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Yamaha FJR1300, Service Manual

The Yamaha FJR1300 Owner's Manual is a comprehensive guide that enables FJR1300 owners to maximize the potential of their motorcycle. This invaluable manual provides in-depth information on maintenance, troubleshooting, and operation, all conveniently available for free download at 88.208.23.73:8080, ensuring a hassle-free ownership experience.

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7 - 14

FI

FUEL INJECTION SYSTEM

Actuator operation verification table

Diag code

Item

Description of action

Data displayed on meter 

(reference value)

30

Ignition coil #1, 4

After 1 second has elapsed from the time the engine stop 
switch has been turned from OFF to ON, it actuates ignition 
coils #1, and 4 for five times every second and illuminates the 
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check that spark is generated, 
5 times with the engine stop 
switch ON.

31

Ignition coils #2, 3

Take the same actions as No. 30 above on ignition coils #2, 
and 3.
Same as above.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Same as above

36

Injector #1

After 1 second has elapsed from the time the engine stop 
switch has been turned from OFF to ON, it actuates the injec-
tor five times every second and illuminates the engine trouble 
warning light.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check the operating sound of 
the injector five times with 
engine stop switch ON.

37

Injector #2

Take the same actions as No. 36 above on injector #2.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Same as above

38

Injector #3

Take the same actions as No. 36 above on injector #3.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Same as above

39

Injector #4

Take the same actions as No. 36 on injector #4.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Same as above

48

AI system solenoid

After 1 second has elapsed from the time the engine stop 
switch has been turned from OFF to ON, it actuates the AI 
system solenoid five times every second and illuminates the 
engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check the operating sound of 
the AI system solenoid.
Same as above

50

Fuel injection system 
relay

After 1 second has elapsed from the time the engine stop 
switch has been turned from OFF to ON, it actuates the fuel 
injection system relay five times every second and illuminates 
the engine trouble warning light (the light is OFF when the 
relay is ON, and the light is ON when the relay is OFF).
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check the fuel injection system 
relay operating sound.
Same as above

51

Radiator fan motor 
relay

After 1 second has elapsed from the time the engine stop 
switch has been turned from OFF to ON, it actuates the radia-
tor fan motor relay five times every 5 seconds and illuminates 
the engine trouble warning light. (ON 2 seconds, OFF 3 sec-
onds)
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check the radiator fan motor 
relay operating sound.
Same as above

52

Headlight relay 1

Take the same actions as in No. 51 above, on the headlight 
relay 1. (ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then 

turn it back ON.

Check the relay operating 
sound.
Same as above

Summary of Contents for FJR1300

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

Page 2: ...2002 by Yamaha Motor Corporation U S A First edition June 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 16 18 ...

Page 3: ...information changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and ...

Page 4: ...of each page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 5: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap base grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following...

Page 6: ......

Page 7: ...S GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 8: ...NTS 1 31 IMPORTANT INFORMATION 1 35 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 35 REPLACEMENT PARTS 1 35 GASKETS OIL SEALS AND O RINGS 1 35 LOCK WASHERS PLATES AND COTTER PINS 1 36 BEARINGS AND OIL SEALS 1 36 CIRCLIPS 1 36 CHECKING THE CONNECTIONS 1 37 SPECIAL TOOLS 1 38 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 11 ELECTRICAL SPECIFICATIO...

Page 9: ...TEM DIAGRAMS 2 38 CABLE ROUTING 2 42 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 1 SEATS AND FUEL TANK 3 4 SEATS 3 4 FUEL TANK 3 5 T BAR 3 6 REMOVING THE FUEL TANK 3 7 REMOVING THE FUEL PUMP 3 7 INSTALLING THE FUEL PUMP 3 8 INSTALLING THE FUEL HOSE 3 8 INSTALLING THE T BAR 3 8 ...

Page 10: ...TEM 3 47 CHANGING THE COOLANT 3 48 CHASSIS 3 51 ADJUSTING THE FRONT BRAKE 3 51 ADJUSTING THE REAR BRAKE 3 52 CHECKING THE BRAKE FLUID LEVEL 3 53 CHECKING THE BRAKE PADS 3 54 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 54 CHECKING THE BRAKE HOSES 3 55 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 56 ADJUSTING THE SHIFT PEDAL 3 57 CHECKING THE FINAL DRIVE OIL LEVEL 3 58 CHANGING THE FINAL DRIVE OIL 3 58 CHECKIN...

Page 11: ...BRAKE MASTER CYLINDER 4 26 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 27 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 30 FRONT BRAKE CALIPERS 4 33 REAR BRAKE CALIPER 4 35 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 37 DISASSEMBLING THE REAR BRAKE CALIPER 4 38 CHECKING THE FRONT AND REAR BRAKE CALIPERS 4 39 ASSEMBLING AND INSTALLI...

Page 12: ...OCK ABSORBER ASSEMBLY 4 86 CHECKING THE CONNECTING ARM AND RELAY ARM 4 86 INSTALLING THE RELAY ARM 4 87 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 87 SWINGARM 4 88 REMOVING THE SWINGARM 4 90 CHECKING THE SWINGARM 4 90 INSTALLING THE SWINGARM 4 91 SHAFT DRIVE 4 93 TROUBLESHOOTING 4 93 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 4 96 MEASURING THE RING GE...

Page 13: ... HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 31 GENERATOR AND STARTER CLUTCH 5 33 GENERATOR ROTOR AND STARTER CLUTCH 5 33 STATOR ASSEMBLY 5 35 REMOVING THE GENERATOR 5 36 REMOVING THE S...

Page 14: ...2 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PUMP 5 63 INSTALLING THE OIL STRAINER 5 63 INSTALLING THE OIL PAN 5 63 MIDDLE GEAR 5 65 REMOVING THE MIDDLE GEAR 5 69 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 70 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 70 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 70 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 71 ASSEMBLING THE MIDDLE DRIVE SHAFT AS...

Page 15: ... DRUM ASSEMBLY 5 115 CHECKING THE TRANSMISSION 5 115 INSTALLING THE TRANSMISSION 5 117 BALANCERS 5 118 FRONT BALANCER 5 118 REAR BALANCER 5 119 CHECKING THE BALANCER 5 120 INSTALLING THE FRONT BALANCER 5 120 INSTALLING THE REAR BALANCER 5 122 CHAPTER 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 4 OIL COOLER 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COO...

Page 16: ... 7 38 AIR INDUCTION SYSTEM 7 40 AIR INJECTION 7 40 AIR CUT OFF VALVE 7 40 AIR INDUCTION SYSTEM DIAGRAMS 7 41 AIR CUT OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 7 42 REED VALVES 7 43 CHECKING THE AIR INDUCTION SYSTEM 7 44 CANISTER FOR CALIFORNIA ONLY 7 45 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS 8 1 CHECKING SWITCH CONTINUITY 8 3 CHECKING THE SWITCHES 8 4 CHECKING THE BULBS AND BULB SOCKET...

Page 17: ...G 8 30 CHECKING THE LIGHTING SYSTEM 8 32 SIGNALING SYSTEM 8 36 CIRCUIT DIAGRAM 8 36 TROUBLESHOOTING 8 38 CHECKING THE SIGNALING SYSTEM 8 39 COOLING SYSTEM 8 46 CIRCUIT DIAGRAM 8 46 TROUBLESHOOTING 8 47 FUEL INJECTION SYSTEM 8 51 CIRCUIT DIAGRAM 8 51 TROUBLESHOOTING 8 52 CHECKING THE FUEL PUMP 8 58 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 8 59 WINDSHIELD DRIVE SYSTEM 8 63 CIRCUIT DIAGRAM...

Page 18: ...EATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 6 FAULTY LIGHTING OR SIGNALING SYSTEM 9 6 HEADLIGHT DOES NOT LIGHT 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT LIGHT 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT LIGHT 9...

Page 19: ...CYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 20: ... in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected ...

Page 21: ...e injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake temperature sensor coolant temperature sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor and the...

Page 22: ...Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection O2 sensor Gas emission O2 concentration detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine R...

Page 23: ... sensor Then the signals are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection timing and ignition timing and then sends con trol commands to the respective output interface circuits D Output interface circuits The output interface circuits convert the control signals output by...

Page 24: ...f switch is tripped 2 Operating the headlight illumination relay On the model for Europe the ECU causes the headlight relay 2 to output a constant ON signal provided that the main switch is ON On the model for Australia the ECU controls the headlight relay 2 in accordance with the engine speed as required by the daytime illumination specification 3 Operating the radiator fan motor in accordance wi...

Page 25: ...nstream of the pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose becomes clogged This valve opens when the fuel pressure at the discharge outlet reaches between 440 and 640 kpa and returns the fuel to the...

Page 26: ...ake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the dia phragm opens allowing the fuel to return from the fuel outlet to the fuel tank via the fuel return hose As a result because the intake vacuum fluctuates in accordance with the changes in the operating conditions in ...

Page 27: ... that is integrated with the needle to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized The injecto...

Page 28: ...ion of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calcu lated data in order to determine the corresponding injection timing Based on the changes in the time intervals of the signals generated by the pickup coil the ECU calculates the ignition timing advance to suit the operating conditions The injection timing is also advanced in accord...

Page 29: ... and sends it to the ECU Based on this signal and the signal from the crankshaft position sensor the ECU then actuates the injector of the cylinder that is currently in order to supply fuel 1 Cylinder identification sensor 2 Cam È Cam lift É Crankshaft position sensor signal Ê Cylinder identification sensor signal Ë Cylinder firing order Ì 4 cam lobe onto exhaust camshaft Í Combustion Î Exhaust Ï ...

Page 30: ...son with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve 1 Moving contact 2 Resistor board 3 Spring È Output voltage É Idling output position Ê Mechanical stopper Ë Mechanical stopper Ì Effective electrical a...

Page 31: ...ilicon diaphragm converts the intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure Atmospheric pressure sensor The atmospheric pressure sensor is used for making compensations to the changes in the air density caused by the change...

Page 32: ... sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures This sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures The thermistor converts the temperature ...

Page 33: ...on level is known When a difference in the oxygen concentration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and generates an electromotive force The electro motive force increases when the oxygen concentration level is low rich air fuel ratio and the elec tromotive force decreases when the oxygen concentration level is...

Page 34: ...of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the motorcycle has overturned and stops the delivery of fuel to the engine by turning OFF the fuel injection system relay that powers the fuel pump and the injectors Once the cut off switch is tripped the ECU maintains this state therefore even if the...

Page 35: ...an injection command to the injectors Furthermore the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on the signals from these sensors Determining the basic injection duration The intake air volume determines the basic injection duration In order to operate the engine in an optimal condition it is necessary to su...

Page 36: ...ns This system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating condition of the engine The fuel is cut off under conditions that do not require fuel in order to stop the injection Intake air pressure Engine rpm Degree of opening of throttle Basic injection quantity Comp...

Page 37: ...signal to the injector The battery voltage determines the reactive injection duration High voltage short reactive injection duration Low voltage long reactive injection duration LIST OF FUEL INJECTION COMPENSATIONS Compensation item Check item Sensor used Starting injection 1 Coolant temperature Coolant temperature sensor After start injection After start enrichment 2 Coolant temperature Coolant t...

Page 38: ...ned through the throttle position intake air pressure and engine speed to which injection duration compensation based on the sig nals from various sensors such as the intake temperature sensor atmospheric pressure sensor and O2 sensor is added to determine the final injection duration As a result fuel is supplied to the cylinders Normal synchronous injection 1 Injector 1 2 Injector 2 3 Injector 3 ...

Page 39: ... fuel only once immediately upon receiving the signals from the sensors during the cranking of the engine This is called asyn chronous injection in contrast to synchronous injection which is a normal cylinder injection that is effected on a cylinder by cylinder basis After the asynchronous injection is completed and until the ECU receives signals from the cylinder identification sensor the injecto...

Page 40: ...ough the coolant tem perature determines the initial starting enrichment coefficient the coefficient subsequently changes in accordance with the damping factor The enrichment ratio is the highest immediately after the engine is started and diminishes gradually The enrichment of fuel in this manner ensures a stable engine operation immediately after the engine is started Changes in compensation coe...

Page 41: ...e coolant temperature The coefficient increases with the decrease in the coolant temperature and decreases with the increase in the coolant temperature The ratio of fuel enrichment also changes with the changes in the coefficient Changes in compensation coefficient and compensation injection duration 1 0 60 C Warm up enrichment Long Short Injection duration Compensation injection duration Duration...

Page 42: ...ncreases the actual enrich ment volume The enrichment volume is executed in accordance with the acceleration enrichment coefficient when the movement of the throttle position sensor has met the acceleration condition as defined by the ECU Thereafter the enrichment volume is regulated by the coefficient that changes in accordance with the damping rate Acceleration injection duration basic injection...

Page 43: ... the cylinders is stopped when fuel cut off control is executed thus improving fuel economy È Engine speed É Duration Ê Fuel cut off control stopping fuel injection Ë Basic injection duration Ì Basic injection duration Over revving control This function effects fuel cut off control when the engine speed becomes greater than the pre scribed value The fuel cut off control regulates the engine speed ...

Page 44: ...ust gas is provided in the exhaust pipe for the purpose of maximizing the performance of the three way cat alytic converter and to clean the exhaust gas at a high degree of efficiency Based on this data the ECU applies more precise compensation to the basic air fuel ratio in order to maintain the mixture in the vicinity of the stoichiometric air fuel ratio of 14 7 1 Through the joint effort of the...

Page 45: ...ion of platinum and are converted into harmless carbon dioxide CO2 and water H2O resulting in cleaner exhaust gases The NOx is reduced by the reduction function of rhodium which converts NOx into harmless nitro gen N2 and oxygen O2 resulting in cleaner exhaust gases To clean the exhaust gases at a high rate of efficiency through the maximization of these catalytic capacities it is necessary to mai...

Page 46: ...e mixture is lean as indicated by excessive O2 region B Under these conflicting characteristics the system maintains the mixture within an extremely narrow range C of stoichiometric ratio 14 7 1 As a result the function of the catalyst is maximized making it possible to clean the exhaust gases at a high degree of efficiency 0 13 13 5 14 14 5 15 15 5 16 20 40 60 80 100 HC NOx CO 14 7 Conv ...

Page 47: ...basic injection volume based on the signals that are input from various sensors and regulates the duration of the current applied to the injectors É Current is applied to the injectors enabling them to inject fuel Ê The engine undergoes combustion and exhaust Ë The O2 sensor detects the level of oxygen concentration in the exhaust gases and outputs a lean or rich air fuel ratio signal in accordanc...

Page 48: ...t through the reed valve The air cut off valve is controlled by the signals from the ECU in accordance with the combustion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to fl...

Page 49: ...air passage and flows into the reed valves of the cyl inders When the current flows to the solenoid coil in accordance with a signal from the ECU the plunger in the core becomes attracted towards the coil When this attraction force overcomes the pressure of the spring the valve is pulled in along with the plunger comes in contact with valve block B and closes the air passage The ECU controls the o...

Page 50: ...showing the time after the error has been corrected 1 Fuel meter 2 Clock 3 Coolant temperature meter 4 TRIP meter 5 TRIP ODO meter 6 RESET button 7 SELECT button 8 Engine trouble warn ing light 9 Oil level warning light Mode ECU transmission data Meter indication Display description Common to all modes Vehicle speed Trip meter 4 digits including decimals Engine warning indicator lamp Indicator lam...

Page 51: ...rts a sys tem check System normal Normal meter display Malfunction detection A fault code number appears on the clock LCD The engine trouble warning light illuminates The engine cannot be started in this mode Diagnosis mode Enables the verification of the operation of the actuator and various sensors Turn the engine stop switch to OFF Turn it ON when the diagnostic code is 09 or 03 1 Press the SEL...

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

Page 53: ...nd place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in qualit...

Page 54: ...g oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips a...

Page 55: ... times 3 Check all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 56: ...ls are needed to remove the main axle assembly YM 01229 Gear holder This tool is needed when removing or installing the coupling gear nut YM 01230 Final drive gear lash tool This tool is needed when measuring the final gear backlash YU 01235 Universal magneto rotor holder This tool is needed to hold the camshaft sprocket when loosen or tighten the camshaft sprocket bolts YU 01304 Piston pin puller...

Page 57: ...is tool is needed to hold the damper rod assembly when loosen or tighten the damper rod assembly bolt YM 01471 Frame spanner socket This tool is needed to loosen or tighten the spacer bolt YS 01880 A Primary sheave holder This tool is used to hold the generator rotor when removing or installing the generator rotor bolt generator shaft bolt or crankshaft position sensor rotor bolt Compression gauge...

Page 58: ...re gauge Oil pressure adaptor B These tools are needed to measure engine oil pressure Valve spring compres sor set YM 04019 Valve spring compres sor attachment YM 04108 Valve spring compressor set Valve spring compressor attachment These tools are needed to remove and install the valve assemblies YM 04050 Piston bearing retainer remover This tool is needed when removing or installing the final dri...

Page 59: ...eded when removing or installing the damper spring YM 04097 Valve guide remover ø5 This tool is needed to remove and install the valve guide YM 04098 Valve guide installer ø5 This tool is needed to install the valve guide YM 04099 Valve guide reamer ø5 This tool is needed to rebore the new valve guide YM 08037 Piston ring compressor This tool is used to compress the piston rings when installing th...

