 4 Tie rod 1 5 Tie rod joint 3 TIP The tie rod joint bolt center is a one way bolt 6 Front arm 2 6 1 5 5 4 2 3 5 6 6 1 LS LS LS LS LS LS LS LS LS L...

Страница 186: ...edure applies to both of the lower brackets 1 Bearing race cover 1 2 Upper ring nut 1 3 Lock washer 1 4 Center ring nut 1 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 2 1 3 4 5 7 6 1st 38 Nm...

Страница 187: ...ring inner race 1 10 Upper bearing 1 11 Lower bearing 1 12 Lower bearing inner race 1 13 Dust seal 1 14 Lower bearing outer race 1 15 Upper bearing outer race 1 16 Steering stopper 1 8 9 10 15 14 11 1...

Страница 188: ...ECKING THE STEERING HEAD on page 4 85 4 Check Front arms Tie rod Tie rod joints Lower brackets Bends cracks damage Replace EAS31222 INSTALLING THE LOWER BRACKETS 1 Lubricate Upper bearings Lower beari...

Страница 189: ...icle on the centerstand b Face the handlebar straight ahead c Mark the tread center at the most forward point on each front tire d Measure the width A between the marks e Rotate the front tires 180 un...

Страница 190: ...Order Job Parts to remove Q ty Remarks Handlebar Refer to HANDLEBAR on page 4 60 Lower brackets Refer to FRONT ARMS AND LOWER BRACKETS on page 4 76 1 Horn 1 2 Main switch 1 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Страница 191: ...ront lower link arm 1 4 Lower bracket pipe 2 5 Luggage hook 1 6 Main switch bracket 1 7 Rear lower link arm 1 1 2 3 4 4 30 Nm 3 0 m kgf 22 ft Ibf T R 88 Nm 8 8 m kgf 64 ft Ibf T R 88 Nm 8 8 m kgf 64 f...

Страница 192: ...emove Q ty Remarks 1 Upper ring nut 1 2 Lock washer 1 3 Center ring nut 1 4 Rubber washer 1 5 Lower ring nut 1 6 Steering column 1 7 Upper bearing cover 1 1 2 3 4 7 6 5 1st 38 Nm 3 8 m kgf 27 ft Ibf 2...

Страница 193: ...earing inner race 1 9 Upper bearing 1 10 Lower bearing 1 11 Lower bearing inner race 1 12 Dust seal 1 13 Collar 1 14 Lower bearing outer race 1 15 Upper bearing outer race 1 8 9 15 14 10 11 12 13 1st...

Страница 194: ...ing column Bearing races steering column a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Install new bearing races NOTICE ECA14270 If the bearing race is not in...

Страница 195: ...lower link arm bolts to front lower link arm 11 temporarily tighten Front lower link arm bolts to lower bracket pipe 12 temporarily tighten Upper link arm 13 Upper link arm bolts to lower bracket pipe...

Страница 196: ...h bracket bolt 88 Nm 8 8 m kgf 64 ft lbf Rear lower link arm bolt to lower bracket pipe 110 Nm 11 m kgf 80 ft lbf Front lower link arm bolt to lower bracket pipe 110 Nm 11 m kgf 80 ft lbf Upper link a...

Страница 197: ...CHASSIS 4 on page 4 8 Muffler Refer to ENGINE REMOVAL on page 5 3 Radiator cover Refer to RADIATOR on page 6 1 1 Rear wheel axle nut 1 2 Rear brake hose holder 1 3 Rear brake caliper 1 New New New LS...

Страница 198: ...absorber assembly 2 5 Spacer 1 6 Swingarm 1 7 Collar 1 8 Oil seal 1 9 Circlip 1 10 Bearing 1 11 Oil seal 1 New New New LS LS LS 8 5 9 11 6 7 4 10 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft I...

Страница 199: ...e brake lever when removing the brake caliper EAS31229 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorb...

Страница 200: ...Tighten the rear wheel axle nut 2 then the swingarm mounting bolts 3 4 5 Install Rear shock absorber assemblies TIP Tighten the rear shock absorber assembly nuts and bolts temporarily and then tighte...

