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CRANKSHAFT

5-76

EAS26010

REMOVING THE CONNECTING RODS

1. Remove:

• Connecting rod caps “1”
• Connecting rods
• Big end bearings

TIP

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

EAS26090

CHECKING THE CRANKSHAFT AND 
CONNECTING RODS

1. Measure:

• Crankshaft runout

Out of specification 

→

 Replace the crank-

shaft.

2. Check:

• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces

Scratches/wear 

→

 Replace the crankshaft.

3. Measure:

• Crankshaft-pin-to-big-end-bearing clearance

Out of specification 

→

 Replace the big end 

bearings.

The following procedure applies to all of the 
connecting rods.

NOTICE

ECA13930

Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big 
end bearings must be installed in their origi-
nal positions.

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a. Clean the big end bearings, crankshaft pin, 

and the inside of the connecting rod halves.

b. Install the big end upper bearing into the con-

necting rod and the big end lower bearing into 
the connecting rod cap.

TIP

Align the projections “a” on the big end bearings 
with the notches “b” in the connecting rod and 
connecting rod cap.

c. Put a piece of Plastigauge® “1” on the crank-

shaft pin.

d. Assemble the connecting rod halves.

TIP

• Do not move the connecting rod or crankshaft 

until the clearance measurement has been 
completed.

• Lubricate the bolts threads and nut seats with 

molybdenum disulfide grease.

• Make sure the projection “c” on the connecting 

rod faces towards the left side of the crank-
shaft.

 

Runout limit C

0.020 mm (0.0008 in)

 

Oil clearance

0.023–0.046 mm (0.0009–0.0018 
in)

Содержание XVS950CU 2014

Страница 1: ...2014 SERVICE MANUAL XVS950CU XVS950CUE 1XC 28197 E0...

Страница 2: ...VS950CUE 2014 SERVICE MANUAL 2014 by Yamaha Motor Co Ltd First edition November 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is e...

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

Страница 4: ...b section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section...

Страница 5: ...N SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease...

Страница 6: ......

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

Страница 8: ......

Страница 9: ...9 ABS OPERATION 1 15 ABS WARNING LIGHT AND OPERATION 1 18 INSTRUMENT FUNCTIONS 1 19 IMPORTANT INFORMATION 1 21 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 21 REPLACEMENT PARTS 1 21 GASKETS OIL SEALS AN...

Страница 10: ...E IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the rider seat...

Страница 11: ...and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically contr...

Страница 12: ...sor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor lean angle sensor speed sensor except for ABS models rear wheel sen sor for ABS models and O2...

Страница 13: ...c maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 2 3 4 6 7 8 9 10...

Страница 14: ...occurs between the tires and the road surface This causes a difference between the wheel speed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the...

Страница 15: ...eel speed reduction rate exceed the preset values the ABS ECU de termines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figur...

Страница 16: ...ys WARNING EWA1XC1004 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of t...

Страница 17: ...lso includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning ligh...

Страница 18: ...and are installed close to the wheel sensors As the sensor rotor rotates the hall element in the hall IC installed in the wheel sensor generates the voltage which is proportional to the magnetic flux...

Страница 19: ...vicing are completed the ABS warning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mph or faster NOTICE ECA1XC1002 If the rear wheel is raced with the vehicle on a suit...

Страница 20: ...is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet sol...

Страница 21: ...1 12 Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 2 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Rais...

Страница 22: ...lfunction is detected in the ABS a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19...

Страница 23: ...tch was turned on During this test a clicking noise can be heard from under the seat and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but...

Страница 24: ...e brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the orific...

Страница 25: ...utlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped bac...

Страница 26: ...As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brak...

Страница 27: ...to shorten the braking distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore...

Страница 28: ...odes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 clock ODO If the fuel level warning light comes on the odometer display will automatically change to the fuel reserve...

Страница 29: ...em indicator light will flash and the display will indicate a fault code TIP If the display indicates fault code 52 this could be caused by transponder interference If this fault code appears try the...

Страница 30: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Страница 31: ...air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after on...

Страница 32: ...tener 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 fast...

Страница 33: ...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 34: ...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 35: ...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 36: ...most part stores 5 Check 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 measuri...

Страница 37: ...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 Reference pages Pocket tester 90890 03112 Analog poc...

Страница 38: ...amper rod holder 22 mm 90890 01365 4 80 4 82 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 80 4 82 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 82 4 82 4 83 Fork...

Страница 39: ...ammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 20 Weight 90890 01084 YU 01083 3 5 20 Valve spring compressor 90890 04019 YM 04019 5 30 5 35 Valve spring compressor attachment 90890 01243 V...

Страница 40: ...0 mm YM 04066 5 31 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 37 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 45 5 45 5 46 5 46 5 53 5 58 Flywheel puller 90890 013...

Страница 41: ...pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 6 10 Pressure gauge 90890 03153 YU 03153 6 10 Fuel pressure adapter 90890 03176 YM 03176 6 10 Test harness TPS 3P 90890 03204 YU 03204 6...

Страница 42: ...SPECIAL TOOLS 1 33 Test harness S pressure sensor 3P 90890 03207 YU 03207 7 167 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 7 168 Tool name Tool No Illustration Reference pages...

Страница 43: ...NERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART...

Страница 44: ...S950CUE 2DX5 AUS except for ABS models Dimensions Overall length 2290 mm 90 2 in Overall width 830 mm 32 7 in Overall height 1120 mm 44 1 in Seat height 690 mm 27 2 in Wheelbase 1570 mm 61 8 in Ground...

Страница 45: ...10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 4 30 L 4 55 US qt 3 78 Imp qt Without oil filter c...

Страница 46: ...ing chain Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside diameter 11 981 11 991...

Страница 47: ...012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025...

Страница 48: ...0 0012 0 0022 in Limit 0 15 mm 0 0059 in Diameter D 84 955 84 970 mm 3 3447 3 3453 in Height H 8 0 mm 0 31 in Offset 0 50 mm 0 0197 in Piston pin bore inside diameter 21 004 21 015 mm 0 8269 0 8274 in...

Страница 49: ...h A 97 95 98 00 mm 3 856 3 858 in Runout limit C 0 020 mm 0 0008 in Big end side clearance D 0 320 0 474 mm 0 0126 0 0187 in Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack...

Страница 50: ...pump Pump type Electrical Maximum consumption amperage 2 0 A Fuel injector Model quantity 1450 2 Resistance 12 0 Throttle body Type quantity ACW35 1 ID mark 1TP1 00 Fuel line pressure at idling 220 3...

Страница 51: ...ENGINE SPECIFICATIONS 2 8 Oil temperature 60 0 70 0 C 140 00 158 00 F Throttle grip free play 4 0 6 0 mm 0 16 0 24 in...

Страница 52: ...ss Size 100 90 19M C 57H Manufacturer model BRIDGESTONE EXEDRA G721 Wear limit front XVS950CU 1 6 mm 0 06 in XVS950CUE 1 0 mm 0 04 in Rear tire Type Tubeless Size 150 80B16M C 71H Manufacturer model B...

Страница 53: ...e pad lining thickness inner 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder i...

Страница 54: ...r models equipped with gas cylinders Spring installed length 159 7 mm 6 29 in for models not equipped with gas cylinders 120 5 mm 4 74 in for models equipped with gas cylinders Spring rate K1 37 30 N...

Страница 55: ...or type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Manufacturer GS YUASA Ten ho...

Страница 56: ...orn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal hazard relay Relay type Semi transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Minimu...

Страница 57: ...ELECTRICAL SPECIFICATIONS 2 14 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 30 0 A for ABS models...

Страница 58: ...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 speci...

Страница 59: ...olt M8 2 20 Nm 2 0 m kgf 14 ft lbf Rear cylinder right cover bracket bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Shift arm pinch bolt M6 1 16 Nm 1 6 m kgf 12 ft lbf Tappet cover bolt M6 18 10 Nm 1 0 m kgf 7 2...

Страница 60: ...bracket bolt M10 2 35 Nm 3 5 m kgf 25 ft lbf Muffler protector 1 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector 2 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector inner M6 3 8 Nm 0 8 m kgf 5 8 ft lb...

Страница 61: ...2 bolt M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Starter clutch bolt M8 3 24 Nm 2 4 m kgf 17 ft lbf Primary drive gear nut M18 1 100 Nm 10 m kgf 72 ft lbf Use a lock washer Clutch boss nut M20 1 125 Nm 12 5 m...

Страница 62: ...o 65 Nm 6 5 m kgf 47 ft lbf Front cylinder head Rear cylinder head TIP Connecting rod bolt Tighten the connecting rod bolts to 15 Nm 1 5 m kgf 11 ft lbf and then tighten them further to reach the spec...

Страница 63: ...ighten the generator cover bolts in the order shown in the illus tration TIP Clutch cover bolt Temporally tighten the bolts a and b and then tighten the clutch cover bolts in the order shown in the il...

Страница 64: ...gnition coil bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Ignition coil bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable locknut crankcase side M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator bracke...

Страница 65: ...orque M25 1 52 Nm 5 2 m kgf 38 ft lbf See TIP Lower ring nut final tightening torque M25 1 18 Nm 1 8 m kgf 13 ft lbf See TIP Lower bracket pinch bolt M10 4 23 Nm 2 3 m kgf 17 ft lbf Front fork damper...

Страница 66: ...ft lbf Tail brake light and rear fender nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate bracket and rear fender bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate light nut M5 2 3 8 Nm 0 38 m kgf 2 8...

Страница 67: ...t M8 2 23 Nm 2 3 m kgf 17 ft lbf Rear brake hose guide bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose union bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Rear brake hose holder bolt M6 1 10 Nm 1 0 m kgf 7...

Страница 68: ...0 7 m kgf 5 1 ft lbf Rear wheel sensor bolt for ABS models M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear wheel sensor lead holder bolt for ABS models M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Hydraulic unit assembly unio...

Страница 69: ...r ring nut 1 First tighten the lower ring nut to approximately 52 Nm 5 2 m kgf 37 ft lbf with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 18 Nm 1 8 m kg...

Страница 70: ...ilter cartridge union bolt Crankcase stud bolts Starter clutch idle gear 1 shaft Starter clutch idle gear 1 Starter clutch gear inner and outer surfaces Starter clutch and metal to metal moving parts...

Страница 71: ...TION POINTS AND LUBRICANT TYPES 2 28 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankcase breather pipe Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lub...

Страница 72: ...ivoting point and metal to metal moving parts Footrest assembly pivoting point Throttle grip tube guide inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Bra...