Page 60: ...1001 05 01 Quick Gasket This sealant is used to seal two mating surfaces e g crankcase mating sur faces YM 04140 Bearing retainer wrench This tool is needed when removing or installing the middle driven shaft bear ing retainer YM 03176 Fuel pressure adapter This tool is needed to measure fuel pressure Tool No Tool name Function Illustration SPECIAL TOOLS ...

Page 61: ...mm 55 9 in Seat height 805 mm 31 7 in Wheelbase 1 515 mm 59 6 in Minimum ground clearance 135 mm 5 3 in Minimum turning radius 3 100 mm 122 0 in Weight Wet with oil and a full fuel tank 274 kg 604 lb USA 275 kg 605 lb California Dry without oil and fuel 237 kg 522 lb Maximum load total of cargo rider passenger and accessories 202 kg 445 lb USA 201 kg 443 lb California GENERAL SPECIFICATIONS 1 2 ...

Page 62: ...g reserve 25 L 22 01 Imp qt 26 43 US qt Reserve only 5 L 4 40 Imp qt 5 29 US qt Engine oil Lubrication system Wet sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 5 C 40 F or higher Quantity Total amount 4 9 L 4 31 Imp qt 5 18 US qt Without oil filter cartridge replace ment 3 8 L 3 34 Imp qt 4 02 US qt With oil filter cartridge replacement 4 0 L 3 52 Imp qt 4 23 US qt Oil press...

Page 63: ...2 7 kPa 0 93 1 23 kg cm2 13 27 17 45 psi Valve relief pressure 4 9 kPa 0 05 kg cm2 0 70 psi Radiator core Width 360 mm 14 17 in Height 295 8 mm 11 65 in Depth 27 mm 1 06 in Coolant reservoir Capacity 0 485 L 0 43 Imp qt 0 51 US qt From low to full level 0 15 L 0 13 Imp qt 0 16 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 75 48 25 28 1 395 Max impeller shaft tilt...

Page 64: ...rance 0 028 0 062 mm 0 0011 0 0024 in Intake camshaft lobe dimensions Measurement A 33 05 33 15 mm 1 3012 1 3051 in 32 05 mm 1 2618 in Measurement B 24 997 25 097 mm 0 9841 0 9881 in 23 997 mm 0 9448 in Exhaust camshaft lobe dimensions Measurement A 33 05 33 15 mm 1 3012 1 3051 in 32 95 mm 1 2972 in Measurement B 24 997 25 097 mm 0 9841 0 9881 in 24 897 mm 0 9802 in Max camshaft runout 0 03 mm 0 0...

Page 65: ... 0433 in 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve margin thickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 4 975 4 990 mm 0 1959 0 1965 in 4 945 mm 0 1947 in Exhaust 4 960 4 975 mm 0 1953 0 1959 in 4 930 mm 0 1941 in Valve guide inside diameter Intake 5 000 5 012 mm 0 1969 0 1973 in 5 05 mm 0 1988 in Exh...

Page 66: ... 39 7 mm 1 56 in 37 7 mm 1 48 in Exhaust 39 7 mm 1 56 in 37 7 mm 1 48 in Installed length valve closed Intake 33 mm 1 30 in Exhaust 33 mm 1 30 in Compressed spring force installed Intake 136 158 N 13 9 16 1 kg 30 6 35 5 lb Exhaust 136 158 N 13 9 16 1 kg 30 6 35 5 lb Spring tilt Intake 2 5 1 7 mm 2 5 0 067 in Exhaust 2 5 1 7 mm 2 5 0 067 in Winding direction top view Intake Clockwise Exhaust Clockw...

Page 67: ...1094 in Height H 5 mm 0 2 in Piston pin bore in the piston Diameter 19 004 19 015 mm 0 7482 0 7486 in 19 045 mm 0 7498 in Offset 0 5 mm 0 0197 in Offset direction Intake side Piston pins Outside diameter 18 991 19 000 mm 0 7477 0 7480 in 18 971 mm 0 7469 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions ...

Page 68: ...12 0 0019 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink Small end inside diameter 19 005 19 018 mm 0 7482 0 7487 in Crankshaft Width A 61 6 63 2 mm 2 425 2 488 in Width B 325 1 326 3 mm 12 799 12 846 in Max runout C 0 03 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Big end radial clearance 0 021 0 039 mm 0 0008 0 0015 in Crankshaft journal to cranksh...

Page 69: ...n length 6 44 mm 0 2535 in Push rod bending limit 0 2 mm 0 0079 in Transmission Transmission type Constant mesh 5 speed Primary reduction system Helical gear Primary reduction ratio 75 48 1 563 Secondary reduction system Shaft drive Secondary reduction ratio 35 36 21 27 33 9 2 773 Operation Left foot operation Gear ratios 1st gear 43 17 2 529 2nd gear 39 22 1 773 3rd gear 31 23 1 348 4th gear 28 2...

Page 70: ... 2 94 kgf cm2 41 81 psi Throttle bodies Model manufacturer quantity 42EHS MIKUNI 4 Intake vacuum pressure 33 3 kPa 250 mm Hg 9 8 in Hg Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ID mark FJR1300 5JW1 21 USA FJR1300 5JW8 31 California Shaft drive Final gear backlash 0 1 0 2 mm 0 004 0 008 in Item Standard Limit ...

Page 71: ... 0 5 mm 0 02 in Rear wheel Wheel type Cast wheel Rim Size 17 M C MT 5 50 Material Aluminum Wheel travel 125 mm 4 92 in Wheel runout Max radial wheel runout 1 0 mm 0 04 in Max lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 ZR 17 M C 58 W Model manufacturer MEZ4J FRONT METZELER BT020F N BRIDGESTONE Tire pressure cold 0 90 kg 0 198 lb 250 kPa 2 5 kgf cm2 36 psi 90 202 k...

Page 72: ...iameter thickness 298 5 mm 11 73 0 20 in Min thickness 4 5 mm 0 18 in Max deflection 0 1 mm 0 004 in Brake pad lining thickness 5 5 mm 0 22 in 0 5 mm 0 02 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 30 2 mm 1 19 in and 27 mm 1 06 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position below the top of the rider footrest 4...

Page 73: ... 0 999 kg mm 55 96 lb in Spring stroke K2 91 135 mm 3 58 5 31 in Optional spring available No Fork oil Recommended oil Suspension oil M1 Quantity each front fork leg 670 cm3 23 6 Imp oz 22 3 US oz Level from the top of the inner tube with the inner tube fully com pressed and without the fork spring 100 mm 3 94 in Inner tube outer diameter 48 mm 1 89 in Inner tube bearing 0 2 mm 0 01 in Damper adju...

Page 74: ... 2 91 in 72 52 mm 2 86 in Installed length 65 4 mm 2 57 in Spring rate K1 71 6 N mm 7 30 kg mm 408 86 lb in Spring stroke K1 0 31 3 mm 0 1 23 in Spring rate K2 102 N mm 10 4 kg mm 582 45 lb in Spring stroke K2 31 3 60 0 mm 1 23 2 36 in Optional spring available No Standard spring preload gas air pres sure 1 200 kPa 12 0 kg cm2 171 psi Spring preload adjusting positions Rider only SOFT With passeng...

Page 75: ...ing system System type AC magneto Model manufacturer TLNZ79 DENSO Nominal output 14 V 490 W at 5 000 r min Stator coil resistance color 0 15 0 23 Ω W W Voltage regulator Regulator type Semiconductor short circuit Model manufacturer FH001 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier Model manufacturer FH001 SHINDENGEN Rectifier capacity 35 A Withstand voltage 200 V Battery Battery typ...

Page 76: ... 96 in 23 5 mm 0 93 in Mica undercut 1 5 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Model manufacturer quantity YF 12 NIKKO 2 Max amperage 3 A Performance 105 113 db 2 m 6 6 ft Coil resistance 1 15 1 25 Ω Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Self cancelling device built in No ...

Page 77: ...5 0 F Valve lift full open 8 mm 0 31 in Intake air temperature sensor Model manufacturer 25978 MITSUBISHI Resistance 5 4 6 6 Ω at 80 C 176 F Coolant temperature sender Model manufacturer 8CC MITSUBISHI Resistance 5 21 6 37 kΩ at 0 C 32 F 0 290 0 354 kΩ at 80 C 176 F Fuses amperage quantity Main fuse 50 A 1 Fuel injection system fuse 15 A 1 Headlight fuse 25 A 1 Tail position light fuse 10 A 1 Sign...

Page 78: ... specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Spee...

Page 79: ...7 2 LT Stator assembly lead holder Screw M6 1 6 0 6 4 3 Pickup coil rotor cover Bolt M6 8 12 1 2 8 7 Ignition timing check bolt M8 1 15 1 5 11 Crankshaft position sensor Bolt M5 2 4 0 4 2 9 LT Pickup coil rotor Bolt M10 1 45 4 5 32 Clutch cover Bolt M6 10 12 1 2 8 7 Damper cover Screw M6 4 12 1 2 8 7 LT Oil guide plate Bolt M6 2 10 1 0 7 2 Clutch spring plate retainer Bolt M6 6 8 0 8 5 8 Clutch bo...

Page 80: ...2 1 2 8 7 E Crankcase Bolt M6 17 10 1 0 7 2 E Rear balancer cover Bolt M6 4 12 1 2 8 7 Balancer lever Bolt M8 2 14 1 4 10 Balancer shaft pinch bolt M6 2 10 1 0 7 2 Plate Torx screw M6 2 12 1 2 8 7 LT Connecting rod Nut M8 8 See NOTE 3 M Shift drum retainer Bolt M6 2 10 1 0 7 2 LT Main axle assembly Torx screw M6 3 12 1 2 8 7 Stake Air filter case Bolt M6 2 7 0 7 5 1 Air filter case joint clamp scr...

Page 81: ...ten the crankcase bolts further to reach the specified angle 120 in the proper tightening sequence 3 Tighten the connecting rod nuts to 20 Nm 2 0 m kg 14 ft lb and then tighten the connecting rod nuts further to reach the specified angle 120 Thermostat assembly Torx screw M6 1 10 1 0 7 2 Thermostat housing cover Bolt M6 2 10 1 0 7 2 Water pump Bolt M6 3 12 1 2 8 7 Water pump housing cover Bolt M6 ...

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

Page 83: ... nut M18 125 12 5 90 Rear wheel axle pinch bolt M8 16 1 6 11 Brake torque rod M8 16 1 6 11 Rear brake caliper retaining bolt M10 27 2 7 19 Brake hose union bolt M10 30 3 0 22 Front brake master cylinder M6 10 1 0 7 2 Right rider footrest bracket and frame M8 28 2 8 20 Rear master cylinder and right rider footrest bracket M8 18 1 8 13 Rear brake hose holder and brake torque rod M6 10 1 0 7 2 Clutch...

Page 84: ...ft rider footrest bracket and engine M10 49 4 9 35 Left rider footrest bracket sidestand bracket and frame M10 63 6 3 45 Ring gear bearing housing and final drive housing M10 40 4 0 29 Ring gear bearing housing and final drive housing M8 23 2 3 17 Stopper bolt M10 9 0 9 6 5 Gear coupling and final drive pinion gear M16 110 11 0 80 Final drive pinion gear bearing retainer M65 110 11 0 80 Sidestand ...

Page 85: ...ms intake and exhaust M Valve stem ends intake and exhaust E Water pump impeller shaft E Oil pump rotors inner and outer E Oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Starter clutch assembly E Primary driven gear E Push rods and ball LS Transmission gears wheel and pinion M Main axle and drive axle M Shift drum E Shift forks and shift fork guide bars E Shift shaft E ...

Page 86: ...ver mating surface Sealant Cylinder head cover Sealant Crankcase mating surface Sealant Clutch cover crankcase mating surface Sealant Generator cover crankcase mating surface Sealant Pickup coil rotor cover crankcase mating surface Sealant Left middle gear cover crankcase mating surface Sealant ...

Page 87: ...and pivoting point and sliding surface LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivot bolt and contact surface LS Clutch lever pivot bolt and contact surface LS Rear shock absorber assembly oil seal LS Rear shock absorber assembly bearing LS Rear shock absorber assembly spacer LS Pivot shaft LS Connecting arm bearing LS Spacer relay ...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 102: ...able 2 Brake cable 3 Clutch cable 4 Main switch lead 5 Headlight lead 6 Fuse box 7 Thermostat assembly breather hose 8 Coolant reservoir hose 9 Hazard switch 0 Rectifier regulator A Plate B Plunger control unit hose 2 C Radiator D Radiator fan coupler ...

Page 103: ...ervoir hose and thermostat assembly breather hose through the left slit of the plate Ë To the thermostat housing Ì After passing the coolant reservoir hose through the two hose guides behind the plate pass the hose through the right hole of the plate Í Pass the plunger control unit hose 2 on the inside of the plate Î To the radiator fan Ï Pass the radiator fan lead on the outside of the plate ...

Page 104: ...Main fuse 8 Front turn signal lead 9 Spark plug lead 4 0 Spark plug lead 1 A Ignition coil lead 1 4 B Ignition coil 1 4 C Coolant reservoir D Coolant reservoir breather hose E Coolant reservoir hose F Pickup coil lead G Starter motor lead H Spark plug lead 2 I Spark plug lead 3 J Ignition coil 2 3 K Starter relay L Negative battery lead ...

Page 105: ...nnector so that the ignition coil lead can be turned outward Ì Support the coolant reservoir breather hose with the hose holder attached to the coolant reser voir Í Pass the brake cable through the brake cable guide Î Pass the coolant reservoir hose through the hole of the plate Ï Pass the coolant reservoir hose through the hose guide attached to the coolant reservoir Ð Pass the negative battery l...

Page 106: ... of the coolant reservoir hose should extend at least 50 mm 2 0 in from the hose guide Ó Fasten the spark plug lead 1 and 4 at the number tag Ô Pass the wire harness spark plug leads 1 2 3 and 4 through the right slit of the battery bracket Õ Pass the starter motor lead negative battery lead wire harness and spark plug leads 2 and 3 through the battery stay Be sure to pass the starter motor lead a...

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

Page 108: ...ifier regulator 5 Clutch cable 6 Fuel tank overflow hose 7 Fuel tank breather hose 8 Stator coil lead 9 Sidestand switch 0 Sidestand switch lead A Oil level switch lead B Brake cable C Coolant reservoir hose D Thermostat assembly breather hose E Headlight lead F Radiator fan lead G Wire harness ...

Page 109: ...ame Ë Clamp the wire harness with the plastic band attached to the frame Ì To the fuel tank Í Pass the stator coil lead at the fork of the wire harness Î Attach the clutch cable to the frame using the clutch cable holders Ï Insert the harness holder into the hole on the rear end of the frame Ð Pass the brake cable through the brake cable guide Ñ To the wire harness Ò Contact the clutch cable to th...

Page 110: ...ten the tail brake light lead with a plastic band to the frame Ì Pass the tail brake light lead between the rear cover and frame Í Pass the wire harness on the inside of the seat lock cable Î Support the wire harness and ignitor unit lead with the cable holder attached to the tray Ï Pass the fuel tank breather hose air filter case breather hose and fuel tank over flow hose through the hose guide Ð...

Page 111: ...ead 4 Headlight lead 5 Main switch lead 6 Throttle cable 7 Right handlebar switch lead 8 T bar 9 Spark plug lead 3 0 Spark plug lead 2 A Spark plug lead 1 B Spark plug lead 4 C Cable guide D Throttle position sensor E Fuel return hose F Sidestand switch lead CABLE ROUTING ...

Page 112: ...cables through the hole on the right side of the frame Ë To the lower right slit of the plate Ì To the cylinder identification sensor Í To the fuel tank Î Pass the cylinder identification sensor lead through the lead guide of throttle body Ï Pass the fuel sender lead and fuel pump lead harness over the fuel return hose Ð To the sidestand switch Ñ Pass the cylinder identification sensor lead under ...

Page 113: ... leads 1 2 3 and 4 and the wire harness head light lead main switch lead right handlebar switch lead and left handlebar switch lead Install the thermostat heat protector throttle cables spark plug leads wire harnesses and air cut off valve under the cable guide in the respective order Ô To the left slit of the plate CABLE ROUTING ...

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

Page 115: ...ttached to the frame Ê Pass the CYCLELOCK coupler through the inside of the storage box of the U lock Ë Pass the CYCLELOCK coupler through the lead guide Ì Pass the pressure sensor lead and engine stop switch lead through the lead guide Í Pass the wire harnesses under the tray bracket CABLE ROUTING ...

Page 116: ...anister charge hose 5 Canister purge hose 6 Rollover valve 7 Canister È To the left front of the fuel tank É To the left rear of the fuel tank Ê To the throttle bodies Ë Align the white paint marks on the canister purge hose and canister charge hose with the outer edges of the hose holders CABLE ROUTING ...

Page 117: ...ance Check and adjust valve clearance when engine is cold Every 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventila tion system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses and vacuum hose for cracks or damage Replace if necessary 5 Muffler and exhau...