Страница 201: ...VING THE CAMSHAFT 5 18 CHECKING THE CAMSHAFT 5 18 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 18 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 2...

Страница 202: ...5 42 INSTALLING THE PRIMARY SHEAVE V BELT AND SECONDARY SHEAVE 5 42 INSTALLING THE V BELT CASE 5 44 STARTER CLUTCH 5 46 CHECKING THE STARTER WHEEL 5 48 CHECKING THE STARTER CLUTCH 5 48 CHECKING THE T...

Страница 203: ...NG THE CRANKSHAFT ASSEMBLY 5 64 CHECKING THE CRANKSHAFT ASSEMBLY 5 64 CHECKING THE CRANKCASE 5 65 CHECKING THE BEARING 5 65 CHECKING THE OIL PUMP DRIVE GEAR 5 65 INSTALLING THE CRANKSHAFT 5 65 ASSEMBL...

Страница 204: ...gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head va...

Страница 205: ...ENGINE INSPECTION 5 2 10 Install Center cover Refer to GENERAL CHASSIS 1 on page 4 1...

Страница 206: ...s to remove Q ty Remarks 1 Muffler protector 1 2 Muffler joint bolt 1 Loosen 3 Muffler 1 4 Muffler joint 1 5 Gasket 1 6 Exhaust pipe 1 7 Gasket 1 3 2 1 5 4 6 7 New New LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf...

Страница 207: ...21 Rear fender flap Rear fender Bottom cover Air filter case Refer to GENERAL CHASSIS 4 on page 4 8 GENERAL CHASSIS 9 on page 4 21 and GENERAL CHASSIS 10 on page 4 23 Rear brake caliper Rear brake hos...

Страница 208: ...k Refer to FUEL TANK on page 7 1 Fuel injector Refer to FUEL INJECTOR on page 7 5 Throttle body Intake manifold Refer to THROTTLE BODY on page 7 7 1 Coolant reservoir hose 1 Disconnect 2 Coolant tempe...

Страница 209: ...ut bolt front side 2 2 4 Engine mounting nut bolt rear side 2 2 5 Engine bracket 1 6 Collar 2 7 Stopper 2 8 Engine 1 2 5 1 1 6 8 7 7 6 2 3 4 4 4 3 4 3 54 Nm 5 4 m kgf 39 ft Ibf T R 28 Nm 2 8 m kgf 20...

Страница 210: ...rear side 5 5 Install Engine bracket bolt nut 7 TIP Do not fully tighten the nut 6 Install Rear shock absorber assemblies 8 7 Tighten Engine bracket nut 7 TIP Before tightening the engine bracket nut...

Страница 211: ...nuts TIP Tighten each nut to specification in the order of exhaust pipe nut 1 exhaust pipe nut 2 exhaust pipe nut 1 5 Tighten Muffler bolts 6 Tighten Muffler joint bolt TIP When tightening the muffler...

Страница 212: ...fer to THERMOSTAT on page 6 5 Fuel injector Refer to FUEL INJECTOR on page 7 5 Intake manifold Refer to THROTTLE BODY on page 7 7 1 Spark plug cap 1 Disconnect 2 Spark plug 1 10 Nm 1 0 m kgf 7 2 ft Ib...

Страница 213: ...ylinder head cover 1 7 Cylinder head cover gasket 1 8 Dowel pin 1 9 Cylinder head cover breather plate 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 N...

Страница 214: ...1 15 Camshaft stopper plate 1 16 Cylinder head 1 17 Cylinder head gasket 1 18 Dowel pin 2 19 Oil nozzle 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7...

Страница 215: ...lt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket 2 TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cam...

Страница 216: ...pattern TIP To ensure an even surface rotate the cylinder head several times EAS31232 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket...

Страница 217: ...wise b Align the I mark a on the AC magneto rotor with the match mark b on the right crank case c Install the timing chain 1 onto the camshaft sprocket 2 then the camshaft sprocket onto the camshaft a...