Страница 73: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30...

Страница 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART...

Страница 75: ...strainer 2 Oil pump assembly 3 Oil delivery pipe 2 4 Relief valve assembly 5 Drive axle 6 Oil filter cartridge 7 Main axle 8 Main gallery 9 Crankshaft 10 Clutch cover 11 Valve stem end intake side 12...

Страница 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS...

Страница 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil delivery pipe 2 3 Relief valve assembly...

Страница 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35...

Страница 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Camshaft 2 Crankshaft...

Страница 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37...

Страница 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil drain bolt 2 Crankshaft...

Страница 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39...

Страница 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Drive axle 2 Oil delivery pipe 1 3 Main axle 4 Oil delivery pipe 2 5 Oil pump assembly 6 Oil strainer...

Страница 84: ...CABLE ROUTING except for ABS models 2 41 EAS1XC1003 CABLE ROUTING except for ABS models Handlebar top and front view 1 2 3 4 5 6 6 A B C D G F F 5 G E 2 3 2 3 4 7 8 9 1 H I J K L 10 A D 5 6 M N O...

Страница 85: ...witch lead with the plastic band at the bend in the handlebar E Fasten the left handlebar switch lead with the plastic band Align the plastic band with the locknut F Point the end of the plastic band...

Страница 86: ...CABLE ROUTING except for ABS models 2 43 Headlight 3 2 2 1 A D B 1 4 5 6 7 7 8 8 9 9 10 11 C 12 12 12 13...

Страница 87: ...assembly lead 11 Right handlebar switch lead 12 Wire harness 13 Left handlebar switch lead A Fasten the headlight lead and intake air temperature sensor sub wire harness with the holder Be sure to pos...

Страница 88: ...E ROUTING except for ABS models 2 45 Steering head cable right side view G 4 5 H H 6 I J K L 7 M 1 2 A B C D 3 E F 7 U V W 9 X Y Z S T 1 5 AE AD AJ AA AF AB AC 14 P O N AG 6 AH AI R 10 10 8 Q 13 12 1...

Страница 89: ...S Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the clutch cable and wire harness with the band making sure to point the end of the band d...

Страница 90: ...CABLE ROUTING except for ABS models 2 47 Clutch cable right side view 3 3 4 3 3 H K I L A B C D E G F J J 1 2 5 6 7 8 5 5 10 10 11 11 9 3 4...

Страница 91: ...O2 sensor lead with the plastic band Face the buckle of the plastic band upward with the end pointing downward F Insert the projection on the wire harness holder into the hole in the battery box G Ins...

Страница 92: ...CABLE ROUTING except for ABS models 2 49 Frame inner side view A 1 2 B 3 4 5 C D E 6 F G H I J 7 8 9 10 K 11...

Страница 93: ...the speed sensor D To the starter relay E Route the starter motor lead to the front of the frame cross member F Route the starter motor lead and rear brake light switch lead under the engine bracket...

Страница 94: ...CABLE ROUTING except for ABS models 2 51 Rear brake hose right side view C G H E F C D A B 1 1 2 3 3 3 3 I J K L...

Страница 95: ...ier regulator bracket D Fasten the brake fluid reservoir hose at the white paint mark E Route the brake fluid reservoir hose to the outside of the engine bracket rear lower side F Point the ends of th...

Страница 96: ...CABLE ROUTING except for ABS models 2 53 Front brake hose front and left side view 2 A 1 1 B D 1 1 3 3 3 3 3 C...

Страница 97: ...t brake hose through the cable guide B 20 40 C Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder D Fasten the front brak...

Страница 98: ...CABLE ROUTING except for ABS models 2 55 Steering head left side view A B C 1 2 5 6 7 8 9 10 D F G 11 12 K J I H L M N 3 4 E...

Страница 99: ...side with the plastic band Be sure to position the smaller coupler above the larger coupler F After connecting the immobilizer unit coupler insert the projection on the coupler into the hole in the f...

Страница 100: ...CABLE ROUTING except for ABS models 2 57 Spark plug lead B A 2 2 1 1 C F 3 4 5 6 7 8 10 D E 9...

Страница 101: ...inder spark plug lead with the holder B Fasten the fuel return hose with the holder C Fasten the hose protector of the fuel tank breather hose with the hose holder Make sure that the fuel tank breathe...

Страница 102: ...UTING except for ABS models 2 59 Electrical components tray left side view 4 6 6 8 7 14 15 P S P Q 1 2 3 4 4 5 6 7 12 3 1 1 3 3 4 2 3 20 20 A C D E F G H I J K L M N O U W X V B B R 8 9 10 11 13 16 17...

Страница 103: ...rt the projection on the coupler cover into the hole in the frame L Fasten the oil level switch lead and sidestand switch lead with the holder Position the holder between the sidestand switch coupler...

Страница 104: ...CABLE ROUTING except for ABS models 2 61 Rectifier regulator rear view 1 2 3 4 5 6 8 9 10 10 11 A B C 14 D 12 F G H 15 16 I 7 E 13...

Страница 105: ...ery A Insert the projection the stator motor lead holder into the hole in the engine bracket rear lower bracket B Insert the projection on the wire harness holder into the hole in the battery box C In...

Страница 106: ...CABLE ROUTING except for ABS models 2 63 Rear fender top and left view 1 2 3 4 4 A B 6 2 5 5 1 1 1 7 8 C C C D E H F G 3 9 10 11...

Страница 107: ...ute the tail sub wire harness through the guides and then secure the lead by bending the guides around the lead B Align the white tape on the tail sub wire harness with the guide C Install each couple...

Страница 108: ...CABLE ROUTING except for ABS models 2 65 Fuel tank 5 K 1 M H 8 8 R 10 10 3 7 7 7 9 N O P Q I H J J 2 3 4 5 6 D E F F G L L A B C 1 2 11...

Страница 109: ...n or more I Install the fuel return hose completely onto the hose fitting of the pressure regulator making sure that the yellow paint mark on the hose is facing outward J Align the ends of the hose cl...

Страница 110: ...CABLE ROUTING except for ABS models 2 67 Fuel tank breather hose left and rear view D 1 A 1 1 2 2 B B 3 3 C...

Страница 111: ...overflow hose from rollover valve A Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box B 2 8 mm 0 08 0 31 in C Install the fuel tank breather hose hose joint...

Страница 112: ...CABLE ROUTING except for ABS models 2 69 Fuel tank breather hose right side view 1 2 3 A B...

Страница 113: ...Intake air pressure hose 2 Intake air pressure sensor 3 Fuel tank breather hose hose joint to rollover valve A Point the ends of the hose clamp to the right B Install the intake air pressure hose wit...

Страница 114: ...CABLE ROUTING except for ABS models 2 71 Intake air pressure sensor hose top view 1 B C 2 A...

Страница 115: ...pressure sensor hose 2 Hose fitting A Point the ends of the hose clamp to the right B Install the intake air pressure sensor hose completely onto the hose fitting making sure that the yellow paint ma...

Страница 116: ...CABLE ROUTING except for ABS models 2 73 Crankcase breather hose left side view H 1 A A B 1 C 2 D F G I 3 E...

Страница 117: ...ioner D Point the ends of the hose clamp rearward E Align the hose clamp with the yellow paint mark on the crankcase breather hose F Install the crankcase breather hose completely onto the hose joint...

Страница 118: ...CABLE ROUTING for ABS models 2 75 EAS1XC1004 CABLE ROUTING for ABS models Handlebar top and front view 1 2 3 4 5 6 6 A B C D G F F 5 G E 2 3 2 3 4 7 8 9 1 H I J K L 10 A D 5 6 M N O...

Страница 119: ...end in the handlebar E Fasten the left handlebar switch lead with the plastic band Align the plastic band with the locknut F Point the end of the plastic band downward G Face the buckle of the plastic...

Страница 120: ...CABLE ROUTING for ABS models 2 77 Headlight 3 2 2 1 A D B 1 4 5 6 7 7 8 8 9 9 10 11 C 12 12 12 13...

Страница 121: ...Clutch cable 10 Meter assembly lead 11 Right handlebar switch lead 12 Wire harness 13 Left handlebar switch lead A Fasten the headlight lead and intake air temperature sensor sub wire harness with th...

Страница 122: ...E ROUTING for ABS models 2 79 Steering head cable right side view G 4 5 6 H H 7 I J K L 8 M 1 2 A B C D 3 E F 8 U V W 10 X Y Z S T 1 6 AF AE AK AB AA AG AC AD 15 P O N AH 7 AI AJ R 11 11 9 Q 14 13 1 6...

Страница 123: ...park plug lead is not pinched between the rear cylinder head and the rear right cylinder head cover T Secure the plastic band by inserting the projection on the band into the hole in the frame and the...

Страница 124: ...CABLE ROUTING for ABS models 2 81 Clutch cable right side view A B C D E G F 1 2 6 7 8 5 9 3 4 12 J I H 11 10 3 3 4 3 3 K N L O M M 5 5 13 13 14 14...

Страница 125: ...to route the rear wheel sensor lead to the outside of the frame G Fasten the brake fluid reservoir hose rear brake light switch lead and O2 sensor lead with the plastic band Face the buckle of the pla...

Страница 126: ...CABLE ROUTING for ABS models 2 83 Frame inner side view A 1 2 B 3 4 5 C D 6 E F G H I 7 8 9 10 J 11 13 12...

Страница 127: ...er cover the couplers with the coupler cover C To the starter relay D Route the starter motor lead to the front of the frame cross member E Route the starter motor lead and rear brake light switch lea...

Страница 128: ...CABLE ROUTING for ABS models 2 85 Rear brake hose right side view 1 2 4 4 5 4 5 4 5 I 1 2 B 3 G A H F D E C...

Страница 129: ...eservoir hose at the white paint mark with the holder C To the rear wheel sensor coupler D 85 95 mm 3 35 3 74 in E 75 85 mm 2 95 3 35 in F To the rear wheel sensor coupler G Route the rear wheel senso...

Страница 130: ...CABLE ROUTING for ABS models 2 87 Hydraulic unit inner and left side view 1 2 3 4 A B A B 1 2 3 4 5 5 6...

Страница 131: ...to hydraulic unit 5 Brake hose hydraulic unit to rear brake caliper 6 Rubber cover A Route the brake hose front brake master cylinder to hydraulic unit and brake hose hydraulic unit to front brake ca...

Страница 132: ...CABLE ROUTING for ABS models 2 89 Front brake hose front and right side view 1 A B 1 1 1 2 C D...