Page 118: ...il leakage Repair if necessary 12 Steering bearings Check bearing assembly for looseness Moderately repack with lithium soap based grease every 12 000 mi 19 000 km or 18 months Repack 13 Brake and clutch lever pivot shafts Apply lithium soap based grease lightly 14 Brake and shift pedal pivot shafts Apply lithium soap based grease lightly 15 Final gear oil Check oil level and vehicle for oil leaka...

Page 119: ...e brake or clutch master cylinders caliper cylinders or clutch release cylin der always change the fluid Regularly check the brake and clutch fluid levels and fill the reser voirs as required Every two years replace the internal components of the brake and clutch master cylinders cali per cylinders and clutch release cylinder and change the brake and clutch fluid Replace the brake and clutch hoses...

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

Page 121: ...anel left and right 1 1 2 Bolt 2 3 Nut 1 4 Fuel sender coupler 1 5 Fuel pump coupler 1 6 Fuel tank overflow hose 1 7 Fuel tank breather hose 1 8 Hose holder 1 9 Fuel hose holder 2 10 Fuel hose 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE 11 Fuel return hose 1 12 Bolt 1 13 Fuel tank 1 Refer to REMOVING THE FUEL TANK For installation reverse the removal procedure ...

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

Page 123: ...fuel remain ing in it NOTE Before removing the hoses place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position REMOVING THE FUEL PUMP 1 Remove fuel pump CAUTION Do not drop the fuel pump or give it a strong shock ...

Page 124: ...ross pattern and to the specified torque FWD T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose holders CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct posi tion otherwise the fuel hose will not be properly installed INSTALLING THE T BAR 1 Install T bar CAUTION Always tighten the T bar m...

Page 125: ...uel tank Refer to SEATS AND FUEL TANK Side covers left and right Refer to COWLINGS AND COVERS 1 Air shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Lean angle cut off switch 1 5 Tray 1 6 Fuel tank bracket 1 7 Plastic locking tie 1 8 Intake air temperature sensor coupler 1 9 Crankcase breather hose 1 Disconnect AIR FILTER CASE ...

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

Page 127: ...S AND FUEL TANK 1 Left side cowling 1 2 Right side cowling 1 3 Front bottom cowling 1 4 Front turn signal connector left 2 5 Front turn signal connector right 2 6 Left inner panel front cowling 1 7 Fuse box 1 8 Hazard switch 1 9 Right inner panel front cowling 1 10 Front right inner panel front cowling 1 11 Front left inner panel front cowling 1 12 Sub wire harness coupler 3 13 Front cowling assem...

Page 128: ... front cowling assembly Remove the parts in the order listed 1 Windshield outer bracket 1 2 Windshield 1 3 Grommet 7 4 Windshield inner bracket 1 5 Rear view mirror left and right 2 6 Panel 1 7 Front cowling 1 8 Auxiliary light coupler 2 9 Headlight coupler 2 For assembly reverse the disassembly procedure ...

Page 129: ...3 13 CHK ADJ 1 Order Job Part Q ty Remarks Removing the headlight assembly Remove the parts in the order listed 1 Headlight assembly 1 For installation reverse the removal procedure COWLINGS AND COVERS ...

Page 130: ... the parts in the order listed 1 Windshield drive unit 1 2 Windshield drive unit coupler 2 3 Meter assembly 1 4 Meter assembly coupler 1 5 Headlight relay 1 1 6 Headlight relay 2 1 7 Fuel injection system relay 1 8 Turn signal relay 1 9 Radiator fan motor relay 1 For installation reverse the removal procedure COWLINGS AND COVERS ...

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

Page 132: ...o be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK side cowlings front cowling assembly Refer to COWLINGS AND COVERS Refer to AIR INDUCTION SYSTEM in chapter 7 thermostat assembly Refer to THERMOSTAT in chapter 6 air cut off valve assembly air induction system hoses 2 Remove spa...

Page 133: ...d when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence È Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft counterclockwise as specified in the following...

Page 134: ...lockwise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise 7 Remove intake camshaft caps exhaust camshaft caps timing chain from the camshaft sprockets intake camshaft exhaust camshaft NOTE Refer to CAMSHAFTS in chapter 5 When removing the timing chain and cam shafts fasten the timing chain with a wire to retrieve it if it falls into the crankcase 8 Adjus...

Page 135: ...nded in order to reach the closest equiva lent to the original c Round off the original valve pad number according to the following table EXAMPLE Original valve pad number 148 thickness 1 48 mm Rounded value 150 d Locate the rounded number of the original valve pad and the measured valve clear ance in the valve pad selection table The point where the column and row intersect is the new valve pad n...

Page 136: ...nd intake camshafts timing chain and camshaft caps NOTE Refer to INSTALLING THE CAMSHAFTS CAMSHAFTS in chapter 5 Lubricate the camshafts camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Turn the crankshaft clockwise several full turns to seat the parts g Measure the valve clearance again h If the valve clearance is still o...

Page 137: ... 28 1 32 230 235 240 1 33 1 37 235 240 1 38 1 42 240 MEASURED CLEARANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 03 0 06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 08 0 11 ...

Page 138: ...properly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand 2 Remove rider seat fuel tank T bar Refer to SEATS AND FUEL TANK 3 Remove caps 1 4 Install carburetor synchronizer onto the pipes inductive tachometer onto the spark plug lead of cylinder 1 5 Install fuel tank Refer to SEATS AND FUEL TANK 6 Start the e...

Page 139: ... the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION Do not use the throttle valve adjusting screws to adjust the throttle body synchronization NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mm Hg 0 39 in Hg 9 Measure engine idling speed Out of specification Adjust Ma...

Page 140: ...ree play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in 12 Remove engine tachometer vacuum gauge 13 Remove fuel tank 14 Install T bar 15 Install fuel tank rider seat Refer to SEATS AND FUEL TANK ...

Page 141: ... minutes 2 Remove fuel tank side panels left and right fuel tank front mounting bolts 3 Lift up the front of the fuel tank 4 Attach inductive tachometer onto the spark plug lead of cylinder 1 5 Measure engine idling speed Out of specification Adjust 6 Adjust engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Inductive tachom...

Page 142: ...ont mounting bolts fuel tank side panels left and right Refer to SEATS AND FUEL TANK EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and carburetor syn chronization should be adjusted properly 1 Check throttle cable free play a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 143: ...n a or b until the specified throttle cable free play is obtained e Tighten the locknuts NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction c or d until the specified throttle cable free play is obtained c Tighten the locknu...

Page 144: ... seat Refer to SEATS AND FUEL TANK EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove rider seat fuel tank T bar Refer to SEATS AND FUEL TANK 2 Disconnect spark plug cap 3 Remove spark plug CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders...

Page 145: ... a wire gauge Out of specification Regap 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install T bar fuel tank rider seat Refer to SEATS AND FUEL TANK Spark plug gap 0 7 0 8 mm 0 028 0 031 in T R 13 Nm 1 3 m kg 9 4 ft lb EAS00061 CHECKING THE IGNITION TIMING NOTE Prior to checking the ignition timing check the wiring ...

Page 146: ... cylinder 1 3 Install fuel tank Refer to SEATS AND FUEL TANK 4 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the mark a is within the required firing range b on the timing plate Incorrect firing range Check the ignition system NOTE The ignition timing is not adjustable Timing light YU 33277 A Inductive...

Page 147: ...s to all of the cylinders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove rider seat fuel tank T bar Refer to SEATS AND FUEL TANK 4 Disconnect spark plug cap 5 Remove spark plug CAUTION Before remov...

Page 148: ...difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 14 22 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Compress...

Page 149: ...ir Same as without oil Piston ring s valves cylinder head gasket or pis ton possibly defec tive Repair 10 Install spark plug 11 Connect spark plug cap 12 Install T bar fuel tank rider seat T R 13 Nm 1 3 m kg 9 4 ft lb EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure the motorcycle is upright 2 Start the engine ...

Page 150: ...e clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase NOTE _ API Service SE SF and SG type or equivalent e g SF SE SF SE CC SF SE SD Before checking the engine oil level wait a few minutes until the oil has settled Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 4 Start the engine warm it up for several min utes and then...

Page 151: ...placed perform the following procedure a Remove the left side cowling Refer to COWLINGS AND COVERS b Remove the oil filter cartridge 1 with an oil filter wrench 2 c Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter car tridge d Tighten the new oil filter cartridge to specifi ...

Page 152: ...ded engine oil 9 Install engine oil filler cap 10 Start the engine warm it up for several min utes and then turn it off Quantity Total amount 4 9 L 4 31 Imp qt 5 18 US qt Without oil filter cartridge replacement 3 8 L 3 34 Imp qt 4 02 US qt With oil filter cartridge replace ment 4 0 L 3 52 Imp qt 4 23 US qt 11 Check engine for engine oil leaks 12 Check engine oil level Refer to CHECKING THE ENGINE...

Page 153: ...OIL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification T R Oil gallery bolt 20 Nm 2 0 m kg 14 ft lb EAS00077 MEASURING THE ENGINE OIL PRESSURE 1 Check engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Remove side cowlings 3 Start the engine warm it ...

Page 154: ...nstall main gallery bolt Pressure gauge 90890 03153 Oil pressure adapter B 90890 03124 Engine oil pressure 30 kPa 0 30 kg cm2 4 27 psi Engine speed Approx 1 000 1 100 r min Engine oil temperature 73 C 163 F Engine oil pressure Possible causes Below specifica tion Faulty oil pump Clogged oil filter Leaking oil pas sage Broken or dam aged oil seal Above specifica tion Leaking oil pas sage Faulty oil...

Page 155: ... dial with the arrow mark 2 on the clutch lever holder WARNING After adjusting the clutch lever position make sure the pin on the clutch lever holder is firmly inserted in the hole in the adjusting dial Position 1 Distance a is the larg est Position 5 Distance a is the small est EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitab...

Page 156: ...reful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the res ervoir is horizontal ...

Page 157: ... the hose have disappeared 1 Bleed hydraulic clutch system a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly squeeze the clutch lever several times f Fully squeeze the clutch lever without releasing it g Loosen the ...

Page 158: ...ing the hydraulic clutch system check the clutch operation EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove seats Refer to SEATS AND FUEL TANK left side cover Refer to COWLINGS AND COVERS 2 Remove air shroud 1 3 Remove air filter case cover 1 air filter element 4 Clean air filter element Apply compressed air to the outer surface of the air filter element 5 Check air filter element Damage Replace ...

Page 159: ...nce and possible overheat ing NOTE When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 7 Install air shroud 8 Install left side cover Refer to COWLINGS AND COVERS seats Refer to SEATS AND FUEL TANK EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints 1 R...

Page 160: ...Refer to SEATS AND FUEL TANK EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove rider seat fuel tank Refer to SEATS AND FUEL TANK air filter case Refer to AIR FILTER CASE 2 Check crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly CAUTION Make sure the crankcase breather hose is routed correctly 3 Install air filter case Refer to AIR FILTER CASE fuel tank rider se...

Page 161: ... Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 3 Check tightening torque 4 Install side cowlings Refer to COWLINGS AND COVERS T R Exhaust pipe assembly and bracket bolt 4 17 Nm 1 7 m kg 12 ft lb Exhaust pipe nut 5 20 Nm 2 0 m kg 14 ft lb Muffler and passenger footrest bracket bolt 6 25 Nm 2 5 m kg 18 ft lb Exhaust pipe and muffler bolt 7 20 Nm 2 0 m kg 14 ...

Page 162: ...imum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 4 Start the engine warm it up for several min u...

Page 163: ...ling assembly Refer to COWLINGS AND COVERS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket joint 6 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install front cowling assembly side cowlings Refer to COWLINGS AND COVERS fuel tank rider seat Refer to SEATS AND FUEL TANK ...

Page 164: ...the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiat...

Page 165: ...nes Mixing ratio 1 1 antifreeze water Quantity Total amount 3 2 L 2 82 Imp qt 3 38 US qt Coolant reservoir capacity 0 485 L 0 43 Imp qt 0 51 US qt From minimum to maximum level mark 0 15 L 0 13 Imp qt 0 16 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a do...

Page 166: ...y wash them with water Do not mix different types of antifreeze 12 Install radiator cap 13 Remove coolant reservoir cap cover 1 coolant reservoir cap 14 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 15 Install coolant reservoir cap coolant reservoir cap cover 16 Start the engine warm it up for several min utes and then stop it 17 Check coolant level Refer to CHEC...

Page 167: ... make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake sys tem lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will considerably reduce braking performance and could result in loss of control and poss...

Page 168: ... 1 to specification WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system CAU...

Page 169: ...d level Below the minimum level mark a Add the recommended brake fluid to the proper level È Front brake É Rear brake WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction l...

Page 170: ...cedure applies to all of the brake pads 1 Operate the brake 2 Check front brake pad Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 4 rear brake pad Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 4 È Front brake É Rear brake È É EAS00128 ADJUSTING THE REAR ...

Page 171: ...time c Install the right footrest bracket bolts Direction a Brake light comes on sooner Direction b Brake light comes on later T R Right footrest bracket bolt 28 Nm 2 8 m kg 20 ft lb EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check brake hose 1 Cracks damage wear Replace 2 Check brake hose clamp Loose Tighten the clamp bolt 3...

Page 172: ...nter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Remove right side cover Refer to COWLINGS AND COVERS 2 Bleed hydraulic brake system a Fill the brake fluid reservoir to the proper level with the...

Page 173: ...hten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic brake system check the brake operation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EAS00136 ADJUSTING THE SHIFT PEDAL 1 Check shift pedal position The end 1 of the shift pedal with the left middle gear c...

Page 174: ...ve final drive housing oil filler bolt 1 3 Check final drive oil level The final drive oil level should be to the bot tom brim 1 of the filler hole Below the bottom brim Add the recom mended final drive oil to the proper level 4 Install final drive housing oil filler bolt Recommended oil Shaft drive gear oil Part No 9079E SH001 00 T R 23 Nm 2 3 m kg 17 ft lb EAS00145 CHANGING THE FINAL DRIVE OIL 1...

Page 175: ...efer to CHECKING THE FINAL DRIVE OIL LEVEL Quantity 0 2 L 0 18 Imp qt 0 21 US qt EAS00147 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the motorcycle on a level surface WARNING Securely support the motorcycle so that there is no danger of it falling over NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork le...

Page 176: ...e turn and then tighten it to specification with a steering nut wrench WARNING Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to HANDLEBARS and STEERING HEAD in chapter 4 e Install the rubber washer f Install...

Page 177: ...lebars washer steering stem nut 7 Tighten upper bracket pinch bolts T R 115 Nm 11 5 m kg 85 ft lb T R 34 Nm 3 4 m kg 24 ft lb EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the motorcycle upright and apply ...

Page 178: ...nger of it falling over Spring preload CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting positions Minimum 5 Standard 3 ...

Page 179: ...m 17 clicks out Standard 12 clicks out Maximum 1 click out Compression damping CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust compression damping a Turn the adjusting screw 1 in direction a or b from the fully turned in position Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Adjustin...

Page 180: ...n direction a or b b Adjust the adjusting lever to HARD or SOFT Position a Spring preload is increased suspension is harder Position b Spring preload is decreased suspension is softer Rebound damping CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Rebound damping is increased suspension is har...

Page 181: ...ension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE total of cargo rider passenger and accesso ries Basic weight with oil and a full fuel tank 274 kg 604 lb USA 275 kg 605 lb California Maximum load 2...

Page 182: ...inching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement È Tire É Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tir...

Page 183: ...ointing in the direction of wheel rotation Align the mark 5 with the valve installation point Manufacturer Model Size METZELER MEZ4J FRONT 120 70 ZR17 M C 58W BRIDGESTONE BT020F N 120 70 ZR17 M C 58W Manufacturer Model Size METZELER MEZ4J 180 55 ZR17 M C 73W BRIDGESTONE BT020R N 180 55 ZR17 M C 73W EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Dam...

Page 184: ...sheath Damage Replace 2 Check cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recommended lubricant Engine oil or a suitable cable lubricant EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended ...

Page 185: ...RSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap base grease ...

Page 186: ...yte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION This is a sealed battery Never remove the sealing caps ...

Page 187: ...cket tester to the battery termi nals NOTE The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V...

Page 188: ...are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes ...

Page 189: ...ard charg ing amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes befo...

Page 190: ...ches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set th...

Page 191: ...ry terminals 10 Install right inner panel front cowling Refer to COWLINGS AND COVERS Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove right inner panel front cowling left inner panel front cowling front right inner pane...

Page 192: ... if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Items Amperage rating Q ty Main fuse 50 A 1 Headlight fuse 25 A 1 Radiator fan motor fuse 15 A 1 Signaling system fuse 10 A 1 Fuel injection system fuse 15 A 1 Ignition fuse 10 A 1 Tail position light fuse 10 A 1 Windshield motor fuse 2 A 1 Hazard lighting fuse 10 A 1 Backup fuse 10 A 1 Res...

Page 193: ...sibly cause a fire 4 Install front right inner panel front cowling right inner panel front cowling left inner panel front cowling Refer to COWLINGS AND COVERS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Disconnect headlight coupler 1 2 Remove headlight bulb cover 2 3 Detach headlight bulb holder 1 4 Remove headlight bulb 2 WARNING Since t...