Страница 218: ...truding from the rear left side of the timing chain ten sioner Apply sealant to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin scre...

Страница 219: ...to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to...

Страница 220: ...Remarks Cylinder head Refer to CYLINDER HEAD on page 5 9 1 Locknut 2 2 Adjusting screw 2 3 Rocker arm shaft 2 4 Collar 2 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Camshaft 1 8 Bearing 1 7 Nm 0 7...

Страница 221: ...sed air EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Rocker arm roller 1 Damage wear Repla...

Страница 222: ...r arm inside diameter Out of specification Replace the defective part s EAS30270 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install Bearing 1 onto the cylinder head TIP Install the bearing so that the...

Страница 223: ...ts 4 Install Rocker arms Rocker arm shafts TIP Make sure the rocker arm shafts intake and ex haust are completely pushed into the cylinder head Recommended lubricant Rocker arm roller Molybdenum disul...

Страница 224: ...ove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 9 Rocker arms Camshaft Refer to CAMSHAFT on page 5 17 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exh...

Страница 225: ...he valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4...

Страница 226: ...roper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in...

Страница 227: ...wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c...

Страница 228: ...face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat wid...

Страница 229: ...with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its origin...

Страница 230: ...achment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve Valve sp...

Страница 231: ...d Refer to CYLINDER HEAD on page 5 9 Water pump outlet pipe Refer to WATER PUMP on page 6 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Pis...

Страница 232: ...pen the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or rep...

Страница 233: ...ification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston...

Страница 234: ...IN GUIDE EXHAUST SIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS30294 INSTALLING THE PISTON AND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Upper oil ring rail 3...

Страница 235: ...e crankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While holding the piston with one...

Страница 236: ...nd GENERAL CHASSIS 10 on page 4 23 1 V belt case air filter element cover 1 2 V belt case air filter element support 1 3 V belt case air filter element 1 4 Lower V belt case cover 1 5 V belt case air...

Страница 237: ...re in stalling a new V belt case gasket remove the V belt Refer to Removing the V belt primary sheave and secondary sheave 8 Dowel pin 2 9 V belt case plate 1 10 V belt case bearing retainer 2 11 Bear...

Страница 238: ...ply Shell Sunlight Grease 3 Order Job Parts to remove Q ty Remarks 1 Primary fixed sheave nut 1 2 Conical spring washer 1 3 One way clutch 1 4 Primary fixed sheave 1 5 V belt 1 6 Collar 1 7 Primary sl...

Страница 239: ...y Shell Sunlight Grease 3 Order Job Parts to remove Q ty Remarks 9 Slider 3 10 Primary sheave weight 6 11 Oil seal 2 12 Collar 1 13 Clutch housing nut 1 14 Spacer 1 15 Clutch housing 1 16 Secondary sh...

Страница 240: ...grease R Order Job Parts to remove Q ty Remarks 1 Secondary sheave nut 1 2 Clip 3 3 Clutch carrier plate 1 4 Clutch shoe spring 3 5 Clutch shoe 3 6 Damper 3 7 Clutch carrier 1 8 Compression spring 1...

Страница 241: ...ell dolium grease R Order Job Parts to remove Q ty Remarks 10 Guide pin 3 11 Secondary sliding sheave 1 12 O ring 2 13 Oil seal 2 14 Bearing 1 15 Circlip 1 16 Bearing 1 17 Secondary fixed sheave 1 75...

Страница 242: ...not remove the secondary sheave nut at this stage TIP While holding the secondary sheave with the sheave holder 2 loosen the secondary sheave nut one full turn with the locknut wrench 3 EAS30312 DISA...

Страница 243: ...a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS30315 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean t...

Страница 244: ...and sliding sheaves as a set 3 Check Guide pin 2 Damage wear Replace the secondary fixed and sliding sheaves as a set 4 Check Spring free length Out of specification Replace the spring EAS30320 ASSEM...

Страница 245: ...ded lubricant 5 Install Spring seat Compression spring Clutch carrier 1 Secondary sheave nut 2 TIP While compressing the compression spring with the clutch spring holder 3 install the sec ondary sheav...