Страница 133: ...embly front brake master cylinder to hydraulic unit through the cable guide B Route the brake pipe hose assembly front brake master cylinder to hydraulic unit between the front fork and the pipe secti...

Страница 134: ...CABLE ROUTING for ABS models 2 91 Front brake hose left side view 4 4 5 1 2 3 3 6 7 7 A A B E F E E 7 5 5 G H C C D...

Страница 135: ...in the brake hose bracket and then fasten the brake hose hydraulic unit to front brake caliper and brake hose front brake master cylinder to hydraulic unit with the holder C 85 95 mm 3 35 3 74 in D 75...

Страница 136: ...CABLE ROUTING for ABS models 2 93 Steering head left side view A B C 1 2 5 6 7 8 9 10 D E F G 11 13 12 K J I H L M N O P 3 4...

Страница 137: ...ront wheel sensor lead to the outside of the engine bracket front upper side G Route the fuel pump lead to the outside of the main switch leads and immobilizer unit lead and then fasten the fuel pump...

Страница 138: ...CABLE ROUTING for ABS models 2 95 Spark plug lead 3 3 4 4 5 6 7 8 9 10 11 12 C D A B 1 1 2 2...

Страница 139: ...cylinder head cover 10 Wire harness 11 Crankcase breather hose 12 Hose holder A Fasten the front cylinder spark plug lead with the holder B Fasten the fuel return hose with the holder C Fasten the hos...

Страница 140: ...TING for ABS models 2 97 Electrical components tray left side view 4 8 8 9 16 17 Q T Q R 1 2 3 4 4 7 14 3 1 1 3 3 4 2 3 A C F E G H I J K L M N O P V X Y W B B S 8 9 11 15 18 19 U 5 D 6 10 12 13 10 5...

Страница 141: ...necting the sidestand switch coupler insert the projection on the coupler cover into the hole in the frame M Fasten the oil level switch lead and sidestand switch lead with the holder Position the hol...

Страница 142: ...CABLE ROUTING for ABS models 2 99 Rectifier regulator rear view 1 2 3 4 5 6 9 10 11 11 A B C 14 D 12 F G H 15 17 16 I 7 E 13 8...

Страница 143: ...nd 17 Battery A Insert the projection the stator motor lead holder into the hole in the engine bracket rear lower bracket B Insert the projection on the wire harness holder into the hole in the batter...

Страница 144: ...CABLE ROUTING for ABS models 2 101 Rear fender top and left view 1 2 3 4 4 A B 6 2 5 5 1 1 1 7 8 C C C D E H F G 3 9 10 11...

Страница 145: ...the tail sub wire harness through the guides and then secure the lead by bending the guides around the lead B Align the white tape on the tail sub wire harness with the guide C Install each coupler s...

Страница 146: ...CABLE ROUTING for ABS models 2 103 Fuel tank 5 K 1 M H 8 8 R 10 3 7 7 7 9 N O P Q I H J J 2 3 4 5 6 D E F F G L 10 L A B C 1 2 11...

Страница 147: ...r more I Install the fuel return hose completely onto the hose fitting of the pressure regulator making sure that the yellow paint mark on the hose is facing outward J Align the ends of the hose clamp...

Страница 148: ...CABLE ROUTING for ABS models 2 105 Fuel tank breather hose left and rear view D 1 A 1 1 2 2 B B 3 3 C...

Страница 149: ...rflow hose from rollover valve A Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box B 2 8 mm 0 08 0 31 in C Install the fuel tank breather hose hose joint to...

Страница 150: ...CABLE ROUTING for ABS models 2 107 Fuel tank breather hose right side view 1 2 3 A B...

Страница 151: ...take air pressure hose 2 Intake air pressure sensor 3 Fuel tank breather hose hose joint to rollover valve A Point the ends of the hose clamp to the right B Install the intake air pressure hose with i...

Страница 152: ...CABLE ROUTING for ABS models 2 109 Intake air pressure sensor hose top view 1 B C 2 A...

Страница 153: ...essure sensor hose 2 Hose fitting A Point the ends of the hose clamp to the right B Install the intake air pressure sensor hose completely onto the hose fitting making sure that the yellow paint mark...

Страница 154: ...CABLE ROUTING for ABS models 2 111 Crankcase breather hose left side view H 1 A A B 1 C 2 D F G I 3 E...

Страница 155: ...er D Point the ends of the hose clamp rearward E Align the hose clamp with the yellow paint mark on the crankcase breather hose F Install the crankcase breather hose completely onto the hose joint mak...

Страница 156: ...CABLE ROUTING for ABS models 2 113...

Страница 157: ...E FRONT BRAKE HOSE 3 14 CHECKING THE REAR BRAKE HOSES 3 15 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 15 CHECKING THE WHEEL BEARINGS 3 17 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 3 17 CHECKING TH...

Страница 158: ...KING THE THROTTLE GRIP OPERATION 3 26 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE 3 27 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 27 ADJUSTING THE HEADLIGHT BEAM 3 27 REPLACING THE HEADLIGHT BULB...

Страница 159: ......

Страница 160: ...he 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 50000 km 30000 mi repeat the maintenance inter...

Страница 161: ...ened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease...

Страница 162: ...maging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level...

Страница 163: ...vent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is me...

Страница 164: ...1 5 Disconnect Spark plug caps Refer to ENGINE REMOVAL on page 5 3 6 Remove Spark plugs Refer to CAMSHAFTS on page 5 16 7 Remove Damper cover Generator cover damper Timing mark accessing screw Cranks...

Страница 165: ...learance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure the valve clearance with a thic...

Страница 166: ...properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 6 1 Air duct Refer to BELT DRIVE on page 4 94 Air filter case Refer t...

Страница 167: ...o adjust its vacuum pressure c If the vacuum pressure of the throttle body with the lower pressure is out of specification adjust it to specification first and then syn chronize the throttle bodies TI...

Страница 168: ...nd exhaust bolt 11 Muffler bracket and muffler bolts 12 EAS1XC1027 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume To adjust...

Страница 169: ...Check the clutch system Refer to CLUTCH on page 5 48 WARNING EWA1TP1010 Before checking the clutch operation check the brake system and make sure that the brake is operating at all times during the c...

Страница 170: ...brakes are operating fully EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake flui...

Страница 171: ...he brake 2 Check Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 47 EAS1XC1029 BLEEDING THE HYDRAULIC BRAKE SYSTEM except for...

Страница 172: ...3 11 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation 3 Install Brake fluid reservoir cover EAS1XC1030 BLEEDING THE HYDRAULIC BRAKE SYSTEM for ABS models WARNING EW...

Страница 173: ...ntil all of the air bub bles have disappeared from the brake fluid in the plastic hose j Check the operation of the hydraulic unit Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 67 NOTICE ECA1XC100...

Страница 174: ...e Tighten the holder bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 47 EAS21670 CHECKI...

Страница 175: ...n deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are cente...

Страница 176: ...1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 13 and CHECKING THE REAR WHEEL on page 4 25 EAS1TP1021 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 1 Check Swingarm pivot shaft beari...

Страница 177: ...curely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the sidestand or on a suit able stand so that the rear wheel is elevated 2 Rotate the rear wheel sever...

Страница 178: ...ING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bo...

Страница 179: ...he ring nut slots c 5 Install Upper bracket Refer to STEERING HEAD on page 4 85 EAS1TP1023 LUBRICATING THE STEERING BEARINGS Lubricate the steering bearings EAS1TP1024 CHECKING THE CHASSIS FASTENERS M...

Страница 180: ...CH Refer to ELECTRICAL COMPONENTS on page 7 147 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it f...

Страница 181: ...STING THE REAR SHOCK ABSORBER ASSEMBLIES for models equipped with gas cylinders The following procedure applies to both of the rear shock absorber assemblies WARNING EWA1XC1009 Securely support the ve...

Страница 182: ...pes or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils la beled ENERGY CONSERVING II or high er Do...

Страница 183: ...e the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt alo...

Страница 184: ...cover bracket Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 3 EAS1TP1030 CHECKING THE BRAKE LIGHT SWITCH 1 Check Front brake light switch operation Rear brake light switch operation Whe...

Страница 185: ...ubricate or replace the defective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Rep...

Страница 186: ...and that all lights come on Refer to INSTRUMENT AND CONTROL FUNCTIONS in Owner s manual Faulty Refer to CHECKING THE SWITCHES on page 7 151 and CHECK ING THE BULBS AND BULB SOCKETS on page 7 154 EAS2...

Страница 187: ...90 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the he...

Страница 188: ...PERIODIC MAINTENANCE 3 29 3 Remove Auxiliary light bulb 1 4 Install Auxiliary light bulb Auxiliary light socket 5 Install Headlight lens unit Refer to GENERAL CHASSIS on page 4 1 1 1 New...

Страница 189: ...HE REAR WHEEL DRIVE HUB 4 26 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 26 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR for ABS models 4 26 ASSEMBLING THE REAR WHEEL 4 27 ADJUSTING THE RE...

Страница 190: ...ESTS 4 65 CHECKING THE ABS WARNING LIGHT 4 68 HANDLEBAR 4 69 REMOVING THE HANDLEBAR 4 71 CHECKING THE HANDLEBAR 4 71 INSTALLING THE HANDLEBAR 4 71 FRONT FORK 4 74 REMOVING THE FRONT FORK LEGS 4 78 DIS...

Страница 191: ...BELT DRIVE 4 92 REMOVING THE DRIVE BELT AND DRIVE PULLEY 4 93 CHECKING THE DRIVE BELT 4 93 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 93...

Страница 192: ...eat 1 5 Battery cover holder 1 6 Battery cover 1 7 Brake fluid reservoir cover 1 8 Brake fluid reservoir 1 9 Right side cover 1 For installation reverse the removal proce dure LT 2 3 Nm 0 23 m kgf 1 7...

Страница 193: ...eat 1 TIP Insert the projection a on the rear of the seat into the seat holder b as shown While pushing the front of the seat down so that there is no space between the rubber dampers c and the frame...

Страница 194: ...ry band 2 5 ECU bracket 1 6 Negative battery lead 1 Disconnect 7 Positive battery lead 1 Disconnect 8 Battery 1 9 Tool box band 1 10 Tool box 1 11 Relay unit 1 12 Turn signal hazard relay 1 13 Head li...

Страница 195: ...battery lead starter relay 1 Disconnect 21 Starter relay 1 For installation reverse the removal proce dure Removing the battery and relays Order Job Parts to remove Q ty Remarks 1 5 Nm 0 15 m kgf 1 1...