Page 194: ...and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Attach headlight bulb holder 7 Install headlight bulb cover 8 Connect headlight coupler New EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust headlight beam vertically a Turn the adjus...

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

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

Page 197: ...ace the motorcycle on a suitable stand so that the front wheel is elevated 1 Brake caliper left and right 2 Refer to REMOVING INSTALLING THE FRONT WHEEL 2 Wheel axle pinch bolt 1 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar left 1 6 Collar right 1 7 Brake disc left and right 2 For installation reverse the removal procedure FRONT WHEEL AND BRAKE DISCS 1 2 3 4 ...

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

Page 199: ...move left brake caliper right brake caliper NOTE Do not squeeze the brake lever when remov ing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent wheel axle 2 Check tire front whe...

Page 200: ... seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race 4 or...

Page 201: ...ring the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 059 in below the edge of the brake disc Brake disc deflection limit maxi mum Front 0 1 mm 0 004 in Rear 0 1 mm 0 004 in 3 Measure brake disc thic...

Page 202: ...ification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE EAS00545 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs 1 Lubricate wheel axle oil seal lips 2 Tighten wheel axle 1 wheel axle pinch bolt 2 CAUTION Before tightening the wheel axle nut push down hard on the handle...

Page 203: ...installed 1 Remove balancing weight s 2 Find front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X mark at the bottom of the wheel c Turn the front wheel 90 so that the X mark is positioned as shown d Release the front wheel e When the wheel stops put an X mark at the bottom of the wheel f Repeat steps d throu...

Page 204: ...urn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 205: ...ts in the order listed NOTE Place the motorcycle on a suitable stand so that the rear wheel is elevated 1 Brake torque rod nut bolt 1 1 Refer to INSTALLING THE REAR WHEEL 2 Wheel axle nut 1 3 Wheel axle pinch bolt 1 Loosen 4 Rear wheel axle 1 5 Rear brake caliper 1 6 Rear wheel 1 7 Collar 1 8 Brake disc 1 For installation reverse the removal procedure ...

Page 206: ...e rear wheel Remove the parts in the order listed 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 2 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Spacer 1 0 Collar 1 A Oil seal 1 B Bearing 1 For assembly reverse the disassembly procedure ...

Page 207: ...elevated 2 Remove brake caliper bracket NOTE Do not depress the brake pedal when remov ing the brake caliper bracket with brake cali per 3 Remove rear wheel NOTE Move the rear wheel to the right to separate it from the final drive housing EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL AND BRAKE DISCS 2 Check tire rear wheel Damage wear ...

Page 208: ... 2 Tighten brake torque rod nut wheel axle nut wheel axle pinch bolt T R 30 Nm 3 0 m kg 22 ft lb T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust re...

Page 209: ...ront brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake hose holder bolt 1 2 Brake caliper bolt 2 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Brake pad shim 2 8 Bleed screw 1 For installation reverse the removal procedure ...

Page 210: ...EAS00578 REAR BRAKE PADS Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad 2 3 Brake pad shim 2 4 Bleed screw 1 For installation reverse the removal procedure ...

Page 211: ...ly clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00582 REPLACING THE FRONT ...

Page 212: ... install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto the new brake pads e Install new brake pads and a n...

Page 213: ...level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove retaining bolts 1 brake caliper 2 2 Remo...

Page 214: ...nd a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad springs 3 e Install a new brake pad shim 4 onto each new brake pad 5 f Install new brake pads 5 Install r...

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

Page 216: ...moving the front brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect ...

Page 217: ... bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder holder 1 10 Brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal procedure ...

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

Page 219: ...in the order listed Side cover right Refer to COWLINGS AND COVERS in chapter 3 Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Hose joint 1 7 Rear brake light switch coupler 1 Disconnect 8 Right footrest bracket bolt 2 ...

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

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

Page 222: ...tem 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose ...

Page 223: ...very passages brake master cylinder body Obstruction Blow out with compressed air È Front É Rear È É 2 Check brake master cylinder kit 1 Damage scratches wear Replace È Front É Rear È É 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake master cylin...

Page 224: ...mponents 1 Install brake master cylinder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a in the right handlebar First tighten the upper bolt then the lower bolt Recommended brake fluid DOT 4 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install copper washers 1 brake hose 2 union bolt 3 WARNING Proper brake hose ro...

Page 225: ...luids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of t...

Page 226: ... SYSTEM in chapter 3 EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers 1 brake hose 2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown New T R 30 Nm 3 0 m kg 22 ft lb 2 Fill b...

Page 227: ...servoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to ...

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

Page 229: ...e order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Brake hose holder bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper bolt 2 6 Brake caliper 1 For installation reverse the removal procedure ...

Page 230: ...order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad brake pad shim 2 2 5 Brake caliper piston 4 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 231: ...order listed Brake fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Retaining bolt 2 Loosen 5 Brake torque rod 1 6 Wheel axle nut 1 7 Wheel axle pinch bolt 1 Loosen 8 Rear wheel axle 1 9 Brake caliper 1 For installation reverse the removal procedure ...

Page 232: ...er Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad brake pad shim 2 2 3 Brake pad spring 2 4 Rear brake caliper bracket 1 5 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER 6 Brake caliper piston seal 2 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 233: ...ake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper WARNING Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Rem...

Page 234: ...brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper piston 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake cali...

Page 235: ...ake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals È Front É Rear Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassem bled È É 2 Check...

Page 236: ...ill cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose onto the brake ca...

Page 237: ...ge and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid...

Page 238: ...AULIC BRAKE SYSTEM in chapter 3 EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Re...

Page 239: ...2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cali per 4 Remove brake caliper New T R 30 Nm 3 0 m kg 22 ft lb 5 Install brake pad springs brake pads brake caliper retaining bolts Refer to REPLACING ...

Page 240: ...eading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 7 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in...

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

Page 242: ...Removing the clutch master cylin der Remove the parts in the order listed Clutch fluid Drain 1 Clutch master reservoir cap 1 2 Clutch master reservoir diaphram holder 1 3 Clutch master reservoir diaphram 1 4 Clutch lever 1 5 Bushing 1 6 Clutch switch coupler 1 Disconnect HYDRAULIC CLUTCH ...

Page 243: ... INSTALLING THE CLUTCH MASTER CYLINDER 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 Refer to ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER 12 Clutch switch 1 For installation reverse the removal procedure HYDRAULIC CLUTCH ...

Page 244: ...g the clutch master cylinder Remove the parts in the order listed 1 Clutch master cylinder push rod 1 2 Dust seal 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder 1 For assembly reverse the disassembly procedure HYDRAULIC CLUTCH ...

Page 245: ...h components Clutch fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get immediate medical attention DISASSEMBLING THE CLUTCH MASTER CYLINDER NOTE Before disassembling the clutc...

Page 246: ...Replace the clutch mas ter cylinder clutch fluid delivery passage clutch master cylinder body Obstruction Blow out with compressed air 2 Check clutch master cylinder 1 clutch master cylinder kit 2 Rust scratches wear Replace the clutch master cylinder and clutch master cylinder kit as a set 3 Check clutch master cylinder reservoir 1 Cranks damage Replace clutch master cylinder reservoir diaphragm ...

Page 247: ...clutch fluid Brake fluid DOT 4 1 Install clutch master cylinder 1 NOTE Install the clutch master cylinder holder with the UP mark facing up Align the end of the clutch master cylinder holder with the punch mark a in the left han dlebar First tighten the upper bolt then the lower bolt T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install copper washers 1 clutch hose 2 union bolt 3 WARNING Proper clutch hose routi...

Page 248: ...fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boil...

Page 249: ...h fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 6 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 HYDRAULIC CLUTCH ...

Page 250: ...r Remove the parts in the order listed Clutch fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal procedure HYDRAULIC CLUTCH ...

Page 251: ...r Remove the parts in the order listed 1 Clutch release cylinder piston 1 Refer to DISASSEMBLING THE CLUTCH RELEASE CYLINDER 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly procedure HYDRAULIC CLUTCH ...

Page 252: ...ully 2 Remove clutch release cylinder piston 1 clutch release cylinder spring 2 clutch release cylinder piston seal 3 a Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder WARNING Cover the clutch release cylinder with a rag Be careful not to get injured when the piston is expelled from the clutch release cylinder Never try to pry out t...

Page 253: ...tch release cylinder piston 2 Rust scratches wear Replace the clutch release cylinder and clutch release cylinder piston as a set EAS00315 ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER 1 Install copper washers 1 clutch hose 2 union bolt 3 WARNING Proper clutch hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the clutch hose onto t...

Page 254: ...performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately 3 Bleed clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 Recom...

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

Page 256: ...the front fork legs Front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Collar 2 3 Collar 2 4 Upper bracket pinch bolt 1 Loosen Refer to REMOVING INSTALLING THE FRONT FORK LEGS 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 For installation reverse the removal procedure ...

Page 257: ...order listed The following procedure applies to both of the front fork legs 1 Cap bolt O ring 1 1 Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 2 Damper adjusting rod 1 3 Nut 1 4 Spacer 1 5 Washer 1 6 Fork spring 1 7 Spring seat 1 8 Dust seal 1 9 Oil seal clip 1 0 Damper rod assembly bolt 1 A Copper washer 1 ...

Page 258: ...o DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS C Inner tube 1 D Oil seal 1 Refer to ASSEMBLING THE FRONT FORK LEGS E Seal spacer 1 F Outer tube bushing 1 G Inner tube bushing 1 H Oil flow stopper 1 I Outer tube 1 For assembly reverse the disassembly procedure FRONT FORK ...

Page 259: ... suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolts 3 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Loosen nut 1 cap bolt 2 2 Remove cap bolt nut 3 D...

Page 260: ...damper rod assembly bolt While holding the damper rod with the damper rod holder 2 loosen the damper rod assembly bolt 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully CAUTION Excessive force will damage the oil seal and bush...

Page 261: ... free length a Out of specification Replace Spring free length 261 mm 10 28 in 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper 2 Damage Replace CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembli...

Page 262: ...hen assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install damper rod assembly 1 CAUTION Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the ...

Page 263: ... kg 25 ft lb 4 Install outer tube bushing 1 with the fork seal installer 2 Fork seal installer YM 01442 New 5 Install seal spacer oil seal 1 with the fork seal driver CAUTION Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil s...

Page 264: ...e the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 10 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil NOTE Be sure to stroke the damper rod slowly because the fork oil may spu...

Page 265: ...e top of the inner tube with the inner tube fully compressed and without the spring 100 mm 3 94 in 14 Install nut 1 damper adjusting rod 2 cap bolt 3 a Install the nut 1 and finger tighten it b Install the damper adjusting rod 2 c Install the cap bolt 3 and finger tighten it WARNING Always use a new cap bolt O ring d Hold the cap bolt and tighten the nut 1 to specification T R Nut 25 Nm 2 5 m kg 1...

Page 266: ...E Make sure that the inner tube end is flush with the top of the upper bracket Temporarily tighten the upper and lower bracket pinch bolts WARNING Make sure the brake hoses are routed prop erly 2 Tighten lower bracket pinch bolts 1 cap bolt 2 upper bracket pinch bolt 3 T R 23 Nm 2 3 m kg 17 ft lb T R 25 Nm 2 5 m kg 18 ft lb T R 34 Nm 3 4 m kg 24 ft lb ...

Page 267: ...ront fender Install the collar 2 from the inside of the front fender When installing the front fender make sure that there is no dirt between the front fender and front fork T R 6 Nm 0 6 m kg 4 3 ft lb 4 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 FRONT FORK ...

Page 268: ...lebar Remove the parts in the order listed 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Clutch master cylinder 1 4 Left handlebar switch 1 5 Grip end 1 6 Handlebar grip 1 7 Left handlebar 1 For installation reverse the removal procedure ...

Page 269: ... Front brake light switch connector 2 Disconnect 2 Brake master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Brake master cylinder 1 4 Grip end 1 5 Throttle cable housing 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar switch 1 9 Right handlebar 1 For installation reverse the removal procedure ...

Page 270: ...sed air between the left handle bar and the handlebar grip and gradually push the grip off the handlebar 3 Remove throttle cable housing 1 throttle grip 2 NOTE While removing the throttle cable housing pull back the rubber cover 3 EAS00669 CHECKING THE HANDLEBARS 1 Check left handlebar 1 right handlebar 2 Bends cracks damage Replace WARNING Do not attempt to straighten bent handle bars as this may...

Page 271: ... in the right handlebar 3 Install throttle grip 1 throttle cable housing 2 throttle cables grip end NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar Align the projection a on the throttle cable housing with the hole b in the right handle bar There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and ...

Page 272: ...ndlebar grip grip end a Apply a thin coat of rubber adhesive onto the left end of the left handlebar b Slide the handlebar grip over the left end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clearance a between the throttle grip and the grip ...

Page 273: ...n the slit in the clutch master cylinder holder with the punch mark a in the left han dlebar T R 10 Nm 1 0 m kg 7 2 ft lb 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ...

Page 274: ...ts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebars Refer to HANDLEBARS 1 Lead guide 2 2 Main switch coupler 2 Disconnect Refer to INSTALLING THE STEERING HEAD 3 Steering stem nut 1 4 Upper bracket 1 5 Lower bracket panel 1 6 Brake hose holding bolt 2 ...

Page 275: ... LOWER BRACKET and INSTALLING THE STEERING HEAD 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Bearing cover 1 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearing 1 16 Bearing outer race 2 17 Dust seal 1 For installation reverse the removal procedure ...

Page 276: ... 1 with the special tool 2 WARNING Securely support the lower bracket so that there is no danger of it falling Spanner wrench YU 33975 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosene 2 Check bearings 1 bearing races 2 Damage pitting Replace 3 Replace bearings bearing races a Remove the bearing races from the steering head pipe with a long rod...

Page 277: ...e bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer 2 upper ring nut 3 lo...

Page 278: ...bracket steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK NOTE Temporarily tighten the lower and upper bracket pinch bolts 5 Tighten steering stem nut T R 115 Nm 11 5 m kg 85 ft lb ...

Page 279: ...er Job Part Q ty Remarks Removing the rear shock absorber assembly and relay arm Remove the parts in the order listed Rear wheel Refer to REAR WHEEL AND BRAKE DISC Mufflers exhaust pipe Refer to ENGINE in chapter 5 1 Nut 3 2 Nut washer bolt 1 1 1 Bolt 54 mm 2 13 in Refer to REMOVING INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 3 Nut washer bolt 2 2 2 Bolt 117 mm 4 61 in 4 Connecting arm 2 5 Nut bol...

Page 280: ... 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib Order Job Part Q ty Remarks 9 Relay arm 1 10 Collar 1 11 Collar 1 12 Collar 1 13 Oil seal 6 14 Bearing 2 Refer to INSTALLING THE RELAY ARM 15 Bearing 2 For installation reverse the removal procedure ...

Page 281: ...ause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping performance EAS00688 DISPOSING OF A REAR SHOCK ABSORBER Gas pressure must be released before dispos ing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 15 20...

Page 282: ... swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly bolts Bends damage wear...

Page 283: ...gs 2 Install bearing 1 2 to the relay arm Recommended lubricant Lithium soap base grease Installed depth a 4 0 mm 0 16 in Installed depth b 4 5 mm 0 18 in EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate spacers bearings Recommended lubricant Lithium soap base grease 2 Install rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm ...

Page 284: ...n chapter 5 Rear wheel Refer to REAR WHEEL AND BRAKE DISC Final drive assembly universal joint Refer to SHAFT DRIVE Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1 Right footrest bracket bolt 2 2 Cover 1 3 Cover 1 4 Pivot shaft nut 1 Refer to REMOVING THE SWINGARM 5 Locknut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 ...

Page 285: ...ks 9 Oil seal 2 10 Bearing 2 Refer to INSTALLING THE SWINGARM 11 Spacer 1 12 Oil seal 1 13 Bushing 1 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Spacer 1 18 Bearing 1 Refer to INSTALLING THE SWINGARM For installation reverse the removal procedure ...

Page 286: ...ut b Measure the swingarm side play È by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bushing and bear ings d Check the swingarm vertical movement É by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bushing and bearings T R Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb...

Page 287: ...vot shaft spacers bushing bearings Recommended cleaning solvent Kerosene 4 Check spacers bushing oil seals Damage wear Replace bearings Damage pitting Replace EAS00712 INSTALLING THE SWINGARM 1 Lubricate bearings spacers oil seals pivot shaft Recommended lubricant Lithium soap base grease 2 Install bearing 1 to the swingarm Installed depth a 7 0 mm 0 28 in ...

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

Page 289: ...erky movement during acceleration deceleration or sustained speeds not to be confused with engine surg ing or transmission related movements 2 A rolling rumble noticeable at low speeds a high pitched whine or a clunk from a shaft drive component or from the vicinity of the shaft drive 3 The shaft drive is locked up or no power is transmitted from the engine to the rear wheel A Bearing damage B Imp...