Страница 246: ...heave weights from falling out of the primary sliding sheave 4 Install V belt 1 NOTICE ECA21720 Do not allow grease to come in contact with the V belt TIP Install the V belt with the printed arrow mar...

Страница 247: ...primary fixed sheave nut EAS31235 INSTALLING THE V BELT CASE 1 Install V belt case air duct 1 TIP Be sure to fit the projection a on the V belt case air duct between the projections b on the V belt ca...

Страница 248: ...V BELT AUTOMATIC TRANSMISSION 5 45 a 1 2...

Страница 249: ...OIL on page 3 19 Cylinder head Refer to CYLINDER HEAD on page 5 9 Primary sliding sheave Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 1 Starter clutch cover 1 2 Oil seal 1 3 Dowel pin 2 LT E...

Страница 250: ...le gear shaft 1 6 Starter clutch 1 7 Collar 1 8 Starter wheel 1 9 Bearing 1 10 Timing chain guide stopper 1 11 Timing chain 1 12 Timing chain guide intake side 1 LT E 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Страница 251: ...arter wheel counterclock wise A the starter clutch and the starter wheel should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel clockwise B it shoul...

Страница 252: ...R on page 6 1 1 Crankshaft position sensor coupler Stator coil assembly coupler 1 1 Disconnect 2 AC magneto rotor 1 3 Woodruff key 1 4 Crankshaft position sensor holder 1 5 Crankshaft position sensor...

Страница 253: ...Install Crankshaft position sensor 1 Crankshaft position sensor holder 2 TIP Pass the stator coil assembly lead 3 under the crankshaft position sensor holder 2 Install Woodruff key AC magneto rotor Wa...

Страница 254: ...C MAGNETO 5 51 TIP While holding the AC magneto rotor 2 with the rotor holding tool 3 tighten the AC magneto ro tor nut Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 1 3 2...

Страница 255: ...Refer to GENERAL CHASSIS 4 on page 4 8 1 Starter motor lead 1 Disconnect 2 Engine ground lead 1 Disconnect 3 Rear brake hose holder 1 4 Negative battery lead 1 Disconnect 5 Starter motor 1 10 Nm 1 0...

Страница 256: ...r motor front cover 1 3 Washer 1 4 O ring 1 5 Brush 1 6 Brush spring 2 7 Bearing 1 8 Oil seal 1 9 Armature assembly 1 10 Circlip 1 11 Stator 1 12 O ring 1 13 Starter motor rear cover 1 1 5 Nm 0 15 m k...

Страница 257: ...tion Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5...

Страница 258: ...e the defective part s EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor cover bolts 1 TIP Align the match mark a on the stator with the match mark b on the front and rear cover Brush spri...

Страница 259: ...r cover 1 2 Spring 1 3 Oil strainer 1 4 Oil pump assembly 1 5 Oil pump assembly gasket 1 6 Oil pump housing cover 1 7 Pin 1 8 Oil pump driven gear 1 9 Oil pump inner rotor 1 10 Oil pump outer rotor 1...

Страница 260: ...defective part s EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft 2 Install Oil pump driven gear Oil pump housing 1 Oil pump outer rotor 2 Oil pump inner rotor 3 Pin...

Страница 261: ...ge 4 32 Transmission oil Drain Refer to CHANGING THE FINAL TRANS MISSION OIL on page 3 22 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 1 Transmission case cover 1 2 O...

Страница 262: ...ve Q ty Remarks 5 Primary drive gear 1 6 Bearing 2 7 1st wheel gear 1 8 Drive axle 1 9 Oil seal 1 10 Bearing 2 11 Main axle 1 12 Primary driven gear 1 13 Bearing 2 9 8 10 10 13 6 5 6 12 11 13 8 7 New...

Страница 263: ...ve wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s EAS30438 INSTALLING THE TRANSMISSION 1 Install Oil se...

Страница 264: ...TRANSMISSION 5 61 TIP Tighten the transmission case cover bolts in the proper tightening sequence as shown 1 8 7 6 1 5 4 3 10 2 9...