Страница 196: ...GENERAL CHASSIS 4 5 EAS1TP1065 INSTALLING THE TOOL BOX 1 Install Tool box 1 TIP Install the tool box with the INSIDE mark a facing inward 1 a...

Страница 197: ...Remarks 1 Air filter case cover 1 2 Air filter element 1 3 Air filter case 1 4 Crankcase breather hose 1 Disconnect For installation reverse the removal proce dure New New 2 0 Nm 0 20 m kgf 1 4 ft Ib...

Страница 198: ...light coupler 1 Disconnect Refer to CABLE ROUTING except for ABS models on page 2 41 and CABLE ROUT ING for ABS models on page 2 75 12 Rear right turn signal light coupler 1 Disconnect Refer to CABLE...

Страница 199: ...rear fender Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft...

Страница 200: ...1 Disconnect 3 Auxiliary light coupler 1 Disconnect 4 Intake air temperature sensor coupler 1 5 Headlight body 1 For installation reverse the removal proce dure 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7...

Страница 201: ...the front wheel is elevated 1 Front brake caliper 1 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle cap 1 Except for AUS 4 Front wheel axle 1 5 Front wheel 1 6 Collar 2 7 Front brake disc 1...

Страница 202: ...d holder 1 2 Front brake caliper 1 3 Front wheel sensor 1 4 Front wheel axle pinch bolt 2 Loosen 5 Front wheel axle cap 1 6 Front wheel axle 1 7 Front wheel 1 8 Collar 2 9 Front brake disc 1 For insta...

Страница 203: ...heel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 For ABS models 2 Oil seal 2 3 Wheel bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure 4 3 2 2 3 1 New New Ne...

Страница 204: ...Do not apply the brake lever when remov ing the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the outer tube for ABS models 3 El...

Страница 205: ...ents with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If f...

Страница 206: ...or rotor EAS21960 ASSEMBLING THE FRONT WHEEL NOTICE ECA1XC1011 For ABS models Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off imm...

Страница 207: ...static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitabl...

Страница 208: ...L FRONT BRAKE DISC 1 Install Front brake disc TIP Apply locking agent LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern Install the brak...

Страница 209: ...t wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by...

Страница 210: ...er to GENERAL CHASSIS on page 4 1 1 Rear brake caliper 1 2 Drive belt upper guard 1 3 Drive belt adjusting bolt locknut 2 Loosen 4 Drive belt adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1...

Страница 211: ...removal proce dure Removing the rear wheel except for ABS models Order Job Parts to remove Q ty Remarks LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R...

Страница 212: ...ar wheel sensor lead holder 1 3 Rear wheel sensor 1 4 Drive belt upper guard 1 5 Drive belt adjusting bolt locknut 2 Loosen 6 Drive belt adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Re...

Страница 213: ...ure Removing the rear wheel for ABS models Order Job Parts to remove Q ty Remarks LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft...

Страница 214: ...r wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 8 Bearing 1 9 Collar 1 10 Bearing 1 11 Collar 1 12 Rear wheel drive hub damper 6 13 Rear wheel 1 For installation reverse...

Страница 215: ...EAR WHEEL 4 24 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Bearing 1 2 Oil seal 1 3 Bearing 1 4 Spacer 1 For assembly reverse the disassembly pro cedure LS New New New 4 1 3...

Страница 216: ...depress the brake pedal when re moving the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket for ABS...

Страница 217: ...TOR for ABS models NOTICE ECA1XC1012 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cann...

Страница 218: ...spacer 5 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the bra...

Страница 219: ...to ADJUSTING THE DRIVE BELT SLACK on page 3 18 8 Tighten Rear wheel axle nut 9 Install for ABS models Rear wheel sensor NOTICE ECA1XC1023 Make sure there are no foreign materials in the rear wheel se...

Страница 220: ...t TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is install...

Страница 221: ...marks 1 Front brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 2 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal...

Страница 222: ...brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 2 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal proce dure 6 6...

Страница 223: ...1 3 Brake master cylinder reservoir diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake light switch 1 8 F...

Страница 224: ...Removing the front brake master cylinder Order Job Parts to remove Q ty Remarks 7 6 1 2 3 4 5 8 9 10 11 12 New S 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 Nm 0 1 m kgf 0 7 ft Ibf T R 1 Nm 0 1 m kgf 0 7 ft I...

Страница 225: ...34 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 For assembly reverse the disassembly pro cedure BF...

Страница 226: ...to BLEEDING THE HYDRAULIC BRAKE SYSTEM except for ABS models on page 3 12 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Front brake hose 1 4 Front brake caliper bracket bolt 2 5 Front brake...

Страница 227: ...r ABS models on page 3 13 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Brake pipe hose assembly hydraulic unit to front brake caliper 1 4 Front brake caliper bracket bolt 2 5 Front wheel se...

Страница 228: ...rake pad spring 1 5 Brake pad support 2 6 Brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 11 Bush 1 For ABS models Fo...

Страница 229: ...to hy draulic unit 1 Disconnect 6 Brake pipe hose assembly holder rear side 1 7 Brake pipe hose assembly holder front side 1 8 Brake pipe hose assembly hydraulic unit to front brake caliper 1 9 Brake...

Страница 230: ...10 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so...

Страница 231: ...pad shims brake pad supports and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed scre...

Страница 232: ...ABS models TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons 1 Brake caliper pist...

Страница 233: ...o swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brak...

Страница 234: ...dels on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer...

Страница 235: ...ake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install Brake hose gaskets Front brake hose 1 Front brake hose union bolt 2 WARNIN...

Страница 236: ...eling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM except for ABS models on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 EAS1XC1055 INSTALLIN...

Страница 237: ...Install Brake hose gaskets Brake hose hydraulic unit to front brake cali per Brake hose front brake master cylinder to hydraulic unit Front brake hose union bolts WARNING EWA1XC1013 Proper brake hose...

Страница 238: ...to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Rear brake pad shim 2 5 Rear brake pad spring 2 For installation reverse the removal proce dur...

Страница 239: ...rvoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose ho...

Страница 240: ...removal proce dure Removing the rear brake master cylinder except for ABS models Order Job Parts to remove Q ty Remarks New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 23 N...

Страница 241: ...voir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose wheel sensor lead holder 1 8 Rear w...

Страница 242: ...witch 1 For installation reverse the removal proce dure Removing the rear brake master cylinder for ABS models Order Job Parts to remove Q ty Remarks New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0...

Страница 243: ...er Job Parts to remove Q ty Remarks 1 Rear brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Brake hose joint 1 4 Bush 1 5 Brake master cylinder body 1 For assembly reverse the disassembly...

Страница 244: ...for ABS models on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper retainin...

Страница 245: ...rake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper bracket 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad spring 2 For assembly reve...

Страница 246: ...Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 39 4...

Страница 247: ...ified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC...

Страница 248: ...E REAR BRAKE CALIPER WARNING EWA1TP1007 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponen...

Страница 249: ...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 5 Bleed Brake system...

Страница 250: ...and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Install Brake hose joint Brake master cylinder kit Rear brake master cylinder joint TIP The rear brake...

Страница 251: ...he brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Theref...

Страница 252: ...age 4 94 Drive pulley housing Refer to ENGINE REMOVAL on page 5 3 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Brake hose rear brake master cylinder to hy draulic u...

Страница 253: ...installation reverse the removal proce dure Removing the hydraulic unit assembly and brackets Order Job Parts to remove Q ty Remarks New New New 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf...

Страница 254: ...E SYS TEM for ABS models on page 4 61 1 Hydraulic unit assembly 1 2 Hydraulic unit assembly upper bracket 1 3 Hydraulic unit assembly lower bracket 1 4 Rubber cover 1 5 Seal 1 For installation reverse...

Страница 255: ...em to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupl...

Страница 256: ...the specified torque starting with the bolt 1 5 Install Brake hose hydraulic unit to front brake cali per 1 Brake hose front brake master cylinder to hydraulic unit 2 Brake hose hydraulic unit to rear...

Страница 257: ...reful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted...

Страница 258: ...the wheels are not rotating 1 Place the vehicle on a suitable stand 2 Turn the main switch to OFF 3 Remove Left side cover Rider seat ECU bracket Battery cover Refer to GENERAL CHASSIS on page 4 1 4 C...

Страница 259: ...c unit assembly 10 If the operation of the hydraulic unit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no dang...

Страница 260: ...been met Off The brake lever and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsati...

Страница 261: ...assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch...

Страница 262: ...lebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Clutch switch coupler 1 Disconnect 9 Left handlebar switch 1 10 Handlebar grip 1 11 Clutch cable 1 Disconnect 12 Clutch lever 1 13 Clut...

Страница 263: ...llation reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks LT LS LS 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...

Страница 264: ...bar 1 Upper handlebar holders 2 NOTICE ECA1TP1010 First tighten the bolts on the upper side of the upper handlebar holder and then on the lower side Turn the handlebar all the way to the left and righ...

Страница 265: ...ndlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be less than 3 mm 0 12 in of...

Страница 266: ...mark a on the handle bar First tighten the upper bolt then the lower bolt 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 10 12 Adjust Throttle grip free play...

Страница 267: ...light pinch bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 9 Air temperature sensor bracket 1 Left side only 10 Air temperature sensor 1 Left side only 11 Front turn signal ligh...

Страница 268: ...gnal light pinch bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 9 Air temperature sensor bracket 1 Left side only 10 Air temperature sensor 1 Left side only 11 Front turn signal...

Страница 269: ...fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 11 Damper rod 1 12 Damper rod ring 1 13 Rebound...

Страница 270: ...low stopper 1 20 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks LT LS LS LS New 7 New 8 New 15 16 1 New 17 20 New...

Страница 271: ...hile drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Front fork damper rod bolt 1 Copper washer TIP While...

Страница 272: ...he front fork leg do not allow any foreign ma terial to enter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Mak...

Страница 273: ...p TIP Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the f...

Страница 274: ...with the outer tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and d...

Страница 275: ...coupler into the slot a in the front turn signal light 2 Install Front fork leg 1 Temporarily tighten the lower bracket pinch bolts TIP Make sure the inner tube end is flush with the top of the upper...

Страница 276: ...light bracket 1 2 Front brake hose holder 1 Except for ABS models 3 Front brake hose wheel sensor lead holder 1 For ABS models 4 Steering stem nut 1 5 Washer 1 6 Upper bracket 1 7 Lock washer 1 8 Uppe...

Страница 277: ...outer race 2 19 Lower bracket cap 1 For installation reverse the removal proce dure Removing the upper bracket and lower bracket Order Job Parts to remove Q ty Remarks 11 10 9 8 7 12 13 18 14 18 15 17...