Page 290: ...ation Diagnosis Possible incorrect reassembly or too little gear backlash WARNING Insufficient gear backlash is extremely destructive to the gear teeth If a test ride following reassembly indicates these symptoms stop riding immediately to mini mize gear damage c A slight clunk evident at low speed opera tion not to be confused with normal motor cycle operation Diagnosis Possible broken gear teeth...

Page 291: ...ed YES Replace the wheel bearing Refer to FRONT WHEEL AND BRAKE DISCS NO Place the motorcycle on a suitable stand so that the rear wheel is elevated and then spin the rear wheel Is the wheel bearing dam aged NO Rear wheel bearings and shaft drive bear ings are probably not damaged Repeat the test or remove and check the components YES Remove the rear wheel Is the wheel bear ing damaged YES Replace...

Page 292: ...3 Check shaft drive housing for oil leaks a Thoroughly clean the entire motorcycle and then completely dry it b Apply a leak locating compound or dry pow der spray to the shaft drive c Test ride the motorcycle long enough to locate a leak Oil leak Repair or replace the faulty part s 1 Oil seal 2 O ring 3 Forward NOTE What may appear to be an oil leak on a new or fairly new motorcycle may result fr...

Page 293: ... overtighten the bolt c Install the final drive gear lash tool 2 and dial gauge 3 a Dial gauge plunger contact point 60 mm 2 36 in d Gently rotate the gear coupling from engagement to engagement e Record the reading on the dial gauge f Remove the dial gauge final gear backlash band and bolt g Rotate the final drive pinion gear 90 h Reinstall the bolt special tool and dial gauge i Repeat steps d to...

Page 294: ...ct the suitable shim s and thrust washer with the following chart b If it is necessary to increase the ring gear backlash by more than 0 2 mm reduce the thrust washer thickness by 0 2 mm for every 0 2 mm increase of ring gear shim thick ness c If it is necessary to reduce the ring gear backlash by more than 0 2 mm increase the thrust washer thickness by 0 2 mm for every 0 2 mm decrease of ring gea...

Page 295: ...earance a Out of specification Adjust 1 Stopper bolt 2 Ring gear 3 Install ring gear bearing housing along with the ring gear Ring gear to stopper bolt clear ance 0 30 0 60 mm 0 01 0 02 in EAS00722 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove ring gear 1 stopper bolt 2 stopper bolt shim s 3 ring gear bearing housing 2 Select stopper bolt shim s Stopper bolt shims Thickness mm 0 10 0 ...

Page 296: ...CAUTION The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Apply LOCTITE onto the stopper bolt 4 Measure ring gear to stopper bolt clearance NOTE If the ring gear to stopper bolt clearance is out of specification repeat the above procedure T R 9 Nm 0 9 m kg 6 5 ft lb ...

Page 297: ...ng the final drive assembly Remove the parts in the order listed Final gear oil Drain Rear wheel Refer to REAR WHEEL AND BRAKE DISC 1 Final drive assembly 1 Refer to INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY For installation reverse the removal procedure ...

Page 298: ...e order listed Final drive assembly 1 Shift arm 1 Refer to INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY 2 Left footrest bracket 1 Refer to REMOVING THE LEFT FOOTREST BRACKET 3 Dust cover 1 4 Dust seal 1 5 Universal joint 1 For installation reverse the removal procedure SHAFT DRIVE ...

Page 299: ...parts in the order listed 1 Circlip 2 2 Oil seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing oil seal 1 1 6 Dust cover 1 Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 Ring gear bearing 1 1 8 Ring gear shim s 9 Thrust washer 1 0 Stopper bolt 1 Left hand threads A Stopper bolt shim s ...

Page 300: ...SEMBLY and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR C Gear coupling 1 D Bearing retainer oil seal 1 1 Left hand threads E Final drive pinion gear bearing 1 1 F Final drive pinion gear shim s G Bearing 1 H Bearing 1 I Oil seal 1 J Collar 1 K Final drive housing 1 For assembly reverse the disassembly procedure ...

Page 301: ... THE FINAL DRIVE ASSEMBLY 1 Remove ring gear bearing housing nuts ring gear bearing housing bolts NOTE Working in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loosened remove them and the bolts 2 Straighten punched portion of the nut 3 Remove nut gear coupling 1 with the gear holder 2 Gear holder YM 01229 ...

Page 302: ...e new bearings CAUTION The final drive pinion gear should only be removed if ring gear replacement is neces sary NOTE Lightly tap on the end of the final drive pinion gear with a soft hammer Piston bearing retainer remover YU 04050 EAS00725 REMOVING AND INSTALLING THE RING GEAR BEARINGS 1 Remove collar 1 oil seal 2 bearing 3 with an suitable press tool 4 and an appropriate support for the final dr...

Page 303: ...difficult procedure and is rarely neces sary 4 Install bearing a Heat the final gear case to approximately 150 C 302 F b Install the bearing outer races with a socket or appropriate tool that matches the diame ter of the races c Install the inner race onto the final drive pin ion gear New 5 Install collar 1 oil seal 2 bearing 3 with a suitable press tool 4 and an appro priate support for the final...

Page 304: ...he final drive housing and the drive pinion gear 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b To find final drive pinion gear shim thickness A use the following formula Where a a numeral positive or negative on the final drive pinion gear to be divided by 100 and added to 84 If there is not a numeral available on the final drive pinion gear a equals zero b a numeral on the fin...

Page 305: ...0 mm 0 02 in final drive pinion gear shim Final drive pinion gear shims Thickness mm 0 30 0 40 0 50 Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 c To find ring gear shim thickness B use the following formula Where c a numeral on the final drive housing to be divided by 100 and added to 45 d a numeral usually on the outside of the ring gear bearing housing to be divided by 100 and added to 3 ...

Page 306: ...lculated ring gear shim thick ness is 0 51 mm 0 02 in Shim sizes are supplied in the following thick nesses Since the ring gear shims are only available in 0 10 mm 0 004 in increments round off the hundredths digit In the example above the calculated ring gear shim thickness is 0 51 mm 0 02 in The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm 0 02 in ring gear shim Ring...

Page 307: ...on bearing retainer remover YM 04050 T R 110 Nm 11 0 m kg 80 ft lb 3 Install gear coupling 1 nut 2 with the coupling gear holder 3 CAUTION Apply LOCTITE to the nut 4 Lock the threads with a drift punch Gear holder YM 01229 T R 110 Nm 11 0 m kg 80 ft lb 5 Install ring gear bearing housing along with the ring gear but without the thrust washer 6 Adjust ring gear backlash Refer to MEASURING THE RING ...

Page 308: ...asti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bearing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the following chart i Repeat the measurement steps until the ring gear to thrust washer clearance i...

Page 309: ...aft splines with the driven yoke of the universal joint 3 Tighten final drive assembly nuts Recommended lubricant Lithium soap base grease T R 42 Nm 4 2 m kg 30 ft lb 4 Install shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm 5 Install rear wheel Refer to REAR WHEEL AND BRAKE DISC 6 Fill final drive assembly Refer to CHECKING THE FINAL DRIVE OIL LEVEL in ch...

Page 310: ...listed Seats fuel tank T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator Refer to RADIATOR in chapter 6 1 O2 sensor coupler 1 Disconnect 2 Muffler left and right 2 3 Exhaust pipe assembly 1 For installation reverse the removal procedure ...

Page 311: ...hrottle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 Air cut off valve assembly hoses reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Thermostat assembly Refer to THERMOSTAT in chapter 6 Engine oil oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Oil cooler Refer to OIL COOLER in chapter 6 Water pump Refer to WATER PUMP in chapter 6 1 2 3 4 5 ...

Page 312: ...d switch coupler 1 Disconnect 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect 6 Stator assembly coupler 1 Disconnect 7 Oil level sensor connector 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Neutral switch connector 1 Disconnect 10 Speed sensor coupler 1 Disconnect 11 Ground lead 1 For installation reverse the removal procedure ...

Page 313: ...6 m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE Place a suitable stand under the frame and engine 1 Bolt engine bracket 1 and engine 2 Refer to INSTALLING THE ENGINE 2 Bolt engine bracket 1 and frame 1 3 Engine bracket 1 1 4 Bolt engine bracket 2 and frame 4...

Page 314: ...R T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Order Job Part Q ty Remarks 11 Nut 1 Refer to INSTALLING THE ENGINE 12 Spacer bolt 1 Loosen 13 Rear upper mounting bolt 1 14 Rear lower mounting bolt 1 15 Spacer 1 16 Engine 1 For installation reverse t...

Page 315: ...0 pinch bolt A NOTE Tighten the spacer bolt 2 to specification with a frame spanner socket B When tightened the spacer bolt 2 should be flat against the engine surface Frame spanner socket YM 01471 T R 55 Nm 5 5 m kg 40 ft lb T R 45 Nm 4 5 m kg 32 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 45 Nm 4 5 m kg 32 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 24 Nm 2 4 m kg 17 ft lb T R 24...

Page 316: ... lb 5 Temporarily tighten the bolt engine bracket 1 and frame 1 and bolts engine bracket 1 and engine 2 NOTE When temporarily tightened the bolts 1 2 should be flat against the engine and frame surface 6 Tighten the bolts in the following order bolt engine bracket 1 and engine 1 bolts engine bracket 1 and fame 2 T R 32 Nm 3 2 m kg 23 ft lb T R 16 Nm 1 6 m kg 11 ft lb ENGINE ...

Page 317: ...e cylinder head cover Remove the parts in the order listed Reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Spark plug 4 2 Cylinder identification sensor 1 3 Cylinder head cover 1 Refer to INSTALLING THE CAM SHAFTS 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing chain guide top side 1 For installation reverse the removal ...

Page 318: ...TEM in chapter 7 Pickup coil rotor cover Refer to PICKUP COIL ROTOR 1 Timing chain tensioner 1 Refer to REMOVING INSTALLING THE CAMSHAFTS 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Dowel pin 16 6 Intake camshaft 1 7 Exhaust camshaft 1 8 Intake camshaft sprocket 1 Refer to INSTALLING THE CAM SHAFTS 9 Exhaust camshaft sprocket 1 ...

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

Page 320: ...on the pickup coil rotor with the crankcase mating surface b NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Loosen cap bolt 1 3 Remove timing chain tensioner 2 gasket 4 Remove camshaft caps dowel pins CAUTION To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross patte...

Page 321: ...imensions a and b Out of specification Replace the cam shaft Minimum cam lobe dimensions Intake camshaft a 32 05 mm 1 2618 in b 23 997 mm 0 9448 in Exhaust camshaft a 32 95 mm 1 2972 in b 24 897 mm 0 9802 in 3 Measure camshaft runout Out of specification Replace Maximum camshaft runout 0 03 mm 0 0012 in 4 Measure camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaf...

Page 322: ...rnal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in CHECK...

Page 323: ...ming chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS00217 INSTALLING THE CAMSHAFTS 1 Install exhaust camshaft sprocket 1 intake camshaft sprocket 2 with the special tool 3 NOTE Make sure that the holes a in the cylinder 4 cam and marks b and c on the camshaft sprockets are in the position shown in the i...

Page 324: ...g the timing chain start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side Make sure the marks e on the timing chain sprockets are parallel with the edge of the cylinder head d Intake side e Exhaust side f Cylinder 1 cam E E 3 Install dowel pins intake camshaft caps exhaust camshaft caps NOTE The I mark refers to the intake camshaft caps and th...

Page 325: ... T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise b With the timing chain tensioner rod turned all the way into the timing chain tensioner housing with the thin screwdriver still installed i...

Page 326: ... turns clockwise 7 Check T mark a Make sure the T mark a on the pickup coil rotor is aligned with the crankcase mat ing surface b camshaft holes c Make sure the holes c in the cylinder 4 cam are aligned with the arrow marks d on the camshaft caps Out of alignment Adjust Refer to the installation steps above 8 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANC...

Page 327: ... Apply bond T1541 1 onto the mating sur faces of the cylinder head cover and cylinder head cover gasket Apply bond YGK8624 C1 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 328: ... Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Radiator Refer to RADIATOR in chapter 6 Exhaust pipe assembly Refer to ENGINE Camshafts Refer to CAMSHAFTS 1 Cylinder head 1 Refer to INSTALLING THE CYLINDER HEAD 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal procedure ...

Page 329: ...E Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit ...

Page 330: ...ad NOTE Pass the timing chain through the timing chain cavity 3 Tighten cylinder head bolts M10 1 NOTE Do not reuse the cylinder head bolts The tightening procedure of the cylinder head bolts is angle controlled therefore tighten the bolts using the following proce dure a Lubricate the cylinder head bolts and wash ers with engine oil b Install the washers and cylinder head bolts c Tighten the cyli...

Page 331: ...n the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagonal bolt note that the angle from one corner to another is 60 T R Cylinder head ...

Page 332: ...e valves and valve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 16 Refer to REMOVING INSTALLING THE VALVES 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Valve spring 16 6 Intake valve 4 7 Exhaust valve 4 8 Oil seal 16 9 Lower spring seat 16 10 Valve guide 16 For installation reverse the removal procedure ...

Page 333: ...properly seal 1 Remove valve lifter 1 valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve for leakage Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves prop...

Page 334: ...hment 3 Valve spring compressor set YM 03153 Attachment YM 04108 4 Remove upper spring seat 1 valve spring 2 valve 3 oil seal 4 lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides ...

Page 335: ...valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve...

Page 336: ... thickness Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in 6 Measure valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm 0 0004 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves ...

Page 337: ... and valve face contacted one another the blueing will have been removed Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 4 Lap valve face valve seat NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to t...

Page 338: ...off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS00241 CHECKING TH...

Page 339: ...ring force installed 13 9 16 1 kg at 33 mm 30 6 35 5 lb at 1 30 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Maximum valve spring tilt 1 7 mm 0 07 in EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lift ers and cylinder head ...

Page 340: ... an oil stone 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install lower spring seat 1 oil seal 2 valve 3 valve spring 4 upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Install the valve spring with the larger pitch a facing up b Smaller pitch ...

Page 341: ...e valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve 6 Lubricate valve pad valve lifter with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 7 Install valve pad valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valv...

Page 342: ...er listed Fuel tank seats T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Stator assembly coupler 1 Disconnect 2 Generator cover 1 Refer to REMOVING THE GENERA TOR 3 Generator cover gasket 1 4 Dowel pin 2 GENERATOR AND STARTER CLUTCH ...

Page 343: ... starter clutch idle gear 1 7 Generator rotor 1 Refer to REMOVING INSTALLING THE GENERATOR 8 Woodruff key 1 9 Starter clutch gear 1 Refer to REMOVING INSTALLING THE STARTER CLUTCH 10 Starter clutch 1 For installation reverse the removal procedure GENERATOR AND STARTER CLUTCH ...

Page 344: ...ob Part Q ty Remarks Removing the stator assembly Remove the parts in the order listed 1 Lead holder 1 Refer to INSTALLING THE GENERA TOR 2 Stator assembly 1 For installation reverse the removal procedure GENERATOR AND STARTER CLUTCH ...

Page 345: ...er all of the bolts are fully loosened remove them 2 Remove generator rotor bolt 1 washer NOTE While holding the generator rotor 2 with the primary sheave holder 3 loosen the genera tor rotor bolt Primary sheave holder YS 01880 A 3 Remove generator rotor 1 with the heavy duty puller 2 woodruff key Heavy duty puller YU 33270 B GENERATOR AND STARTER CLUTCH ...

Page 346: ...THE STARTER CLUTCH 1 Check starter clutch rollers 1 Damage wear Replace 2 Check starter clutch idle gear 1 starter clutch gear 2 Burrs chips roughness wear Replace the defective part s 3 Check starter clutch gear s contacting surfaces a Damage pitting wear Replace the starter clutch gear 4 Check starter clutch operation a Install the starter clutch gear 1 onto the starter clutch 2 and hold the sta...

Page 347: ...urn freely otherwise the starter clutch is faulty and must be replaced EAS00355 INSTALLING THE STARTER CLUTCH 1 Install starter clutch starter clutch bolts 1 NOTE While holding the generator rotor with the pri mary sheave holder tighten the starter clutch bolt Primary sheave holder YS 01880 A LT T R 32 Nm 3 2 m kg 23 ft lb EAS00354 INSTALLING THE GENERATOR 1 Apply sealant onto the stator assembly ...

Page 348: ...the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the generator rotor bolt and washer with engine oil 4 Tighten generator rotor bolt 1 NOTE While holding the generator rotor 2 with the primary sheave holder 3 tighten the genera tor rotor bolt Primary sheave holder YS 01880 A T R 130 Nm 13 0 m kg 94 ft...

Page 349: ...apter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Generator cover Refer to GENERATOR ROTOR AND STARTER CLUTCH 1 Pickup coil rotor cover 1 Refer to REMOVING INSTALLING THE PICKUP COIL ROTOR 2 Pickup coil rotor cover gasket 1 PICKUP COIL ROTOR ...

Page 350: ...ankshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 Refer to INSTALLING THE PICKUP COIL ROTOR 6 Pickup coil rotor 1 Refer to REMOVING INSTALLING THE PICKUP COIL ROTOR For installation reverse the removal procedure PICKUP COIL ROTOR ...