Страница 265: ...n Refer to CYLINDER AND PISTON on page 5 28 Primary sheave Secondary sheave Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 Starter clutch Refer to STARTER CLUTCH on page 5 46 Oil pump assembly R...

Страница 266: ...oil filler cap 1 2 Dipstick 1 3 Spring 2 4 Centerstand 1 5 Left crankcase 1 6 Dowel pin 2 7 Spacer 1 8 Crankshaft assembly 1 9 Oil pump drive gear 1 10 Bearing 1 11 Right crankcase 1 11 Nm 1 1 m kgf 8...

Страница 267: ...mbly 1 TIP Remove the crankshaft assembly with the crankcase separating tool 2 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA20630 To protect the end...

Страница 268: ...ugh movement Replace EAS31245 CHECKING THE OIL PUMP DRIVE GEAR 1 Check Oil pump drive gear Damage wear Replace EAS30791 INSTALLING THE CRANKSHAFT 1 Install Crankshaft assembly 1 TIP Install the cranks...

Страница 269: ...ome into contact with the oil gallery 3 Install Crankcase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pattern EAS31247 INSTALLING THE CENTERSTAND 1 Install Centerstand Springs...

Страница 270: ...CRANKSHAFT 5 67...

Страница 271: ...INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 5 CHECKING THE THERMOSTAT ASSEMBLY 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEM...

Страница 272: ...S 9 on page 4 21 1 Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator cover 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7...

Страница 273: ...amper 5 11 Ignition coil connector 2 Disconnect 12 Ignition coil 1 13 Radiator fan case 1 14 Radiator fan 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Страница 274: ...e there is no drop in pressure 4 Check Radiator fan Damage Replace EAS30440 INSTALLING THE RADIATOR 1 Install Radiator fan case 1 TIP Tighten the radiator fan case bolts in the proper tightening seque...

Страница 275: ...si of pres sure c Measure the pressure to check its maintain ing applied pressure 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RA...

Страница 276: ...marks Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Center cover Refer to GENERAL CHASSIS 1 on page 4 1 1 Coolant temperature sensor coupler 1 Disconnect 2 Cooling system air bleed hose 1 D...

Страница 277: ...hole lower line a at 95 C 203 F TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling EAS30445 INSTALLING THE THERMOSTAT ASSE...

Страница 278: ...E ENGINE OIL on page 3 19 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 AC magneto rotor Stator coil assembly Refer to AC MAGNETO on page 5 49 1 Water pump outlet pipe 1 2 Water pump outlet...

Страница 279: ...Dowel pin 1 5 Water pump housing 1 6 Dowel pin 1 7 Circlip 1 8 Washer 2 9 Impeller shaft gear 1 10 Pin 1 11 Impeller shaft 1 12 Water pump seal 1 13 Oil seal 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1...

Страница 280: ...pecified depth as shown in the illustra tion 3 Lubricate Water pump seal 4 Install Impeller shaft 1 Pin 2 TIP After installing the impeller shaft add approxi mately 0 5 cm3 0 017 US oz 0 018 Imp oz of...

Страница 281: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3...

Страница 282: ...WATER PUMP 6 11...

Страница 283: ...STALLING THE FUEL TANK 7 2 CHECKING THE FUEL PRESSURE 7 3 FUEL INJECTOR 7 5 REMOVING THE FUEL HOSE 7 6 CHECKING THE FUEL INJECTOR 7 6 ASSEMBLING THE FUEL INJECTOR 7 6 INSTALLING THE FUEL HOSE 7 6 THRO...

Страница 284: ...n page 4 3 and GENERAL CHASSIS 3 on page 4 5 1 Fuel tank cap 1 2 Fuel pump coupler 1 Disconnect 3 Fuel sender coupler 1 Disconnect 4 Fuel hose connector cover 1 5 Fuel hose 1 Disconnect 6 Fuel pump br...

Страница 285: ...emoved 5 Remove Fuel tank EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS304...

Страница 286: ...fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA21750 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools Although the fuel has been...