Страница 278: ...the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270...

Страница 279: ...ket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 76 TIP Temporarily tighten the upper and lower bracket pinch bolts 6...

Страница 280: ...Drive belt lower guard 1 2 Rear brake hose guide 1 3 Rear shock absorber assembly 2 4 Pivot shaft cover 2 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Collar 2 9 Dust seal 2 10 Spacer 2 11 Dust...

Страница 281: ...oce dure Removing the swingarm and rear shock absorber assemblies Order Job Parts to remove Q ty Remarks LS LS LS New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kg...

Страница 282: ...p or down e If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings collars and dust seals EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Re...

Страница 283: ...rotection to prevent eye damage from released gas or metal chips EAS1XC1039 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber ass...

Страница 284: ...ped with gas cylinders 5 Tighten Rear shock absorber assembly upper bolt 6 Tighten Rear shock absorber assembly lower nut 7 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 18...

Страница 285: ...89 1 Air duct 1 2 Drive pulley cover 1 3 Drive belt 1 4 Speed sensor coupler 1 Disconnect Except for ABS models 5 Speed sensor 1 Except for ABS models 6 Speed sensor bracket 1 Except for ABS models 7...

Страница 286: ...rt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check Drive belt NOTICE ECA1TP1030 To protect the drive belt...

Страница 287: ...s a in the drive axle When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move 4 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 1...

Страница 288: ...BELT DRIVE 4 97...

Страница 289: ...HE CYLINDER HEAD COVERS 5 25 CYLINDER HEADS 5 26 REMOVING THE CYLINDER HEADS 5 27 CHECKING THE CYLINDER HEADS 5 27 INSTALLING THE CYLINDER HEADS 5 27 VALVES AND VALVE SPRINGS 5 29 REMOVING THE VALVES...

Страница 290: ...THE STOPPER LEVER 5 60 INSTALLING THE SHIFT SHAFT 5 60 ELECTRIC STARTER 5 61 CHECKING THE STARTER MOTOR 5 63 ASSEMBLING THE STARTER MOTOR 5 64 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 69 CHECKING...

Страница 291: ...ION 5 80 CHECKING THE SHIFT FORKS 5 83 CHECKING THE SHIFT DRUM ASSEMBLY 5 83 CHECKING THE TRANSMISSION 5 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEM...

Страница 292: ...the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 0 kgf cm 14 5 psi c If the compression pressu...

Страница 293: ...ENGINE INSPECTION 5 2 10 Install Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 3...

Страница 294: ...bracket 1 13 Exhaust pipe protector 3 1 14 Muffler protector 1 1 15 Muffler protector 2 1 16 Muffler cap 1 1 18 13 2 16 3 14 15 17 5 7 8 9 6 6 10 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT...

Страница 295: ...6 6 10 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT 5 LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m k...

Страница 296: ...haust pipe protector 2 bracket band so that its section to crimp is positioned at the location a shown in the illustration TIP Be sure to place the exhaust pipe protector 2 bracket band over the exhau...

Страница 297: ...wn 2 Install Clamp 1 to the muffler assembly TIP Fit the projection a on the clamp into the slot b shown in the illustration Temporarily tighten the clamp bolt 2 3 Install Muffler assembly Muffler bra...

Страница 298: ...8 Rear cylinder left cover bracket 1 9 Rear cylinder right cover bracket 1 10 Ground lead 1 Disconnect 11 Drive pulley housing 1 12 Neutral switch sub wire harness 1 13 Damper 1 14 Dowel pin 2 15 Side...

Страница 299: ...ove Q ty Remarks LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R...

Страница 300: ...26 The shift rod locknut shift pedal side has left hand threads b Turn the shift rod 2 in direction a or b to obtain the correct shift rod length TIP Make sure that the engaged thread length on both e...

Страница 301: ...anifold assem bly Refer to THROTTLE BODIES on page 6 6 1 Starter motor lead 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Oil level switch coupler 1 Di...

Страница 302: ...NE REMOVAL 5 11 EAS1TP1070 INSTALLING THE HORN 1 Install Horn 1 TIP Make sure that the horn bracket 2 contacts the portion a of the stay on the frame T R Horn bracket bolt 30 Nm 3 0 m kgf 22 ft lbf 1...

Страница 303: ...e 2 7 Engine bracket front lower side 1 8 Engine mounting bolt rear lower side 1 9 Engine bracket bolt rear lower side 2 10 Engine bracket rear lower side 1 11 Engine bracket nut front upper side 2 12...

Страница 304: ...or installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks LT LT LT LS 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 88 Nm 8 8 m kgf 64 ft...

Страница 305: ...5 Engine mounting nut rear upper side 16 Engine mounting nut front upper side 17 Engine mounting nut rear lower side 18 Engine mounting nut front lower side 19 TIP Lubricate the engine mounting bolt f...

Страница 306: ...t rear lower side 18 Engine mounting nut front lower side 19 T R Engine mounting nut rear upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting nut front upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mou...

Страница 307: ...Intake manifold assembly Refer to THROTTLE BODIES on page 6 6 1 Tappet cover 4 2 O ring 4 3 Fuel filter bracket 1 4 Front cylinder side cover 1 5 Front cylinder side cover gasket 1 6 Rear cylinder sid...

Страница 308: ...ain tensioner gasket 2 6 Camshaft bolt 2 7 Camshaft sprocket 2 8 Camshaft retainer 2 9 Front cylinder camshaft 1 10 Rear cylinder camshaft 1 11 Intake rocker arm shaft 2 12 Intake rocker arm 2 13 Exha...

Страница 309: ...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 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m...

Страница 310: ...I mark c on the camshaft sprocket with the arrow mark d on the front cylinder head 2 Remove Front cylinder timing chain tensioner 1 3 Remove Front cylinder camshaft sprocket TIP While holding the cams...

Страница 311: ...he camshaft sprocket with the arrow mark d on the rear cylinder head 7 Remove Rear cylinder timing chain tensioner Rear cylinder camshaft sprocket Camshaft retainer Rear cylinder camshaft Intake rocke...

Страница 312: ...ion excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of sp...

Страница 313: ...er gasket 5 Timing chain tensioner rod 6 Damage wear Replace the defective part s EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camsha...

Страница 314: ...mark c on the camshaft sprocket with the arrow mark d on the front cylinder head When installing the front cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the exhau...

Страница 315: ...the crankshaft when installing the camshaft s to avoid damage or improper valve timing TIP To position the rear cylinder piston at TDC on the compression stroke align the I mark c on the camshaft spro...

Страница 316: ...STING THE VALVE CLEAR ANCE on page 3 4 EAS1TP1053 INSTALLING THE CYLINDER HEAD COVERS 1 Install Rear cylinder side cover Fuel filter bracket Tappet covers 2 Install Front cylinder side cover Tappet co...

Страница 317: ...pin 4 8 Cylinder head gasket 2 9 Timing chain guide exhaust side 1 10 Timing chain guide intake side 1 For installation reverse the removal proce dure 1st 15 Nm 1 5 m kgf 11 ft Ibf Final 65 Nm 6 5 m...

Страница 318: ...amag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder heads Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a st...

Страница 319: ...cylinder head nuts in the proper tightening sequence as shown and torque them in three stages T R Cylinder head nut 1st 15 Nm 1 5 m kgf 11 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf Final 65 Nm 6 5 m kgf 47...

Страница 320: ...ty Remarks The following procedure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 26 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust val...

Страница 321: ...cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3...

Страница 322: ...stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010...

Страница 323: ...s from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b o...

Страница 324: ...ping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping p...

Страница 325: ...3 Lubricate Valve stem end with the recommended lubricant Free length intake 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Free length exhaust 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Installed compression s...

Страница 326: ...tall the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the...

Страница 327: ...ts to remove Q ty Remarks Cylinder heads Refer to CYLINDER HEADS on page 5 26 1 Front cylinder 1 2 Rear cylinder 1 3 Front cylinder gasket 1 4 Rear cylinder gasket 1 5 Dowel pin 4 6 Circlip 4 7 Piston...

Страница 328: ...ap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check...

Страница 329: ...ation 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 ring...

Страница 330: ...fication Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 10 mm 0 39 in Piston ring Top ring End gap installed 0...

Страница 331: ...ston fac es towards the front side of the cylinder Before installing the circlips cover the crank case opening with a clean rag to prevent the clips from falling into the crankcase Install the circlip...

Страница 332: ...AND PISTONS 5 41 6 Install Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide through the timing cha...

Страница 333: ...5 3 1 Rectifier regulator coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Damper cover 1 4 Generator cover damper 1 5 Crankshaft end accessing screw 1 6 Timing mark accessing...

Страница 334: ...For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks LT LT LT 11 1 12 13 10 9 7 4 3 5 6 10 8 2 12 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m...

Страница 335: ...rotor 1 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Starter clutch idle gear 2 shaft 1 6 Starter clutch idle gear 2 1 7 Starter clutch idle gear 1 shaft 1 8 Starter clutch idle gear...

Страница 336: ...r clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2...

Страница 337: ...NSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure...

Страница 338: ...TCH 5 47 EAS1TP1054 INSTALLING THE GENERATOR COVER 1 Install TIP Temporally tighten a and b and then tighten the generator cover bolts in the order shown in the illustration T R Generator cover bolt 1...

Страница 339: ...r Refer to GENERATOR AND STARTER CLUTCH on page 5 42 Rear brake master cylinder Right footrest as sembly Rear brake light switch Refer to REAR BRAKE on page 4 47 1 Circlip 1 2 Pull lever 1 3 Pull leve...

Страница 340: ...ve gear 1 15 Woodruff key 1 For installation reverse the removal proce dure Removing the primary drive gear Order Job Parts to remove Q ty Remarks LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kg...

Страница 341: ...r shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 6 Oil seal retainer 1 7 Oil seal 1 For installation reverse the removal proce dure...

Страница 342: ...plate 1 2 Inside diameter 124 mm 4 88 in 8 Clutch plate 8 9 Friction plate 2 7 Inside diameter 124 mm 4 88 in 10 Clutch boss nut 1 11 Conical spring washer 1 12 Clutch boss 1 13 Thrust washer 1 1 14...

Страница 343: ...r 2 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New 6 9 8 8 8 8 8 8 8 9 9...

Страница 344: ...boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 3 Remove Clutch boss nut 1 Conical spring washer 2 Clutch boss 3 EAS25100 CHECKING THE FR...