Page 351: ...them 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the primary sheave holder 4 remove the pickup coil rotor bolt Primary sheave holder YS 01880 A INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 washer pickup coil rotor bolt NOTE Align the projection a into the pickup coil rotor with the groove b into the crankshaft PICKUP ...

Page 352: ... pickup coil rotor bolt Primary sheave holder YS 01880 A T R 45 Nm 4 5 m kg 32 ft lb 3 Apply sealant onto the crankshaft position sensor lead grommet Quick Gasket ACC 11001 05 01 4 Install pickup coil rotor cover 1 NOTE Align the hole a into the pickup coil rotor cover with the pin b T R 12 Nm 1 2 m kg 8 7 ft lb PICKUP COIL ROTOR ...

Page 353: ...Q ty Remarks Removing the clutch cover Remove the parts in the order listed Right side cowling Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the removal procedure CLUTCH ...

Page 354: ...LIC CLUTCH in chap ter 4 Rear balancer Refer to BALANCERS 1 Oil guide plate 1 Refer to REMOVING INSTALLING THE CLUTCH 2 Clutch spring plate retainer 1 3 Clutch spring plate 1 4 Clutch spring plate seat 1 5 Pressure plate 1 6 Short clutch push rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 10 Clutch plate 7 11 Friction plate 2 7 CLUTCH ...

Page 355: ...MOVING INSTALLING THE CLUTCH 13 Clutch boss 1 14 Wire circlip 1 15 Clutch plate 2 1 16 Friction plate 3 1 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Thrust washer 1 20 Spacer 1 21 Clutch housing 1 For installation reverse the removal procedure CLUTCH ...

Page 356: ...raighten the lock washer tab 4 Loosen clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder YM 91042 5 Remove clutch boss nut 1 lock washer 2 clutch boss assembly 3 NOTE There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the b...

Page 357: ...stallation Insert two 5 mm 0 20 in bolts 2 into the spacer and then remove the spacer by pull ing on the bolts EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the frictio...

Page 358: ... a set Maximum Maximum clutch plate warpage 0 1 mm 0 004 in EAS00283 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate 1 Damage Replace 2 Check clutch spring plate seat 2 Damage Replace EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause errati...

Page 359: ...CKING THE CLUTCH PUSH RODS 1 Check O ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks damage wear Replace the defec tive part s 2 Measure long clutch push rod bending Out of specification Replace the long clutch push rod Long clutch push rod bending limit 0 37 mm 0 015 in EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1 Check primary driven gear 1 Damage wear Replace the clutch hous ...

Page 360: ...e of the holes of the clutch housing and primary driven gear and then rotate the inner pri mary driven gear until both primary driver gears are aligned The teeth of both primary driven gears must be aligned for installation 2 Install spacer NOTE Install the spacer with the two screw holes fac ing towards the clutch boss 3 Install clutch boss assembly 1 NOTE If the wire circlip 2 has been removed c...

Page 361: ...ide of the nut Universal clutch holder YM 91042 New T R 90 Nm 9 0 m kg 65 ft lb 6 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Recommended lubricant Lithium soap base grease 7 Install long clutch push rod ball short clutch push rod along with a new O ring 8 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant...

Page 362: ... plate seat 2 clutch spring plate 3 clutch spring plate retainer 4 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 11 Install rear balancer weight Refer to BALANCERS T R 8 Nm 0 8 m kg 5 8 ft lb 12 Install clutch cover 1 NOTE Tighten the clutch cover bolts in the proper tightening sequence as show 8 9 10 1 11 2 12 3 13 4 5 6 7 T R 12 Nm 1 2 m kg 8 7 ft lb CLUTCH ...

Page 363: ...ift shaft Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Clutch housing Refer to CLUTCH 1 Oil baffle plate 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 Refer to INSTALLING THE SHIFT SHAFT 5 Shift shaft spring 1 SHIFT SHAFT ...

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

Page 365: ...pper lever stopper lever spring 2 Damage wear Replace EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum segment assembly 2 Install shift shaft 1 NOTE Lubricate the oil seal lips with lithium soap base grease Hook the end of the...

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

Page 367: ...mbly Refer to ENGINE Air filter case Refer to AIR FILTER CASE in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Sidestand 1 2 Oil level switch connector 1 Disconnect 3 Oil level switch 1 Refer to REMOVING INSTALLING THE OIL PAN 4 Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 7 Oil delivery pipe 1 8 Oil pipe 1 OIL PAN AND OIL PUMP ...

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

Page 369: ...ling the oil pump Remove the parts in the order listed 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump shaft 1 8 Oil pump housing 1 For assembly reverse the disassembly procedure OIL PAN AND OIL PUMP ...

Page 370: ... Check oil pump shaft 1 oil pump housing 2 oil pump housing cover 3 Cracks damage wear Replace the defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clearance b Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 09 0 15 mm 0 0035 0 0059 in Outer rotor to oil pump ho...

Page 371: ...OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil EAS00375 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor oil pump shaft with the recommended...

Page 372: ...oil pump turns smoothly T R 12 Nm 1 2 m kg 8 7 ft lb LT EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer cover must point towards the front of the engine T R 10 Nm 1 0 m kg 7 2 ft lb LT EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket oil pan 1 oil level switch 2 engine oil drain bolt New T R 12 Nm 1 2 m kg 8 7 ft lb T R 10 Nm 1 0 m kg 7...

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

Page 374: ...AN AND OIL PUMP 1 Left middle gear cover 1 2 Left middle gear cover gasket 1 3 Dowel pin 2 4 Right middle gear cover 1 5 Bearing 1 6 Middle driven shaft end cover 1 7 Oil seal 1 8 Middle driven pinion gear nut 1 Loosen 9 Middle driven shaft assembly 1 Refer to REMOVING THE MIDDLE GEAR and INSTALLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 10 Middle driven shaft shim 2 MIDDLE GEAR ...

Page 375: ...T ASSEMBLY 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 Refer to REMOVING THE MIDDLE GEAR and INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 18 Bearing 1 19 Middle drive shaft shim 1 20 Bearing 1 For installation reverse the removal procedure MIDDLE GEAR ...

Page 376: ... Remove the parts in the order listed 1 Spring retainer 2 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVE SHAFT ASSEMBLY 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly reverse the disassembly procedure MIDDLE GEAR ...

Page 377: ... the order listed 1 Middle driven pinion gear nut 1 2 Middle driven shaft 1 3 Middle driven pinion gear 1 4 Bearing retainer 1 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 Bearing 1 6 Middle driven shaft bearing housing 1 For assembly reverse the disassembly procedure MIDDLE GEAR ...

Page 378: ...le holding the middle drive shaft 2 3 Straighten the lock washer tab 4 Loosen middle drive shaft nut 1 NOTE While holding the middle drive shaft 2 5 Straighten the punched point of the middle drive shaft bearing retainer 6 Loosen bearing retainer 1 with the middle drive shaft retainer wrench 2 Middle drive shaft retainer wrench YM 04057 MIDDLE GEAR ...

Page 379: ...ring compressor push plate YM 33286 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Straighten the punched point of the bearing retainer 2 Loosen bearing retainer 1 with the bearing retainer wrench 2 Bearing retainer wrench YM 04140 EAS00438 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Check damper cam surface Scratches wear Replace the damper cam 2 Check spring Cracks damage Replace MIDDLE GEAR ...

Page 380: ...l seal Damage Replace the defective part s EAS00440 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install spring retainers 1 NOTE While compressing the spring with the spring compressor push plate 2 install the spring retainers Spring compressor push plate YM 33286 EAS00442 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten bearing retainer 1 with the bearing retainer wrench 2 Bearing retainer w...

Page 381: ...IVE SHAFT ASSEMBLY 1 Install middle drive shaft shim bearing bearing retainer 1 with the middle drive shaft retainer wrench 2 NOTE Lock the threads on the bearing retainer by staking them with a center punch Middle drive shaft retainer wrench YM 04057 T R 110 Nm 11 0 m kg 80 ft lb 2 Install middle drive pinion gear lock washer middle drive pinion gear nut 1 New T R 110 Nm 11 0 m kg 80 ft lb MIDDLE...

Page 382: ...middle driven shaft assembly 1 middle driven shaft shims 2 middle driven shaft bearing housing bolts NOTE Finger tighten the middle driven shaft housing bolts 2 Tighten middle driven shaft nut 1 NOTE While holding the middle drive shaft 2 Lock the threads on the middle driven shaft nut by staking them with a center punch T R 110 Nm 11 0 m kg 80 ft lb MIDDLE GEAR ...

Page 383: ... lb EAS00449 MEASURING THE MIDDLE GEAR BACKLASH 1 Measure middle gear backlash Out of specification Refer to ADJUST ING THE MIDDLE GEAR BACKLASH a Install the gear lash measurement tool 1 as shown b Make sure the dial gauge plunger contacts the measuring point a on the middle gear backlash band as shown a 38 mm 1 50 in c Hold the middle drive shaft 2 Middle gear backlash 0 10 0 20 mm 0 004 0 008 i...

Page 384: ...BACKLASH 1 Loosen middle driven shaft bearing housing bolts 2 Remove shim s 3 Tighten middle driven shaft bearing housing bolts CAUTION Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too little middle gear backlash and damage the middle gears If the bolts are overtight ened loosen them until the crankcase to middle driven shaft bearing housing clear ance is with...

Page 385: ...ing housing should be approximately 2 mm 0 08 in when mea sured with a thickness gauge 1 4 Hold the middle drive shaft 1 5 Turn middle driven shaft NOTE While carefully tightening the middle driven shaft bearing housing bolts in stages and in a crisscross pattern turn the middle driven shaft back and forth until the dial gauge reads 0 10 0 20 mm 0 004 0 008 in 6 Measure crankcase to middle driven ...

Page 386: ...here fore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm 0 016 in shim Shims are supplied in the following thick nesses Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle driven pinion gear shim Thickness mm 0 10 0 15 0 30 0 40 0 50 0 60 8 Loosen middle driven shaft bearing housing bolts 9 Install shim s 10 Tighten middle driven shaft bearing housing bolts 1...

Page 387: ...hat has had its respective thickness calculated from infor mation marked on the crankcase and the end of the middle drive gear 1 Middle drive gear shim thickness A 2 Middle drive gear shim thickness B b To find middle drive shaft shim thickness A use the following formula a 65 00 b bearing thickness constant c a numeral on the upper crankcase near the main bearing selection numbers and which is ad...

Page 388: ... gear which is added to the nominal size 34 e Measured value f a numeral on the upper crankcase near the main bearing selection numbers and which is added to the nominal size 88 Example If the middle driven pinion gear is marked 03 d is 33 97 i e 34 00 0 03 33 97 e is 54 49 If the upper crankcase is marked 95 f is 87 95 i e 87 00 0 95 87 95 B 33 97 54 49 87 95 0 51 Round off to the hundredths digi...

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

Page 390: ...r listed Engine Refer to ENGINE Cylinder head Refer to CYLINDER HEAD Generator rotor Refer to GENERATOR AND STARTER CLUTCH Pickup coil rotor Refer to PICKUP COIL ROTOR Stopper lever Refer to SHIFT SHAFT Oil pump Refer to OIL PAN AND OIL PUMP Middle drive shaft Refer to MIDDLE GEAR 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 CRANKCASE ...

Page 391: ... 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Collar 1 6 Spacer 1 7 Neutral switch 1 8 Speed sensor 1 9 Lower crankcase 1 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE 10 Dowel pin 3 For installation reverse the removal procedure CRANKCASE ...

Page 392: ...rt Q ty Remarks Removing the oil baffle plates and bearings Remove the parts in the order listed Connecting rod assemblies Refer to CONNECTING RODS AND PISTONS Crankshaft crankshaft journal bearings Refer to CRANKCASE Transmission Refer to TRANSMISSION 1 Oil baffle plate 1 2 Oil delivery pipe 1 3 Plate 1 4 Oil baffle plate 1 5 Bearing 1 CRANKCASE ...

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

Page 394: ... crankcase indicate the crankcase tightening sequence 2 Place the engine upside down 3 Remove lower crankcase CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly M9 115 mm bolts 1 0 M8 65 mm bolts A M8 50 mm bolts B M6 80 mm...

Page 395: ...and crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace CRANKCASE ...

Page 396: ...d camshaft sprockets as a set oil pump drive chain 2 Damage stiffness Replace the oil pump drive chain oil pump drive sprocket and oil pump shaft as a set 2 Check oil pump drive sprocket Cracks damage wear Replace the oil pump drive sprocket and the oil pump drive chain as a set EAS00413 ASSEMBLING THE CRANKCASE 1 Lubricate crankshaft journal bearings with the recommended lubricant Recommended lub...

Page 397: ...in 2 3 mm 0 08 0 12 in of the crankshaft journal bear ings 3 Install dowel pins Quick Gasket ACC 11001 05 01 4 Set the shift drum assembly and transmis sion gears in the neutral position 5 Install lower crankcase 1 onto the upper crankcase 2 CAUTION Before tightening the crankcase bolts make sure the transmission gears shift cor rectly when the shift drum assembly is turned by hand CRANKCASE ...

Page 398: ...5 mm bolts U New 7 Tighten crankcase bolts 1 0 NOTE Do not reuse crankcase bolts 1 0 The tightening procedure of crankcase bolts 1 0 is angle controlled therefore tighten the bolts using the following procedure a Tighten the bolts in the tightening sequence cast on the crankcase b Loosen and retighten the crankcase bolts in the proper tightening sequence as shown T R Crankcase bolt 1 0 1st 20 Nm 2...

Page 399: ...dure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagonal bolt note that the angle from one corner to another is 60 T R Crankcase bolt 1 0 Final Specified angle 120 8 Tighten crankcase bolts A U NOTE Tighten the bolts in the tightening sequence cast on the crankcase T R Bolt A B 24 Nm 2 4...

Page 400: ...er listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 Refer to REMOVING THE CONNECT ING RODS AND PISTONS and INSTALLING THE CONNECTING RODS AND PISTONS 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal procedure CONNECTING RODS AND PISTONS...

Page 401: ...lace 2 Remove piston pin clips 1 piston pin 2 piston 3 connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with...

Page 402: ...ings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the mea surements b If out of specification replace the cylinder and the piston and piston rings as a set Cylinder bore C 79 00 79 01 mm 3 1102 3 1106 in Taper limit T ...

Page 403: ...Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 020 0 045 mm 0 0008 0 0018 in Limit 0 012 mm 0 0005 in EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring gr...

Page 404: ... the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 35 0 45 mm 0 014 0 018 in Limit 0 70 mm 0 028 in 2nd ring 0 75 0 85 mm 0 030 0 033 in Limit 1 20 mm 0 047 in Oil ring 0 2 0 6 mm 0 008 0 024 in EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins 1 Check piston pin Blue discoloration grooves Replace the pisto...

Page 405: ...ecification Replace the piston Piston pin bore diameter in the piston 19 004 19 015 mm 0 7482 0 7486 in Limit 19 045 mm 0 7498 in 4 Calculate piston pin to piston clearance Out of specification Replace the piston pin Piston pin to piston clearance Piston pin bore diameter in the piston b Piston pin outside diameter a Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 0...

Page 406: ...earing into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed...

Page 407: ...arings 2 Select big end bearings P1 P4 NOTE The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 1 respectively then the bearing size for P1 is Bearing size of P1 P...

Page 408: ...Install piston 1 connecting rod 2 piston pin 3 piston pin clip 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod left when the arrow mark b on the piston is pointing up Refer to the illustra tion Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 New 3 Offset piston ring end gaps a Top ring b Lower oil ring ra...

Page 409: ...bricant Recommended lubricant Engine oil 7 Install big end bearings connecting rod assembly 1 into the cylinder and onto the crankshaft pin connecting rod cap onto the crankshaft pin NOTE Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings wit...

Page 410: ...s WARNING Replace the connecting rod bolts and nuts with new ones Clean the connecting rod bolts and nuts NOTE The tightening procedure of the connecting rod nuts is angle controlled therefore tighten the nuts using the following procedure a Tighten the connecting rod nuts to the spec ified torque b Tighten the connecting rod nuts further to reach the specified angle 120 T R Connecting rod nut 1st...

Page 411: ...ghten it Replace the nut with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified angle Tighten the nut until it is at the specified angle NOTE When using a hexagonal nut note that the angle from one corner to another is 60 CONNECTING RODS AND PISTONS ...

Page 412: ...rts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 Refer to REMOVING INSTALLING THE CRANKSHAFT 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal procedure CRANKSHAFT ...

Page 413: ... EAS00396 CHECKING THE CRANKSHAFT 1 Measure crankshaft runout Out of specification Replace the crank shaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Cra...

Page 414: ...e crankshaft jour nal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 2 on each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves NOTE Align the projections a of the crankshaft journal lower bearings with the n...

Page 415: ...ers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is Bearing size of J1 J1 crankcase J1 cranksh...

Page 416: ...ngs into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in its original place 2 Lubricate crankshaft pins connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil CRANKSHAFT ...

Page 417: ...hift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Drive axle assembly 1 Refer to INSTALLING THE TRANSMIS SION 2 Bearing 1 3 Washer 1 4 Shift drum retainer 1 5 Long shift fork guide bar 1 6 Shift fork L 1 7 Shift fork R 1 8 Short shift fork guide bar 1 9 Spring 4 TRANSMISSION ...