Страница 287: ...FUEL TANK 7 4 Refer to INSTALLING THE FUEL TANK on page 7 2...

Страница 288: ...e Q ty Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Fuel injector coupler 1 Disconnect 2 Fuel hose holder 1 3 Fuel hose 1 4 Fuel injector 1 5 Fuel injector adaptor 1 6 Fuel injector joint gasket...

Страница 289: ...ruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 7 6 EAS31252 ASSEMBLING THE FUEL INJE...

Страница 290: ...Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Breather hose throttle body to cylinder 1 4 Throttle cable 2 Disconnect 5 Throttle cable holder 1 6 Air filter case joint clamp screw 1 Lo...

Страница 291: ...1 Loosen 8 Throttle body 1 9 ISC idle speed control unit holder 1 10 ISC idle speed control unit 1 11 Spring 1 12 Intake manifold 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0...

Страница 292: ...21770 Do not adjust the stop screw 1 EAS31254 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 1 Remove the throttle body from the vehicle 2 Remove Screw 1 Plate 2 ISC idle speed control uni...

Страница 293: ...ny areas other than the areas a b and c If the cleaning agent en ters the ISC unit or throttle body thorough ly wipe it off 7 Adjust the ISC unit plunger to the specified distance a from the motor ass...

Страница 294: ...that the rear wheel is elevated 14 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed Within specifi cation Service is finished Out of specification Repla...

Страница 295: ...Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30980 INSTALLING THE THROTTLE BODY 1 Install Throttle body Throttle body joint clamp screw TIP Align the p...

Страница 296: ...THROTTLE BODY 7 13...

Страница 297: ...ESHOOTING METHOD 8 28 YAMAHA DIAGNOSTIC TOOL 8 29 TROUBLESHOOTING DETAILS 8 30 ELECTRICAL COMPONENTS 8 53 CHECKING THE SWITCHES 8 55 CHECKING THE BULBS AND BULB SOCKETS 8 58 CHECKING THE FUSES 8 59 RE...

Страница 298: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...

Страница 299: ...ion sensor 4 Main switch 6 Signaling system fuse 8 Battery 9 Negative battery lead connector 10 Main fuse 13 Sidestand switch 22 ECU engine control unit 23 Ignition coil 24 Spark plug 28 Engine ground...

Страница 300: ...AND CHARGING THE BATTERY on page 8 60 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug...

Страница 301: ...tand switch 9 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 65 Replace the lean angle sensor 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page...

Страница 302: ...ELECTRIC STARTING SYSTEM 8 5 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...

Страница 303: ...fuse 8 Battery 9 Negative battery lead connector 10 Main fuse 11 Starter relay 12 Starter motor 13 Sidestand switch 14 Starting circuit cut off relay 15 Handlebar switch Right 16 Front brake light swi...

Страница 304: ...d switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays...

Страница 305: ...an the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 65 Starter motor is OK Perform the electric starti...

Страница 306: ...h front and rear Refer to CHECKING THE SWITCHES on page 8 55 Replace the brake light switch 10 Check the start switch Refer to CHECKING THE SWITCHES on page 8 55 The start switch is faulty Replace the...

Страница 307: ...ELECTRIC STARTING SYSTEM 8 10...

Страница 308: ...CHARGING SYSTEM 8 11 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM...

Страница 309: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 8 Battery 9 Negative battery lead connector 10 Main fuse 60 Frame ground...

Страница 310: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 60 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 66 Replace the st...

Страница 311: ...CHARGING SYSTEM 8 14...

Страница 312: ...LIGHTING SYSTEM 8 15 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM...

Страница 313: ...ector 10 Main fuse 22 ECU engine control unit 28 Engine ground 34 Meter assembly 35 Multifunction meter 36 Meter light 39 High beam indicator light 42 Tail brake light assembly 45 Tail brake light 47...

Страница 314: ...SOCKETS on page 8 58 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight signaling system and backup Refer to CHECKING THE FUS ES on page 8 59 Replace the fuse s 3 Check the battery...