Страница 345: ...e Replace 3 Measure Clutch spring free height Out of specification Replace the clutch spring plate EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutc...

Страница 346: ...place the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL R...

Страница 347: ...s with engine oil Install the conical spring washer with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss n...

Страница 348: ...1 Pull lever 2 Washer Circlip TIP Make sure that the mark a on the pull lever is facing forward When installing the pull lever push it and check that its punch mark b aligns with the mark c on the cl...

Страница 349: ...her with the groove b in the spacer While holding the generator rotor 4 with the sheave holder 5 tighten the primary drive gear nut Do not allow the sheave holder to touch the projection on the genera...

Страница 350: ...94 Shift arm Refer to ENGINE REMOVAL on page 5 3 Clutch cover Clutch housing Refer to CLUTCH on page 5 48 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 Shift shaf...

Страница 351: ...AFT 1 Install Bearing 1 Oil seals 2 to the crankcase 2 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 TIP Lubricate the oil seal lips with lithium soap based grease Hook the ends of the...

Страница 352: ...g the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0...

Страница 353: ...Remarks 1 O ring 1 2 Starter motor front cover 1 3 Armature assembly 1 4 Starter motor yoke 1 5 Gasket 2 6 Starter motor rear cover 1 7 Brush set assembly 1 8 O ring 1 For assembly reverse the disasse...

Страница 354: ...embly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush set assembly 5 Measure B...

Страница 355: ...EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Brush set assembly 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter mot...

Страница 356: ...page 5 59 1 Oil level switch 1 2 Engine oil drain bolt 1 3 Neutral switch 1 4 Timing chain guide 2 5 Timing chain 2 6 Spacer 1 7 Oil filter cartridge 1 8 Oil delivery pipe 1 1 9 Oil delivery pipe 2 1...

Страница 357: ...to remove Q ty Remarks 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft I...

Страница 358: ...ate 1 1 2 Left crankcase 1 3 Dowel pin 2 4 Joint pipe 1 5 O ring 2 6 Oil baffle plate 2 1 7 Gasket 1 8 Right crankcase 1 9 Stud bolt 6 l 239 mm 9 41 in 10 Stud bolt 2 l 210 mm 8 27 in For installation...

Страница 359: ...rts to remove Q ty Remarks Oil pump assembly Refer to OIL PUMP on page 5 72 Crankshaft Refer to CRANKSHAFT on page 5 75 Transmission Refer to TRANSMISSION on page 5 80 1 Bearing retainer 2 2 Oil seal...

Страница 360: ...ges Obstruction Blow out with compressed air EAS1TP1056 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement...

Страница 361: ...stall Crankcase bolts M10 Crankcase bolts M6 Oil baffle plate 1 bolts TIP Apply locking agent LOCTITE to the threads of the right crankcase bolts and oil baf fle plate 1 bolts Tighten the crankcase bo...

Страница 362: ...CRANKCASE 5 71 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair...

Страница 363: ...ief valve assembly 1 2 Oil pump assembly 1 3 Dowel pin 2 4 Oil pump housing 1 5 Dowel pin 2 6 Impeller shaft 1 7 Pin 1 8 Oil pump inner rotor 1 9 Oil pump outer rotor 1 10 Oil pump housing cover 1 11...

Страница 364: ...ing 3 Spring retainer 4 Damage wear Replace the relief valve as sembly EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE...

Страница 365: ...mp operation Refer to CHECKING THE OIL PUMP on page 5 73 EAS1TP1060 INSTALLING THE OIL PUMP ASSEMBLY 1 Install Oil pump assembly NOTICE ECA1TP1021 After tightening the bolts make sure the oil pump ass...

Страница 366: ...kshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 1 Crankshaft 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bear...

Страница 367: ...he correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pin and th...

Страница 368: ...nce is out of specification select re placement big end bearings 4 Select Big end bearings P1 P2 TIP The numbers a on the connecting rods are used to determine the replacement big end bearing sizes P1...

Страница 369: ...ended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pin TIP Align the projections a on the big end bear ings with the notches b in the connecting rods an...

Страница 370: ...n and then retighten it Replace the bolt with a new one and perform the procedure again NOTICE ECA1TP1022 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until i...

Страница 371: ...rder Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift drum assembly 1 4 Shift fork 1 2 5 Shift f...

Страница 372: ...2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed lock washer retainer 1 5 4th pinion gear 1 6 Collar 1 7 Toothed washer 1 8 Circlip 1 9 3rd pinion gear 1 10 Circlip 1 11 Toothed washer 1 12 5th...

Страница 373: ...wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Toothed washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Circlip 1 13 T...

Страница 374: ...movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift dru...

Страница 375: ...s a rest on the sides of a spline b with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer in the groove a in the drive axle a...

Страница 376: ...eck Transmission Rough movement Repair TIP Apply molybdenum disulfide grease to each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that...

Страница 377: ...PUMP 6 4 INSTALLING THE FUEL SENDER 6 5 THROTTLE BODIES 6 6 CHECKING THE INJECTORS 6 9 INSTALLING THE INJECTORS 6 9 CHECKING THE THROTTLE BODIES 6 9 CHECKING THE INTAKE MANIFOLD JOINTS 6 9 CHECKING TH...

Страница 378: ...Disconnect 6 Fuel hose fuel pump to fuel hose 1 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel sender 1 10 Fuel pump cover 1 11 Fuel pump 1 12 Fuel tank bracket 1 13 Fuel tank bracket damper 1...

Страница 379: ...egulator bracket 1 4 Fuel tank breather overflow hose fuel tank to fuel hose joint 1 5 Fuel hose joint 1 6 Fuel tank breather overflow hose fuel hose joint to rollover valve 1 7 Rollover valve 1 8 Fue...

Страница 380: ...el hose to fuel fil ter slide the fuel hose connector lock 3 in the direction of the arrow shown using a slotted head screwdriver and then disconnect the hose Disconnect the fuel hose from the fuel pu...

Страница 381: ...ip a shall face toward the fuel tank Tighten the fuel pump bolts in the proper tight ening sequence as shown 2 Install Fuel hoses NOTICE ECA1TP1017 When installing a fuel hose make sure that it is sec...

Страница 382: ...Install Fuel sender O ring TIP Position the fuel sender coupler 1 between the guides a on the fuel tank bracket 2 A Connection to fuel pump and fuel filter B Connection between fuel hoses T R Fuel se...

Страница 383: ...ler 1 Disconnect 2 Intake air pressure sensor hose 1 Disconnect 3 Throttle cable 2 Disconnect 4 Throttle body 1 NOTICE ECA1TP1018 The throttle body should not disassem bled 5 Gasket 1 6 ISC idle speed...

Страница 384: ...6 1 Engine temperature sensor coupler 1 Disconnect 2 Fuel injector coupler 2 Disconnect 3 Fuel filter 1 4 Fuel filter cover 1 5 Fuel return hose 1 6 Intake manifold joint clamp screw 2 Loosen 7 Intake...

Страница 385: ...ove Q ty Remarks 1 Pressure regulator 1 2 Inlet pipe assembly 1 3 Injector 2 4 Intake manifold 1 For assembly reverse the disassembly pro cedure LT New New New New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T...

Страница 386: ...he bolts from being tightened to the specified torque 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 7 39 EAS1TP1041 INSTALLING THE INJECTORS 1 Install the injectors...

Страница 387: ...Measure the throttle position sensor output voltage e Adjust the throttle position sensor angle so that the output voltage is within the specified range f After adjusting the throttle position sensor...

Страница 388: ...intake manifold joint 2 to the intake manifold assembly TIP Be sure to fit the projection b on the intake manifold assembly between the projections c on the rear cylinder intake manifold joint c Inst...

Страница 389: ...RAM for ABS models 7 19 TROUBLESHOOTING 7 21 LIGHTING SYSTEM 7 23 CIRCUIT DIAGRAM except for ABS models 7 23 CIRCUIT DIAGRAM for ABS models 7 25 TROUBLESHOOTING 7 27 SIGNALING SYSTEM 7 29 CIRCUIT DIAG...

Страница 390: ...7 111 ABS COUPLER LOCATION CHART 7 113 MAINTENANCE OF THE ABS ECU 7 115 ABS TROUBLESHOOTING OUTLINE 7 115 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 7 116 BASIC PROCESS FOR TROUBLESHOOTING 7 117 A CHECKIN...

Страница 391: ...POSITION SENSOR 7 163 CHECKING THE LEAN ANGLE SENSOR 7 163 CHECKING THE STARTER MOTOR OPERATION 7 164 CHECKING THE STATOR COIL 7 164 CHECKING THE RECTIFIER REGULATOR 7 165 CHECKING THE OIL LEVEL SWIT...

Страница 392: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Страница 393: ...ay unit 19 Neutral switch 20 Sidestand switch 25 Crankshaft position sensor 26 Lean angle sensor 31 ECU engine control unit 32 Front cylinder ignition coil 33 Spark plug 34 Rear cylinder ignition coil...

Страница 394: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Страница 395: ...ition fuse 24 Relay unit 27 Neutral switch 28 Sidestand switch 32 Crankshaft position sensor 33 Lean angle sensor 38 ECU engine control unit 39 Front cylinder ignition coil 40 Spark plug 41 Rear cylin...

Страница 396: ...venting the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sid...

Страница 397: ...ING THE BATTERY on page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Regap or replace the spark plug s 4 Chec...

Страница 398: ...n page 7 151 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELA...

Страница 399: ...IGNITION SYSTEM 7 8...

Страница 400: ...B L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L...

Страница 401: ...rter relay 9 Starter motor 10 Ignition fuse 16 Relay unit 17 Starting circuit cut off relay 19 Neutral switch 20 Sidestand switch 50 Joint coupler 58 Clutch switch 71 Engine stop switch 72 Start switc...

Страница 402: ...L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L...

Страница 403: ...rter relay 9 Starter motor 13 Joint coupler 17 Ignition fuse 24 Relay unit 25 Starting circuit cut off relay 27 Neutral switch 28 Sidestand switch 65 Clutch switch 78 Engine stop switch 79 Start switc...

Страница 404: ...the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one...

Страница 405: ...harge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 164 The starter motor is OK Perform the elec tric starting system troubleshoot...

Страница 406: ...51 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page...

Страница 407: ...ELECTRIC STARTING SYSTEM 7 16...

Страница 408: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Страница 409: ...CHARGING SYSTEM 7 18 1 AC magneto 2 Rectifier regulator 4 Main fuse 5 Battery A Wire harness B Negative battery sub wire harness...