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

Page 419: ...he main axle assem bly Remove the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 0 Collar 1 TRANSMISSION ...

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

Page 421: ...arks Disassembling the drive axle assembly Remove the parts in the order listed 1 Middle drive gear 1 2 Bearing 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 washer 1 7 5th wheel gear 1 8 Circlip 2 9 Toothed washer 2 0 3rd wheel gear 1 TRANSMISSION ...

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

Page 423: ...e clutch side NOTE Remove the main axle assembly with the slide hammer bolt 1 and weight Slide hammer bolt YU 01083 1 Weight J 6125 7 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork TRANSMISSION ...

Page 424: ...ork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum assembly shift drum segment 1 Damage wear Replace the shift drum assembly shift drum bearing 2 Damage pitting Replace the shift drum assembly EAS00425 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specificati...

Page 425: ...ration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips Bends damage looseness Replace TRANSMI...

Page 426: ...esponding hole in the upper crankcase The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Make sure the drive axle bearing circlip 1 is inserted into the grooves a in the upper crankcase The drive axle bearing pin 2 must face towards the rear of the crankcase T R 12 Nm 1 2 m kg 8 7 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 2 Check ...

Page 427: ...ncer Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Balancer lever 1 Refer to INSTALLING THE FRONT BALANCER 2 Balancer shaft 1 3 Washer 2 4 Bearing 2 5 Balancer gear 1 6 Absorber 4 7 Balancer weight 1 For installation reverse the removal procedure BALANCERS ...

Page 428: ...ies Refer to FUEL INJECTION SYSTEM in chapter 7 Clutch cover Refer to CLUTCH 1 Balancer cover 1 2 Balancer cover gasket 1 3 Balancer lever 1 Refer to INSTALLING THE REAR BAL ANCER 4 Balancer shaft 1 5 Washer 2 6 Bearing 2 7 Balancer gear 1 8 Absorber 4 9 Balancer weight 1 For installation reverse the removal procedure BALANCERS ...

Page 429: ...an bearings 2 Damage wear Replace absorbers Damage wear Replace INSTALLING THE FRONT BALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the balancer weight with the mark b in the balancer gear 2 Align T mark on the pickup coil rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres ...

Page 430: ...nstalling the balancer shaft 4 Install balancer lever 1 balancer lever bolt 2 NOTE Temporarily tighten the balancer lever bolt LT 5 Tighten balancer shaft 1 NOTE Tighten the balancer shaft to the specified torque by turning it counterclockwise and then turn it one scale back on the balancer lever scale T R 0 4 Nm 0 04 m kg 0 29 ft lb 6 Tighten balancer lever bolt 1 balancer shaft pinch bolt 2 NOTE...

Page 431: ...BALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the balancer weight with the mark b in the balancer gear 2 Align T mark on the pickup coil rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pickup coil rotor with the crankcase mating sur...

Page 432: ...iven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the primary driven gear point d Make sure that the slot e is facing in the direction indicated in the illustration when installing the balancer shaft 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 Install balancer lever 1 balancer lever bolt 2 NOTE Temporarily tighten the balancer lever bolt LT BALANCERS ...

Page 433: ...bolt 1 balancer shaft pinch bolt 2 NOTE Make sure that the balancer shaft does not rotate T R 14 Nm 1 4 m kg 10 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 7 Start the engine and check that there is no abnormal noise coming from the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale Clockwise Decrease gear lash C...

Page 434: ...er to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator cap 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir cap cover 1 5 Coolant reservoir cap 1 6 Coolant reservoir 1 7 Water pump breather hose 1 ...

Page 435: ...11 Conduit hose 1 12 Radiator inlet hose 1 Disconnect 13 Plunger control unit hose 2 1 Disconnect 14 Oil cooler outlet hose 1 Disconnect 15 Horn connector 4 Disconnect 16 Radiator fan motor coupler 1 Disconnect 17 Radiator 1 18 Horn bracket left and right 2 19 Radiator fan 1 For installation reverse the removal procedure 1 2 3 4 5 6 ...

Page 436: ...ssure Below the specified pressure Replace the radiator cap a Install the radiator pressure tester 1 and radiator pressure tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 93 3 122 7 kPa ...

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

Page 438: ...ed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Radiator assembly Refer to RADIATOR 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal procedure ...

Page 439: ...rfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thin ner 2 Install O ring oil cooler NOTE Make sure the O ring is positioned properly 3 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 New ...

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

Page 441: ... chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Air cut off valve assembly hoses Refer to AIR INDUCTION SYSTEM in chapter 7 1 Plunger control unit hose 1 1 Disconnect 2 Thermostat assembly inlet pipe 1 3 Coolant temperature sensor 1 4 Thermostat assembly breather hose 1 Disconnect 5 Radiator inlet hose 1 Disconnect 6 Thermostat assembly 1 For installation reverse the removal pr...

Page 442: ...Q ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed 1 Thermostat housing cover 1 Refer to ASSEMBLING THE THERMO STAT ASSEMBLY 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly procedure ...

Page 443: ... water observe the ther mostat and thermometer s indicated tem perature 1 Thermostat 2 Thermometer 3 Water 4 Container È Fully closed É Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or over cooling Temperature Opening mm 2 Check thermostat housing cover thermostat housing Cracks damage Replace 3 Check thermostat housin...

Page 444: ...HERMOSTAT ASSEMBLY 1 Lubricate O ring thermostat assembly and thermo stat assembly inlet pipe 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 Recommended lubricant LLC 3 Check cooling system Leaks Repair or replace any faulty part 4 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refe...

Page 445: ...rder listed NOTE It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Right side cowling Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 ...

Page 446: ...b Part Q ty Remarks 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump 1 Refer to INSTALLING THE WATER PUMP For installation reverse the removal procedure ...

Page 447: ... the parts in the order listed 1 Water pump housing cover 1 Refer to ASSEMBLING THE WATER PUMP 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 0 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 448: ...l from the inside of the water pump housing 2 3 Remove oil seal 1 bearing 2 NOTE Tap out the bearing and oil seal from the out side of the water pump housing EAS00473 CHECKING THE WATER PUMP 1 Check water pump housing cover water pump housing impeller rubber damper rubber damper holder water pump seals oil seal Cracks damage wear Replace 2 Check bearing Rough movement Replace 3 Check water pump ou...

Page 449: ... CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools Before installing the water pump seal apply Quick Gasket 2 to the water pump housing 3 È Push down Water pump seal installer YM 33221 4 40 and 50 mm bearing driver YM 04058 5 Quick Gasket ACC 11001 05 01 New New 3 Install rubber damper 1 rubber damper holder 2 NOTE Befor...

Page 450: ...1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in 5 Install impeller 1 circlip NOTE After installation check that the impeller shaft rotates smoothly New 6 Install O ring NOTE Lubricate the O ring with a thin coat of lithium soap base grease New 7 Install water pump housing water pump housing cover WARNING Always use a new copper washer T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 451: ... New T R 12 Nm 1 2 m kg 8 7 ft lb 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 3 Check cooling system Leaks Repair or replace the faulty part 4 Measure radiator cap opening pressure Below the specified pressure Re...

Page 452: ...n hose 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A O2 sensor B Catalytic converter C Crankshaft position sensor D Coolant temperature sensor E Spark plug F Cylinder identifica tion sensor G Pressure regulator H Battery I ECU J Atmosphericpressure sensor K Fuel injection system relay L Engine trouble warn ing light M Lean angle cut off switch N Air cut off valve ...

Page 453: ... Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L Y B L L W Y B L M L Y B L BLACK H L B L P W R W P W B L L BLACK I L P B L P B L L BLACK J Y G B L R W Y G B L Br R R W Br Br R GRAY W U V N GRAY Q R L L B L B L B R L L B D GRAY P R L G B G B G B R...

Page 454: ...e fuel injection stop function is active the warning light blinks while the start switch is being pressed to start the engine If a malfunction in the system is detected by the self diagnostic function this mode provides an appropriate substitute characteristic operation and alerts the rider of the detected malfunction by illuminating a warning light After the engine has been stopped digital number...

Page 455: ...light illuminates 1 4 seconds each time the main switch is turned ON The ECU performs a self diagnosis during this time and turns OFF the light thereafter 2 Warning control when unable to start engine This control is effected when any one of the conditions listed below is present and the starter switch is turned ON a Battery voltage below the specified value defective fuel injection system relay e...

Page 456: ...by observing the self diagnostic fault code number that appears on the multi function meter and cross referencing it on the fault code number table When used in conjunction with the troubleshooting details and by checking the possible items one by one you will be able to identify the cause of the problem in order to carry out an accurate repair work Warning of the occurrence of a malfunction appea...

Page 457: ...uel ratio feed back compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Able Able 14 Faulty intake air pressure sensor pipe system a hose is detached causing the constant application of atmospheric pressure to the sensor or the hose is clogged Able Able 33 Open circuit detected in the pri mary wire of the ignition coil 1 4 Able Able 15 Throttle position s...

Page 458: ...xisted up to that point Able Able 12 Crankshaft position sen sor Stops the engine by stopping the injection and ignition Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system Fixes the intake air pressure to 760 mm Hg 29 92 in Hg Able Able 15 16 Throttle position sensor open or short circuit stuck Fixes the throttle position sensor to fully open Able Able 19 Sidestand sw...

Page 459: ...elect the applicable sensor or actuator from the diagnostic code table If a diagnostic code is available proceed with the operation procedure given below in order to verify the operating conditions of the applicable sensor or actuator Operation procedure make sure to turn OFF the main switch upon completing the operation prep aration Setting the ECU in the diagnosis mode 1 While keeping the SELECT...

Page 460: ...ng the operation of the displayed diagnostic code Verifying various sensors The data representing the operating con ditions of the sensors appears on the trip LCD throttle position sensor angle cool ant temperature atmospheric pressure etc Verifying the operation of actuators Start the operation by turning the stop switch ON injectors relay ignition coil AIS etc If the stop switch is ON turn it OF...

Page 461: ...reinstating the ECU Verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera tion that is applicable to the malfunctioning item Refer to the troubleshooting details Erase the fault code from memory Perform the operation for diagnostic code 62 ...

Page 462: ...ke air pressure sensor Malfunction in ECU 03 Or a stuck throttle position sensor is detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective sensor stuck throttle position sensor 01 15 Throttle position sensor open or short circuit detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective throttle position sensor ...

Page 463: ... in ECU Malfunction in other areas of the fuel system 33 Open circuit is detected in the primary wire of the ignition coil 1 4 Open or short circuit in wiring harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition cutoff circuit system 30 34 Open circuit is detected in the primary wire of the ignition coil 2 3 Open or short circuit in wiring harness Malfunct...

Page 464: ...on of the vehicle pulses that are gen erated when the tire is spun 0 999 resets to 0 after 999 OK if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off switch values Upright 0 4 1 4 V Overturned 3 8 4 2 V 09 Fuel system voltage battery voltage Displays the fuel system voltage battery voltage Engine stop switch is on 0 18 7 V Normally approximately 12 0 V 2...

Page 465: ...tor 4 Take the same actions as No 36 on injector 4 If the engine stop switch is ON turn it OFF once and then turn it back ON Same as above 48 AI system solenoid After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON it actuates the AI system solenoid five times every second and illuminates the engine trouble warning light If the engine stop switch is ON turn...

Page 466: ...e shooting through the self diagnostic function Refer to Troubleshooting details Light does not turn ON NG Inspect and repair the wiring harness OK Only the engine trouble warning light does not turn ON All indicator lights do not turn ON Inspect and repair blown light bulb or wiring harness Inspect and repair the power supply circuit Start the engine OK NG Normal Light turns ON only when the star...

Page 467: ...king condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Code No 12 Symptom No normal signals are received from the crankshaft position sensor Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Inst...

Page 468: ...einstated by turn ing the main switch ON Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White Pink White Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition ...

Page 469: ...ite Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue Defective intake air pressure sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 3 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow B...

Page 470: ... 0 V Power supply wire open circuit 0 V Check for open circuit and replace the throttle position sensor Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow Blue Blue Installed state of throttle position sensor Check the installed area...

Page 471: ...2 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow Blue Blue 1 Installed state of throttle position sensor Check the installed area for looseness or pinching Check that it is installed in the specified position Refer to FUEL INJECT...

Page 472: ...he main switch ON Defective coolant temperature sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Green White Green White Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking co...

Page 473: ...sure sensor coupler Main wiring harness ECU coupler Code No 24 Symptom No normal signal is received from the O2 sensor Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective O2 sensor Replace if defective Reinstated by starting the engine warming it up until the coolant tem perature is 60 C 140 F or more and then runnin...

Page 474: ...if defective Reinstated by starting the engine warming it up until the coolant tem perature is 60 C 140 F or more and then running it between 2 000 3 000 r min until the engine trouble indicator turns off Clogged injector Replace if defective Refer to CHECKING THE INJECTOR Open circuit or ground short in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring ...

Page 475: ...n or short circuit Main wiring harness Black Blue White Gray Green Blue The fuel pressure is too high Compare the fuel pressure at idle and with throttle open About the same Normal Too high Inspect the pressure reg ulator Inspect the pressure reg ulator hose for pinching or kinking Inspect the fuel return hose for pinching or kink ing Inspect the throttle posi tion sensor Other Malfunction in the ...

Page 476: ...and secondary coils for continuity Replace if defective Refer to IGNITION SYSTEM in chapter 8 Reinstated by starting the engine and operating it at idle Open or short circuit in lead wire Repair or replace if there is an open or short circuit Main wiring harness Gray Red Gray Red Red Black Red Black Connected state of connector Inspect the coupler for any pins that may have pulled out Check the lo...

Page 477: ...a Replace if defective Refer to TRANSMISSION in chapter 5 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Main wiring harness Sky blue Sky blue 2 Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Neutral switch coupl...

Page 478: ...unction is detected in the ECU the fault code number might not appear on the meter Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Replace the ECU Reinstated by turn ing the main switch ON ...

Page 479: ...agnosis mode Using the results of the diagnosis mode inspection as reference estimate the cause of the mal function and carry out the inspection and repair of the affected area Symptom The engine trouble warning light does not illuminate when the start switch is pressed Probable mal function area Open or short circuit in start switch Open or short circuit in wiring harness Open circuit in warning ...

Page 480: ...he headlight relay 1 Check the operation of the headlight Classify the malfunctions Malfunction related to the relay Malfunction related to the wiring harness Malfunction in the headlight itself Relay does not operate as checked by sound or tester Check the headlight relay 2 Refer to LIGHTING SYSTEM in chapter 8 Defective replace Inspect the wiring harness and the couplers for continuity Defective...

Page 481: ...t fan does not operate Inspect the fan Refer to COOLING SYSTEM in chapter 8 Defective replace Check the continuity at the contact point of the radiator fan motor relay Refer to COOLING SYSTEM in chapter 8 Defective replace Inspect the wiring harness and couplers for continuity Defective repair or replace Normal according to the diagnosis mode Inspect the coolant temperature sensor by executing dia...

Page 482: ...hod 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode and in case the area of the malfunction has been narrowed down in the inspection method 1 given on the left Inspect ECU coupler Inspect the wiring harness and couplers for continuity Defective repair or replace Inspect meter coupler Inspect the wiring harness and coupl...

Page 483: ...tem relay Open circuit in wiring harness Disconnected battery Defective crankshaft position sensor Defective sidestand switch Tripped lean angle cut off switch Open circuit in ignition coil primary line ECU memory check error Inspection method 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode and in case the area of the m...

Page 484: ...bber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 O2 sensor coupler 1 Disconnect 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness 2 coupler 2 Disconnect 4 Throttle stop screw 1 5 Throttle body joint clamp screw 8 6 Canister purge hose 1 Disconnect 7 Throttle b...

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

Page 486: ...isconnect 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor 1 Disconnect 4 Cylinder 1 injector coupler 1 Disconnect 5 Cylinder 2 injector coupler 1 Disconnect 6 Cylinder 3 injector coupler 1 Disconnect 7 Cylinder 4 injector coupler 1 Disconnect 8 Subwire harness 2 1 9 Negative pressure hose 1 Disconnect 10 Fuel injection pipe 1 11 Pressure regulator 1 ...

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

Page 488: ...ODY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of passages with compressed air CHECKING THE PRESSURE REGULATOR 1 Check pressure regulator Damage Replace FUEL INJECTION SYSTEM ...

Page 489: ...ulator at the joint c Connect the mity vac set 2 onto the nega tive pressure hose from the pressure regu lator d Connect the pressure gauge 3 and adapter 4 onto the fuel injector pipe e Install the fuel tank Refer to SEATS AND FUEL TANK in chap ter 3 f Start the engine g Measure the fuel pressure Mity vac YB 35956 Pressure gauge YU 03153 Fuel pressure adapter YM 03176 Fuel pressure 250 kPa 2 5 kg ...

Page 490: ...e vacuum pressure as described below NOTE The vacuum pressure should not exceed 100 kPa 1 mm Hg 0 039 in Hg Faulty Replace the pressure regulator Increase the vacuum pressure Fuel pressure is decreased Decrease the vacuum pressure Fuel pressure is increased FUEL INJECTION SYSTEM ...