Страница 315: ...k the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or replace the wire har ness Replace the ECU meter assembly or headlight assembly Refer to RE PLACING THE ECU...

Страница 316: ...SIGNALING SYSTEM 8 19 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM...

Страница 317: ...ssembly 35 Multifunction meter 37 Turn signal indicator light Left 38 Coolant temperature warning light 41 Turn signal indicator light Right 42 Tail brake light assembly 43 Rear turn signal light Left...

Страница 318: ...ain headlight signaling system and backup Refer to CHECKING THE FUS ES on page 8 59 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 Clean the battery ter...

Страница 319: ...ight switch Refer to CHECKING THE SWITCHES on page 8 55 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 55 Replace the rear brake ligh...

Страница 320: ...t assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly or ECU Refer to REPLACING THE ECU e...

Страница 321: ...SIGNALING SYSTEM 8 24 NG OK 2 Check the entire speed sensor wir ing Properly connect or replace the wire har ness Replace the meter assembly...

Страница 322: ...FUEL INJECTION SYSTEM 8 25 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM...

Страница 323: ...temperature sensor 19 Intake air pressure sensor 20 Intake air temperature sensor 21 Throttle position sensor 22 ECU engine control unit 23 Ignition coil 24 Spark plug 25 Fuel injector 26 Fuel pump 28...

Страница 324: ...trouble warning light will display the lowest error code or it will be displayed on the Yamaha diagnostic tool which remains stored in ECU memory until deleted Engine trouble warning light fault code...

Страница 325: ...rouble warning light comes on 1 Check Fault code number a Check the fault code number displayed on the multi function meter right display b Identify the faulty system with the fault code number c Iden...

Страница 326: ...puter The displayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool However the diagnostic tool cannot be used to freely change...

Страница 327: ...o work nor mally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 Fault code No 12 1 F...

Страница 328: ...ace the sensor Refer to AC MAGNETO on page 5 49 Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sen...

Страница 329: ...tch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for looseness or pinch ing Im...

Страница 330: ...d Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure Procedure Extend the sidestand and then operate the throttle while pus...

Страница 331: ...tem Intake air pressure sensor system malfunction clogged or de tached Fault code No 15 Item Throttle position sensor open or short circuit detected Fail safe system Able to start engine Able to drive...

Страница 332: ...ot dis played Service is finished Fault code number is displayed Go to item 5 5 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When th...

Страница 333: ...f the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 20 Tool display Sidestand switch ON sidestand retracted OFF sidestand extended Procedure Extend...

Страница 334: ...CU is detected Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 06 Tool display Displays t...

Страница 335: ...e No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Check the coolant temperature sensor Replace th...

Страница 336: ...ck blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for...

Страница 337: ...pler securely or re place the wire harness Start the engine warm it up and then race it Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Wire harne...

Страница 338: ...lace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 65 Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code num...

Страница 339: ...passages for air leaks Start and idle the engine for ap proximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item A 5 A 5 The air volume...

Страница 340: ...B 8 ISC valve operation sound is not heard Go to item B 4 B 4 Installed condition of ISC valve Check the mounting area for looseness or pinching Make sure that the installation position is correct Che...

Страница 341: ...ace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 67 Execute the diagnostic mode Code Nos 36 No operating sound Go to item 3 Operating sound Go to item 6 3 Connection of wire...

Страница 342: ...and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON then to OFF and...

Страница 343: ...re place the wire harness Rotate the left front wheel by hand Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or shor...

Страница 344: ...r this adjustment is made turn the main switch to OFF Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Repeat item 1 If the same number...

Страница 345: ...back fully opens This operation takes approximately 3 seconds Procedure Check that ISC valve is actuated by listening for the operating sound Item Probable cause of malfunc tion and check Maintenance...

Страница 346: ...when the Engine is idling Deceleration is poor when the vehicle is ridden Bad condition of engine or sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 03 01 Met...

Страница 347: ...Check for looseness or pinch ing Start the engine and let it idle for approximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 7 7 De...

Страница 348: ...r is displayed Go to item 9 9 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 59 Start the engine and let it idle for approximately 10 seconds Fault code nu...