Страница 410: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Страница 411: ...CHARGING SYSTEM 7 20 1 AC magneto 2 Rectifier regulator 4 Main fuse 5 Battery A Wire harness B Negative battery sub wire harness...

Страница 412: ...n page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 164 Replace the crankshaft position sen sor stator assembly...

Страница 413: ...CHARGING SYSTEM 7 22...

Страница 414: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Страница 415: ...unit 41 Multi function meter 45 Meter light 46 High beam indicator light 50 Joint coupler 52 Headlight relay 54 Dimmer switch 55 Pass switch 61 Headlight 62 Auxiliary light 67 License plate light 68 T...

Страница 416: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Страница 417: ...U engine control unit 48 Multi function meter 52 Meter light 54 High beam indicator light 59 Headlight relay 61 Dimmer switch 62 Pass switch 68 Headlight 69 Auxiliary light 74 License plate light 75 T...

Страница 418: ...on and signaling system Refer to CHECKING THE FUS ES on page 7 155 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 156 Clean the battery terminals Recharge...

Страница 419: ...e entire lighting system wiring Refer to CIRCUIT DIAGRAM ex cept for ABS models on page 7 23 and CIRCUIT DIAGRAM for ABS models on page 7 25 Properly connect or replace the wire har ness Replace the E...

Страница 420: ...G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Страница 421: ...warning light 48 Turn signal indicator light 49 Fuel sender 50 Joint coupler 51 Turn signal hazard relay 56 Turn signal switch 57 Horn switch 60 Horn 63 Front left turn signal light 64 Front right tur...

Страница 422: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Страница 423: ...ter 50 Oil level warning light 51 Fuel level warning light 56 Turn signal indicator light 57 Fuel sender 58 Turn signal hazard relay 63 Turn signal switch 64 Horn switch 67 Horn 70 Front left turn sig...

Страница 424: ...em hazard light ing and ABS ECU for ABS mod els Refer to CHECKING THE FUS ES on page 7 155 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 156 Clean the bat...

Страница 425: ...e 1 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 15...

Страница 426: ...ABS models on page 7 29 and CIRCUIT DIAGRAM for ABS models on page 7 31 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITC...

Страница 427: ...eplace the fuel sender 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for ABS models on page 7 29 and CIRCUIT DIAGRAM for ABS models on page 7 31 Properly connect or repla...

Страница 428: ...CU coupler white white white red white red Between ABS ECU coupler and ECU coupler white yellow white yellow Between ECU coupler and meter assembly coupler yellow blue yellow blue 2 Check the entire w...

Страница 429: ...SIGNALING SYSTEM 7 38...

Страница 430: ...L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G...

Страница 431: ...ensor 26 Lean angle sensor 27 Throttle position sensor 28 Intake air pressure sensor 29 ISC idle speed control unit 30 Yamaha diagnostic tool coupler 31 ECU engine control unit 32 Front cylinder ignit...

Страница 432: ...L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L...

Страница 433: ...ir temperature sensor 32 Crankshaft position sensor 33 Lean angle sensor 34 Throttle position sensor 35 Intake air pressure sensor 36 ISC idle speed control unit 37 Yamaha diagnostic tool coupler 38 E...

Страница 434: ...low is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to ON and i...

Страница 435: ...de number is dis played 5 Erase the malfunction history in the diagnos tic mode code No 62 Refer to SELF DI AGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 8 5 TIP Turning the main switch to OFF w...

Страница 436: ...sting the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap 1 and then connect the Yamaha diagnostic tool to the coupler TIP When the Yamaha diagnostic tool is connected...

Страница 437: ...t of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code num...

Страница 438: ...isplay freeze frame data The mark is displayed when the freeze frame data is available 10 ECU conduction time hour minute second The total ECU conduction time total hours the vehicle s main switch was...

Страница 439: ...onfirmation of service completion 1 Connection of crankshaft po sition sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and...

Страница 440: ...ntake air pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected...

Страница 441: ...yed Go to item 6 6 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated A...

Страница 442: ...condition Clogged or detached hose Repair or replace the sen sor hose Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code n...

Страница 443: ...locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace th...

Страница 444: ...d with the transmission in gear Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of sidestand switch coupler Check the locking condition of...

Страница 445: ...witch coupler and relay unit cou pler blue green blue green Between relay unit and ECU coupler blue yellow blue black Turn the main switch to ON and then extend and retract the sidestand Fault code nu...

Страница 446: ...isconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switc...

Страница 447: ...rocedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Installed condition of O2 sen sor Improperly installed sensor Reinstall or replace the senso...

Страница 448: ...3 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Check fuel pressure Refer to CHECKING THE PRESSURE REGULATOR OPERATION on page 6 9 Start the en...

Страница 449: ...engine temperature sensor coupler and ECU coupler brown brown Between engine temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black...

Страница 450: ...the sensor 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 number is dis played Go to item 3 3 Defective lean angle sensor...

Страница 451: ...played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between front cylinder igni tion coil coupler and ECU coupler orange orange Start the engine and let it i...

Страница 452: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repla...

Страница 453: ...rol valve and then fully opens the valve ISC operating sound is heard Go to item 2 ISC operating sound is not heard Go to item 2 in sec tion B for the defective ISC idle speed control unit 2 Incorrect...

Страница 454: ...e system Able to start engine Able to drive vehicle Diagnostic code No 54 Actuation Fully closes the ISC valve and then opens the valve This opera tion is performed 3 times and takes approximately 4 s...

Страница 455: ...SC idle speed control coupler and ECU coupler red green red green pink blue pink blue white green white green brown brown Between ISC idle speed control coupler and relay unit coupler red black red bl...

Страница 456: ...ool screen come on each time the fuel injector is actuated Procedure Check that front cylinder injector is actuated five times by listening for the operating sound 37 Actuation Actuates the rear cylin...

Страница 457: ...bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code Nos 36 37 No operating sound Go to...

Страница 458: ...Connect the coupler secure ly or replace the wire har ness 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 number is dis p...

Страница 459: ...indi cated value increases Value does not increase Go to item 2 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re...

Страница 460: ...speed sensor cou pler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Execute the diagnostic mode Code No 07 Rotate the rear whe...

Страница 461: ...increases Value does not increase Go to item 2 in section A for the speed sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the...

Страница 462: ...Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item 9 Incorrect indication Go to item 5 5 Defective re...

Страница 463: ...e number is not displayed Fault code No 42 Except for ABS models Item A Speed sensor no normal signals are received from the speed sensor B Neutral switch open or short circuit is detected C Clutch sw...

Страница 464: ...the transmission is in gear with the clutch lever is released and the sidestand retracted OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 3 3 C...

Страница 465: ...ezed ON Correct indication Go to item 9 Incorrect indication Go to item 6 6 Wire harness continuity Between clutch switch cou pler and relay unit coupler blue yellow black yellow When the clutch lever...

Страница 466: ...umulative and does not reset each time the wheel is stopped Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagno...

Страница 467: ...not increase Go to item 4 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins...

Страница 468: ...not displayed Fault code No 42 For ABS models Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch ope...

Страница 469: ...Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the...

Страница 470: ...ased OFF Correct indication Go to item 9 Incorrect indication Go to item 6 6 Defective neutral switch Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 151 Execute the diagnostic mode...

Страница 471: ...ransmission clutch lever and sidestand Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagnostic mode Code No 07...

Страница 472: ...Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagn...

Страница 473: ...he clutch lever is released and the sidestand retracted OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 8 8 Malfunction in ECU Replace the ECU...

Страница 474: ...t code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Страница 475: ...ted in diagnostic mode code No 60 EE PROM data error for adjust ment of CO concentration of cylinder 1 Change the CO concentra tion of cylinder 1 and re write in EEPROM Refer to ADJUSTING THE EXHAUST...

Страница 476: ...dis played Repeat the mainte nance job Fault code No 50 Item Faulty ECU engine control unit memory When this malfunc tion is detected in the ECU the fault code number might not appear Fail safe syste...

Страница 477: ...ed Service is finished Fault code number is dis played Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code number is not dis played Service is fini...

Страница 478: ...or data from the ECU cannot be received correctly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of mal function and check Maint...

Страница 479: ...tion of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har nes...

Страница 480: ...switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 4 Item ECU engine control unit...

Страница 481: ...FUEL INJECTION SYSTEM 7 90...

Страница 482: ...G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Страница 483: ...ch 4 Main fuse 5 Battery 7 Fuel injection system fuse 10 Ignition fuse 16 Relay unit 18 Fuel pump relay 31 ECU engine control unit 37 Fuel pump 50 Joint coupler 71 Engine stop switch A Wire harness B...

Страница 484: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Страница 485: ...h 4 Main fuse 5 Battery 10 Fuel injection system fuse 13 Joint coupler 17 Ignition fuse 24 Relay unit 26 Fuel pump relay 38 ECU engine control unit 44 Fuel pump 78 Engine stop switch A Wire harness B...

Страница 486: ...ery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 151 The engine...

Страница 487: ...FUEL PUMP SYSTEM 7 96...

Страница 488: ...y G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B...

Страница 489: ...5 Battery 7 Fuel injection system fuse 10 Ignition fuse 13 Backup fuse 15 Immobilizer unit 31 ECU engine control unit 41 Multi function meter 47 Immobilizer system indicator light 50 Joint coupler A...

Страница 490: ...L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L...

Страница 491: ...5 Battery 10 Fuel injection system fuse 13 Joint coupler 17 Ignition fuse 21 Backup fuse 23 Immobilizer unit 38 ECU engine control unit 48 Multi function meter 55 Immobilizer system indicator light A...

Страница 492: ...ering key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard ke...

Страница 493: ...Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hour...

Страница 494: ...ch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key...

Страница 495: ...Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Im...

Страница 496: ...AND CHARGING THE BATTERY on page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the main switch immobil...

Страница 497: ...ey 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted be tween the ECU and the immobil...

Страница 498: ...seconds Units of 1 Cycles of on for 0 5 second and off for 0 5 second Example fault code 52 56 ECU Unidentified code is received Noise interference or disconnected lead ca ble 1 Check the wire harness...

Страница 499: ...IMMOBILIZER SYSTEM 7 108...

Страница 500: ...L Y G B L B R Br Y B L L L L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W...

Страница 501: ...pler 14 Front wheel sensor 15 Rear wheel sensor 16 ABS test coupler 17 Ignition fuse 18 ABS ECU fuse 19 Signaling system fuse 38 ECU engine control unit 48 Multi function meter 53 ABS warning light 75...