Page 491: ...d exhaust gases is approximately 600 1 112 F to 700 C 1 292 F EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant tem perature is below the specified...

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

Page 493: ...ing the air cut off valve assembly and hoses Remove the parts in the order listed Rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 1 Air cut off valve assembly 1 2 Hose 1 3 3 Hose 2 2 4 Pipe 1 1 5 Hose 3 1 6 Pipe 2 1 7 Hose 4 1 8 Hose 5 1 9 Resonator hose 1 10 Pipe 3 1 For installation reverse the removal procedure ...

Page 494: ...es Remove the parts in the order listed Air cut off valve assembly hoses Thermostat assembly Refer to THERMOSTAT in chapter 6 Spark plug caps 1 Reed valve cover 1 1 2 Reed valve cover 2 3 1 3 Reed valve cover 4 1 4 Reed valve assembly 4 5 Plate 4 For installation reverse the removal procedure ...

Page 495: ...UCTION SYSTEM 1 Check hoses Loose connection Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed fibre reed stopper reed valve seat Cracks damage Replace the reed valve assembly 3 Check air cut off valve Cracks damage Replace ...

Page 496: ...ats fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 1 Clamp 2 2 Canister charge hose 1 Disconnect 3 Rollover valve 1 4 Canister to rollover valve hose 1 Disconnect 5 Canister purge hose 1 Disconnect 6 Canister bracket 1 7 Canister 1 For installation reverse the removal procedure ...

Page 497: ...hield drive unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake switch 6 Clutch switch 7 Fuse box 8 Radiator fan motor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil level switch C Rear brake switch D Horn E Ignition coil F Main fuse 1 2 3 4 5 6 7 8 ...

Page 498: ...re sensor 4 Atmospheric pressure sensor 5 Lean angle cut off switch 6 ECU 7 Starting circuit cut off relay 8 Speed sensor 9 Cylinder identification sensor 0 O2 sensor A Crankshaft position sensor B Headlight relay 1 C Headlight relay 2 D Fuel injection system relay E Turn signal relay F Radiator fan motor relay ...

Page 499: ...e When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of elect...

Page 500: ...NTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch R W L W B R B R W B W B R B R W Y Br L W BLACK L Y B Y B Y L Y BLACK BLACK B B BROWN Sb Sb B B BLUE Dg Ch Dg Ch Br W Br W ON OFF RED R Br L B L Y OFF R ON Br L B L Y R Y L B P B Dg Ch Br W L Y Sb B Y Lg B P R YG B Lg B Sb UP DOWN DgBr W Ch 1 2 3 4 6 7 5 8 0 A 9 B C D E ...

Page 501: ...h 4 Dimmer switch 5 Horn switch 6 Windshield position switch 7 Turn signal switch 8 Front brake light switch 9 Engine stop switch 0 Start switch A Rear brake light switch B Neutral switch C Sidestand switch D Hazard switch E Fuse CHECKING THE SWITCHES ...

Page 502: ...d B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs D and E are used for meter and in...

Page 503: ...f the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal 1 and the negative tester...

Page 504: ...ster No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester YU 0311...

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

Page 506: ... spark Dynamic spark tester YM 34487 Pocket tester YU 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the batt...

Page 507: ...nition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20 C 68 F Is the spark plug cap OK Replace the spark plug cap 6 Ignition coil resistance The following p...

Page 508: ...wn Tester positive probe gray 1 Tester negative probe black 2 Measure the crankshaft position sensor resistance Crankshaft position sensor resis tance 420 8 569 3 Ω at 20 C 68 F between gray and black Is the crankshaft position sensor OK Replace the crank shaft position sensor 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main s...

Page 509: ...t cut off relay for continuity Tester positive probe blue green 1 Tester negative probe blue yellow 2 Continu ity Tester positive probe blue yellow 1 Tester negative probe blue green 2 No conti nuity Lg L G L Y Sb B Y L W R B L W 2 1 NOTE When you switch the positive and negative tester probes the readings in the above chart will be reversed Are the tester readings correct Replace the starting cir...

Page 510: ...CK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L Y B L L W Y B ...

Page 511: ... the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND I...

Page 512: ... 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replac...

Page 513: ...ay from the wire harness Connect the pocket tester Ω 1 to the starting circuit cut off relay terminals as shown Measure the starting circuit cut off relay for continuity as follows Lg L G L Y Sb B Y B R B L W Tester positive probe sky blue 1 Tester negative probe light green 2 Continu ity Tester positive probe sky blue 1 Tester negative probe black yellow 3 Tester positive probe sky blue 1 Tester ...

Page 514: ...2 Tester positive probe red 3 Tester negative probe black 4 Does the starter relay have continuity between red and black Replace the starter relay R B R L W R W 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch 8 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine s...

Page 515: ...OK Replace the clutch switch 12 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch 13 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects Replace the ECU Properly connect or repair the starting system s wiring ...

Page 516: ...rder Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Throttle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal procedure ...

Page 517: ...9 ft Ib Order Job Part Q ty Remarks Disassembly the starter motor Remove the parts in the order listed 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 0 Collar 1 STARTER MOTOR ...

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

Page 519: ...specification Replace the starter motor Commutator wear limit 23 5 mm 0 93 in 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator Mica undercut 1 5 mm 0 06 in ...

Page 520: ...YU 03112 Armature coil Commutator resistance 1 0 024 0 030 Ω at 20 C 68 F Insulation resistance 2 Above 1 MΩ at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush length wear limit 3 65 mm 0 14 in 6 Measure brush spring force Out of specification Replace the brush springs as a set Brush spring force 5 28 7 92 N 538 808 gf 18 98 28 50 oz 7 Check gear teeth Da...

Page 521: ...the brush seat with the tab b in the starter motor front cover 2 Install starter motor yoke 1 starter motor front cover 2 starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers 3 Install O rings bolts New T R 4 Nm 0 4 m kg 2 9 ft lb ...

Page 522: ...b B Y L W B R B Lg R B L G L Y B Y L Y ç z Br L Br L L Br G Br L R W R W R W Br L R W L W R B å Br L Br Br B Br B Br B B R B R B C R R B L Y L Y B R L R L R B R L Y R L A A Br G Br G A Br W Br W A G B G B Lg Sb Dg Ch Br W G B Br G Br W A L L R L A G Y R B B R B R G B R B G Y G Y B B L B B Lg Sb Lg Sb Lg Sb Br B v o n m Y Br R W w y R B L Y R L R R W G Y L Br B G B B Y G G L L B Y B G L R Y L B L B...

Page 523: ...for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead...

Page 524: ...ter positive probe white 1 Tester negative probe white 2 Tester positive probe white 1 Tester negative probe white 3 Measure the stator coil resistances Stator coil resistance 0 15 0 23 Ω at 20 C 68 F Is the stator coil OK Replace the stator assembly W W W Ω 1 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly conne...

Page 525: ... R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L Y B L L W Y B L M L Y ...

Page 526: ...light high beam indicator light taillight or meter light Pocket tester YU 03112 1 Main tail position light and headlight fuses Check the main tail position light and head light fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main tail position light and head light fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTE...

Page 527: ...he headlight relay 1 for continuity Battery positive terminal blue black 1 Battery negative terminal yellow black 2 Tester positive probe red yellow 3 Tester negative probe green blue 4 Does the headlight relay 1 have continuity between red yellow and green blue Replace the head light relay 1 R Y G L L B Y B 6 Headlight relay 2 Disconnect the headlight relay 2 from the wire harness Connect the poc...

Page 528: ... the lighting system s wiring properly con nected and without defects Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair the lighting system s wiring G L Y G B B G 1 Headlight bulb and socket Check the headlight bulb and socket for continuity Are the headlight bulb and socket OK Replace the head light bulb socket or both ...

Page 529: ...ust be repaired R W G W Y L Lg Y Ch Dg L R G B W Br R W 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Are the meter light bulb and socket OK Replace the meter light bulb socket or both 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Tester positive probe blue 1 Tester negative probe black white 2 Set the main switch to ON Meas...

Page 530: ...tage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Tester positive probe blue 1 Tester negative probe black 2 Set the main switch to ON Measure the voltage 12 V of blue 1 on the tail brake light coupler wire harness side Is the voltage within specification This circuit is OK wiring circuit from the main switch to the tail brake light cou pler is fault...

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

Page 532: ... B Y L Y R L B L Y G Y B k c Ch B Y G B B G P G B Y G B Y L R G W R L O B O B O B B L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L...

Page 533: ...ing light _ Left turn signal indicator light a Right turn signal indicator light c Oil level switch h Turn signal switch i Horn switch j Horn k Front turn signal light left l Front turn signal light right m Hazard switch s Tail brake light t Rear turn signal light left u Rear turn signal light right v Rear brake light switch w Turn signal relay x Windshield drive unit Hazard lighting fuse å Signal...

Page 534: ... lighting windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system hazard lighting windshield motor and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery term...

Page 535: ...t the horn terminal as shown Tester positive probe brown 1 Tester negative probe ground Set the main switch to ON Measure the voltage 12 V of black white at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired Br P 3 Horn Disconnect the black connector at the horn terminal Connect a jumper lead 1 to the h...

Page 536: ...s the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail light assembly coupler wire harness side as shown Tester positive probe yellow 1 Tester negative probe black 2 Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow 1 on the tail light assembly coupler wire harness side Is...

Page 537: ...S Is the turn signal switch OK Replace the left han dlebar switch 3 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Tester positive probe brown green 1 Tester negative probe ground Set the main switch to ON Measure the voltage 12 V on brown green 1 at the turn signal relay coupler Is the voltage within specification The wiring circuit from the main switch to the...

Page 538: ...n signal light Tester positive probe dark green 2 Tester negative probe ground Ch Dg Ch Dg Ch B Y L Dg Y L B 1 2 R W G W Y L Lg Y Ch Dg L R G B W Br R W Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V of the chocolate 1 or dark green 2 Is the voltage within specification This circuit is OK The wiring circuit from the turn signal switch to the front turn signal l...

Page 539: ... conti nuity NOTE When you switch the positive and negative tester probes the readings in the above chart will be reversed Are the tester readings correct Replace the starting circuit cut off relay Lg L G L Y Sb B Y L W R B L W 1 2 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Tester positive probe brown red 1 Tester negative probe light green 2 Set the main sw...

Page 540: ... pan Check the engine oil level switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine oil level switch OK Replace the engine oil level switch 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Tester positive probe white 1 Tester negative probe black white 2 Set the main switch to ON Measure the voltage 5 V of white 1 and black white 2 at the meter ass...

Page 541: ...e stopper Fuel sender resistance Full position of the float 19 21 Ω at 20 C 68 F Empty position of the float 139 141 Ω at 20 C 68 F Is the fuel sender OK Replace the fuel pump G W B B R L 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Tester positive probe green white 1 Tester negative probe black white 2 Set the main switch to ON Measure the voltage 12 V of gre...

Page 542: ... B L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L ...

Page 543: ...he coolant temperature gauge needle fails to move when the engine is warm Pocket tester YU 03112 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING ...

Page 544: ...ect the green white 1 and black blue 2 terminals with a jumper lead 3 shown Does the radiator fan motor turn The radiator fan motor is faulty and must be replaced G W B L 6 Radiator fan motor relay Disconnect the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown Check the radiator fan motor of continuity Batte...

Page 545: ...step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped...

Page 546: ...Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly con nected and without defects Replace the ECU Properly connect or repair the cooling system s wiring COOLING SYSTEM ...

Page 547: ...r W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L Y B L L W Y B L M L Y B L BLACK H L B L P W R W P W B L L BLACK I L P B L P B L L BLACK J Y G B L R W Y G B L Br R R W Br Br R GRAY W U V N GRAY Q R L L B L B L B R L L B D GRAY...

Page 548: ... EAS00749 YES NO EAS00750 YES NO If the fuel injection system fails to oper ate Pocket tester YU 03112 1 Main fuel injection system and ignition fuses Check the main fuel injection system and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main fuel injection system and igni tion fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKI...

Page 549: ... Replace the fuel injection system relay R R L R B L Y 6 Fuel pump resistance Disconnect the fuel pump coupler from the fuel pump Connect the pocket tester Ω 1 to the fuel pump coupler as shown Tester positive probe red blue 1 Tester negative probe black 2 Measure the fuel pump resistance Fuel pump resistance 0 2 3 0 Ω at 20 C 68 F Is the fuel pump OK Replace the fuel pump 7 Crankshaft position se...

Page 550: ...ntification sensor output voltage Cylinder identification sensor output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less Is the cylinder identification sensor OK Replace the cylinder identification sensor W L Y B L L W B B L 9 Speed sensor output voltage Measure the speed sensor output voltage Connect the pocket tester DC 20 V to the speed sensor coupler terminal as s...

Page 551: ...est step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dro...

Page 552: ... subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it T R Intake air temperature sensor 18 Nm 1 8 m kg 13 ft lb Is the intake air temperature sensor OK Replace the intake air temperature sensor Br W B L 12 Intake air pressure sensor output voltage Connect the pocket tester DC 20 V to the intake air intake air pressure sensor coupler ...

Page 553: ...atmo spheric pressure sensor L B L P 14 AI system solenoid Remove the AI system solenoid coupler from the wire harness Connect the pocket tester Ω 1 to the AI system solenoid terminal as shown Tester positive probe brown 1 Tester negative probe brown red 2 Measure the AI system solenoid resistance AI system solenoid resistance 19 25 Ω at 20 C 68 F Is the AI system solenoid OK Replace the AI sys te...

Page 554: ...soline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check fuel pump operation a Insert the plug 1 to fuel return hose end b Fill the fuel tank c Put the end of the fuel hose into an open container d Connect the battery 12 V to the fuel pump terminals as sh...

Page 555: ...position sensor d Connect the pocket tester Ω 1k to the throttle position sensor e While slowly opening the throttle check that the throttle position sensor resistance is within the specified range NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those specified Out of specification or th...

Page 556: ...he throttle position sensor b Remove the throttle position sensor from the throttle body c Connect the pocket tester Ω 1k to the throttle position sensor d Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor Tester positive probe blue terminal 1 Tester negative probe black blue terminal 2 Maximum throttle position sensor resistance 4 0...

Page 557: ...lightly from those specified Tester positive probe yellow terminal 3 Tester negative probe black blue terminal 2 Throttle position sensor resis tance 0 5 1 0 kΩ at 20 C 68 F yellow black blue 3 Adjust throttle position sensor angle a Disconnect the throttle position sensor cou pler from the throttle position sensor b Connect the pocket tester Ω 1k to the throttle position sensor c Measure the thro...

Page 558: ...olds Loosen the throttle posi tion sensor screws 4 Connect the pocket tester Ω 100 to the throttle position sensor e Adjust the throttle position sensor angle so the measured resistance is within the speci fied range After adjusting the throttle position sensor angle tighten the throttle position sensor screws Tester positive probe yellow terminal 3 Tester negative probe black blue terminal 2 Thro...

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

Page 560: ...k the main windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main windshield motor and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the ba...

Page 561: ...link until the windshield has stopped and is all the way down If the neutral indicator light does not turn off replace the windshield drive unit 5 Wiring Check the entire windshield drive system s wiring Refer to CIRCUIT DIAGRAM Is the windshield drive system s wiring properly connected and without defects Replace the wind shield drive unit Properly connect or repair the windshield drive system s ...

Page 562: ...or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft ...

Page 563: ... Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle bodies Im...

Page 564: ...IFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever...

Page 565: ...ged clutch release cylinder Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00855 OVERHEATING ENGINE Clogged coolant passages Heavy carbon buildup in cylinder head s and piston s Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Damaged or leaking radiator Faulty radi...

Page 566: ... EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Loose drain bolt Damaged drain bolt gasket MALFUNCTION Bent or damaged inner tube Bent or damaged outer...

Page 567: ...e EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main Burnt out headlight bulb Faulty headlight relay 1 Faulty headlight relay 2 Faulty ECU HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded...

Page 568: ...LINKS QUICKLY Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb HORN DOES NOT SOUND Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness ...

Page 569: ... level warning light Z Neutral indicator light Multi function meter Engine trouble warning light High beam indicator light _ Left turn signal indicator light a Right turn signal indicator light b Meter light c Oil level switch d Left handlebar switch e Clutch switch f Dimmer switch g Windshield position switch h Turn signal switch i Horn switch j Horn k Front turn signal light left l Front turn si...

Page 570: ......

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

Page 572: ... White Yellow White Black Yellow Black Yellow Green Yellow Blue Yellow Red D D D R LR B D ON OFF 1 RED RED BLACK BLACK BLACK BLACK BLACK GRAY 9 F 0 7 8 6 A A A A B C B B A A A A A A B B B B y BLACK BLACK BROWN BLUE BLUE BLACK B C A C A C A B j j UP DOWN ON OFF B D E E E D E E C WIRE HARNESS SUB WIRE HARNESS 1 B WIRE HARNESS SUB WIRE HARNESS 1 A WIRE HARNESS SUB WIRE HARNESS 1 z BROWN D WIRE HARNES...

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