Страница 349: ...FUEL INJECTION SYSTEM 8 52...

Страница 350: ...ELECTRICAL COMPONENTS 8 53 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 6 9 11 12 10 8 7 13 17 18 19 23 22 21 20 14 15 16...

Страница 351: ...relay 9 Starting circuit cut off relay 10 Headlight relay 11 ECU engine control unit 12 Rectifier regulator 13 ISC idle speed control unit 14 Throttle position sensor 15 Intake air pressure sensor 16...

Страница 352: ...ELECTRICAL COMPONENTS 8 55 EAS30549 CHECKING THE SWITCHES ON R Br OFF B P G Y L B Ch Dg Br W B L G R Br L G L Y G Y B Dg P Ch Br W L B B L Y G Y L Y B L Y B B 1 2 3 4 5 6 7 8...

Страница 353: ...ELECTRICAL COMPONENTS 8 56 1 Front brake light switch 2 Start switch 3 Horn switch 4 Dimmer switch 5 Turn signal switch 6 Rear brake light switch 7 Main switch 8 Sidestand switch...

Страница 354: ...1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main...

Страница 355: ...bulbs 1 Remove Bulb WARNING EWA17540 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA14381 Be sure to hold the socke...

Страница 356: ...e the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse...

Страница 357: ...RLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If t...

Страница 358: ...tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the bat...

Страница 359: ...t voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is hig...

Страница 360: ...ation Replace a Remove the ignition coil from the spark plug b Connect the pocket tester 1 to the igni tion coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery t...

Страница 361: ...witch to ON d Measure the ignition spark gap a e Crank the engine by pushing the of the start switch and gradually increase the spark gap until a misfire occurs EAS30560 CHECKING THE CRANKSHAFT POSITI...

Страница 362: ...leshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 8 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a j...

Страница 363: ...THE FUEL SENDER 1 Remove Fuel pump from the fuel tank 2 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester 10 100 to the fuel sender terminals...

Страница 364: ...h coolant 2 TIP Make sure that the coolant temperature sensor terminals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Mea...

Страница 365: ...ELECTRICAL COMPONENTS 8 68 c Measure the fuel injector resistance Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 2 1...

Страница 366: ...ELECTRICAL COMPONENTS 8 69...

Страница 367: ...9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE T...

Страница 368: ...d or damaged fuel hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty batte...

Страница 369: ...loose or worn clutch shoe spring 2 Clutch shoe s Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt Slipping V belt Oil or grease on...

Страница 370: ...amaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head component...

Страница 371: ...Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal swit...

Страница 372: ...when the engine is idling 39 Injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Speed sensor no normal signals are received from the speed sensor 44 EEPROM...

Страница 373: ...the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sen sor and incline it more than 50 degrees Upright 0 4 1 4 Overturned 3 7 4 4 09 Fuel system voltage...

Страница 374: ...ontrol number 0 254 Diagnostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals Illuminates the engine trou ble warning light Check that...

Страница 375: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 8...

Страница 376: ...beam indicator light 40 Engine trouble warning light 41 Turn signal indicator light Right 42 Tail brake light assembly 43 Rear turn signal light left 44 Rear turn signal light Right 45 Tail brake lig...

Страница 377: ......

Страница 378: ......

Страница 379: ...MW125 2014 MW125F 2015 WIRING DIAGRAM MW125 2014 MW125F 2015 SCH MA DE C BLAGE MW125 2014 MW125F 2015 SCHALTPLAN MW125 2014 MW125F 2015 SCHEMA ELETTRICO MW125 2014 MW125F 2015 DIAGRAMA EL CTRICO...

Страница 380: ...MW125 2014 MW125F 2015 WIRING DIAGRAM MW125 2014 MW125F 2015 SCH MA DE C BLAGE MW125 2014 MW125F 2015 SCHALTPLAN MW125 2014 MW125F 2015 SCHEMA ELETTRICO MW125 2014 MW125F 2015 DIAGRAMA EL CTRICO...

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