Страница 502: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 111 EAS27740 ABS COMPONENTS CHART 1 2 3 4 6 7 8 9 10 11 12 5 5...

Страница 503: ...S motor fuse 2 ABS test coupler 3 ABS ECU fuse 4 ABS solenoid fuse 5 Hydraulic unit assembly 6 ABS warning light 7 Front brake caliper 8 Front wheel sensor 9 Front wheel sensor rotor 10 Rear brake cal...

Страница 504: ...SYSTEM for ABS models 7 113 EAS27750 ABS COUPLER LOCATION CHART 1 2 4 5 L R L B B L R B 3 R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y R B R G G B Sb W Y Lg Ch Dg B L Y L Y G P W W G Gy...

Страница 505: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 114 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS test coupler 4 ABS ECU coupler 5 Front wheel sensor coupler...

Страница 506: ...using the Yamaha diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 7 119 For troubleshooting items other than the following...

Страница 507: ...bjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfu...

Страница 508: ...ly Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The connection with the Yamaha diagnostic tool is defective The ABS ECU fuse is blown The ABS...

Страница 509: ...defective Replace the hydraulic unit assembly EAS1XC1006 A 2 THE ABS WARNING LIGHT AND ALL OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING...

Страница 510: ...ECU coupler and the ABS test coupler Check for continuity between the blue red terminal of the ABS ECU coupler and the blue red ter minal of the ABS test coupler Check for continuity between the blue...

Страница 511: ...TI LOCK BRAKE SYSTEM for ABS models 7 120 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal ope...

Страница 512: ...st of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displa...

Страница 513: ...e received intermit tently while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor rotor or incorrect installa...

Страница 514: ...wheel sensor and the hydraulic unit assembly Defective front wheel sensor or hydraulic unit assembly 16 Rear wheel sensor open or short circuit Open or short circuit is de tected in the rear wheel se...

Страница 515: ...h circuit Defective signaling sys tem tail brake light or brake light switch Defective coupler be tween the signaling sys tem tail brake light or brake light switch and the hydraulic unit assem bly Op...

Страница 516: ...the hydraulic pres sure Incorrect installation of the front wheel sensor Incorrect rotation of the front wheel Front brake dragging Defective hydraulic unit assembly 42 47 Rear wheel ABS intermit ten...

Страница 517: ...nected battery terminal Defective charging sys tem 53 Vehicle system power supply voltage of ABS ECU power supply is low Power voltage supplied to the ABS ECU in the hy draulic unit assembly is too lo...

Страница 518: ...ear wheel sensor and the hydraulic unit assem bly Defective rear wheel sensor Defective hydraulic unit assembly Fault code No Item Symptom Check point Fault code No 11 25 Item Front wheel sensor inter...

Страница 519: ...sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if neces sary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and...

Страница 520: ...or or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSO...

Страница 521: ...r or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR for ABS mod els on page 4 26 Fault code No 15 Item Front wheel sensor open or short circuit Sy...

Страница 522: ...between the black yellow terminal 3 and the blue terminal 4 and between the black yellow terminal 3 and the green terminal 5 If there is short circuit the wire harness is defec tive Replace the wire h...

Страница 523: ...rminal 5 If there is no continuity the wire harness is defec tive Replace the wire harness Check that there is no short circuit between the white red terminal 1 and the white terminal 2 and between th...

Страница 524: ...13 3 Defective sensor rotor or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FR...

Страница 525: ...ls on page 4 26 Fault code No 21 Item Hydraulic unit assembly defective solenoid drive circuit Symptom Solenoid drive circuit in the hydraulic unit assembly is open or short circuited Order Item compo...

Страница 526: ...rmal ABS solenoid power sup ply Symptom Power is not supplied to the solenoid circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS solen...

Страница 527: ...y abnormal ABS motor power supply Symptom Power is not supplied to the motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS motor...

Страница 528: ...use Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM for ABS models on page 4 61 Fault code No 41 Item Front wheel A...

Страница 529: ...wheel sensor are received intermittently while the vehicle is traveling For fault code No 42 Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS E...

Страница 530: ...nsor if neces sary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 13 3 Defective sensor rotor or incorr...

Страница 531: ...OR for ABS mod els on page 4 26 4 Defective rear wheel sensor or incor rect installation of the sensor Check the wheel sensor for damage and the in stalled condition of the sensor Repair or replace th...

Страница 532: ...between the battery and the hy draulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS ECU fuse brown white brown white 4 Defective charging system Check th...

Страница 533: ...al data is detected in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to AB...

Страница 534: ...ircuit between the black yellow terminal 3 and the blue terminal 1 If there is a short circuit the wire harness is de fective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective front wheel...

Страница 535: ...rcuit between the black yellow terminal 3 and the white terminal 1 If there is a short circuit the wire harness is de fective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective rear wheel s...

Страница 536: ...the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISC on page 4 17 and INSTALL ING THE REAR WHEEL REAR BRAKE DISC on page 4 27 3 Perform brake line routing co...

Страница 537: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 146...

Страница 538: ...ELECTRICAL COMPONENTS 7 147 EAS27970 ELECTRICAL COMPONENTS 3 1 2 6 4 9 10 11 12 13 14 16 7 5 8 15...

Страница 539: ...ition coil 5 ABS ECU electronic control unit for ABS models 6 Turn signal hazard relay 7 ECU engine control unit 8 Rear wheel sensor for ABS models 9 Speed sensor except for ABS models 10 Neutral swit...

Страница 540: ...ELECTRICAL COMPONENTS 7 149 1 2 5 7 10 8 9 6 16 15 14 13 4 3 11 12...

Страница 541: ...unit 4 Battery 5 Lean angle sensor 6 Headlight relay 7 Starter relay 8 ABS motor fuse for ABS models 9 Fuel injection system fuse except for ABS models 10 Main fuse 11 Fuse box 1 12 Fuse box 2 for AB...

Страница 542: ...AS27980 CHECKING THE SWITCHES 1 6 5 7 8 4 3 2 R Br P B W Br Y G R Y B Y Br W Dg P Br L O Ch L Y 14 15 12 13 11 ON OFF P R Br R Br Br R O L R Y O Dg Br W Ch R N L 10 9 Dg Br B Ch B B B P Y G B Y L W B...

Страница 543: ...brake light switch 3 Reset switch 4 Select switch 5 Engine stop switch 6 Start switch 7 Hazard switch 8 Rear brake light switch 9 Neutral switch 10 Sidestand switch 11 Dimmer switch 12 Pass switch 13...

Страница 544: ...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 545: ...the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until...

Страница 546: ...ter selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verif...

Страница 547: ...ifferent from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte l...

Страница 548: ...contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery beco...

Страница 549: ...e should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current...

Страница 550: ...fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C A Except for ABS models B For ABS models 1 Positive battery terminal 2 Negative batte...

Страница 551: ...ification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage 1 Positive ba...

Страница 552: ...probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity...

Страница 553: ...S The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket...

Страница 554: ...oupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Re...

Страница 555: ...e gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of spe...

Страница 556: ...t of specification Replace the oil level switch a Connect the pocket tester 100 to the oil level switch terminal as shown b Measure the oil level switch resistance Charging voltage 14 V at 5000 r min...

Страница 557: ...uel sender or thermistor Replace the fuel sender EAS1TP1011 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the oil level detection circuit 1 Check Oil le...

Страница 558: ...the pocket tester 1 k to the en gine temperature sensor as shown b Measure the engine temperature sensor re sistance 3 Install Engine temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR...

Страница 559: ...1 Remove Intake air temperature sensor WARNING EWA1TP1020 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air...

Страница 560: ...1012 CHECKING THE FUEL INJECTORS The following procedure applies to all off the fuel injectors 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel in...

Страница 561: ...MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 2 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEG...

Страница 562: ...y fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged o...

Страница 563: ...shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GE...

Страница 564: ...damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper brac...

Страница 565: ...ction Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty tur...

Страница 566: ...ort circuit detected in the primary lead of the rear cylinder ignition coil 7 61 37 Component other than ISC idle speed control unit is defective ISC operating sound is heard 7 62 Defective ISC idle s...

Страница 567: ...between the ECU and the multi function meter 7 85 Er 2 ECU engine control unit internal malfunction output signal error no signals are received from the ECU within the specified duration 7 86 Er 3 ECU...

Страница 568: ...nd does not reset each time the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sensor and incline it more than 45 degrees Upright 0 4 1 4 Overturned 3 7 4...

Страница 569: ...stand is extended OFF 60 EEPROM fault code dis play No history 00 No malfunctions detect ed If the self diagnosis fault code 44 is indicat ed the ECU is defec tive History exists 01 or 02 Cylinder fa...

Страница 570: ...dure 30 Front cylinder ignition coil Actuates the front cylinder ignition coil five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen come on each time the ig...

Страница 571: ...nostic tool screen go off When the relay is off the CHECK indicator and on the Yamaha diag nostic tool screen come on Check that the relay unit fuel pump relay is actuat ed five times by listening fo...

Страница 572: ...lebar switch 54 Dimmer switch 55 Pass switch 56 Turn signal switch 57 Horn switch 58 Clutch switch 59 Passing light OPTION 60 Horn 61 Headlight 62 Auxiliary light 63 Front left turn signal light 64 Fr...

Страница 573: ...der 58 Turn signal hazard relay 59 Headlight relay 60 Left handlebar switch 61 Dimmer switch 62 Pass switch 63 Turn signal switch 64 Horn switch 65 Clutch switch 66 Passing light OPTION 67 Horn 68 Hea...

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Страница 577: ...L B L R R L Gy G Gy W L W R W B Y Br Br W L Y P W W Y B L B L B L L L L Y Y G G Y Gy B L B L B L B L B L B L B L B L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L B R B B B B Gy R Br...

Страница 578: ...excepto modelos con ABS 2014 DIAGRAMA EL CTRICO A ON OFF P R N L SELECT RESET C C E E E D D D D B L Y B A D F E C E A A D B C A A A B Gy B B B B B B B B Db B B B Gy Gy Db B B Gy Gy Gy B B B B Gy Gy B...

Страница 579: ...W B Y Br W Br B Br W L Y B Y Br Ch Dg G L R Y B L G L G L G L Y G B L B R Br Y B L L L L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R...

Страница 580: ...A A ON OFF P R N L SELECT RESET C C E E E D D D D S B A D F E C E A A D B C A A A B Gy B B B B B B B B B B B B B Gy Gy B B Gy Gy Gy B B B B Gy Gy B B Gy B Gy B B B B B B Db B B B B Gy B Gy 2 3 4 5 6 7...

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