Yamaha FZ09E, Service Manual

Page 1: ...SERVICE MANUAL LIT 11616 27 39 FZ09E FZ09EC 1RC 28197 10 ...

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Page 3: ...amaha Motor Corporation U S A First edition August 2013 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 PIN LIT 11616 27 39 ...

Page 4: ...h the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains ...

Page 5: ...sassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc This step explains removal and disassembly procedure only For installation and asse...

Page 6: ...erviceable with engine mounted 1 Gear oil m Filling fluid 1 Molybdenum disulfide oil B Lubricant 1 Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease g Engine speed Silicone grease iJj Electrical data J A Apply locking agent LOCTITE 1 m Engine oil Replace the part with a new one 1 Silicone fluid m ...

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

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Page 9: ... 4 YCC T Yamaha Chip Controlled Throttle 1 9 IMPORTANT INFORMATION 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS 1 11 GASKETS 01L SEALS AND 0 RINGS 1 11 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND 01L SEALS 1 11 CIRCLIPS 1 12 RUBBER PARTS 1 12 BASIC SERVICE INFORMATION 1 13 QUICK FASTENERS 1 13 ELECTRICAL SYSTEM 1 13 SPECIAL TOOLS 1 18 ...

Page 10: ...NTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EA 20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts IDENTIFICATION 1 1 ...

Page 11: ...nts for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection Fl system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at...

Page 12: ...at are input from the throttle position sensor accelerator position sensor coolant temperature sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor speed sensorand 0 2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of f...

Page 13: ... 1 4 FEATURES a self diagnosis device a brightness control mode TIP Be sure to turn the key to ON before using the SELECT and RESET buttons To switch the speedometer and multi function displays between kilometers and miles press the SELECT button for at least one second Tachometer 1 2 ri i _ II d jjJ111111 a Al 1 ssses s sss _ 1 Tachometer 2 Tachometer red zone The tachometer allows the rider to m...

Page 14: ...gments and fuel level warning indicator il flash eight times then go off for approximately 3 seconds Refer to CHECKING THE FUEL METER FU EL LEVEL WARNING LIGHT on page 8 105 Eco indicator 1 1 Eco indicator ECO 1 5 FEATURES This indicator comes on when the vehicle is be ing operated in an environmentally friendly fu el efficient manner The indicator goes off when the vehicle is stopped TIP Consider...

Page 15: ...F TRIP and starts counting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter odometer in stantaneous fuel consumption and average fuel consumption modes in the following order F TRIP km L U100 km or MPG AVE__ _ 1 6 FEATURES km L AVE__ _ U100 km or AVE__ _ MPG F Air__ F ODO TRIP 1 TRIP 2 F TRIP To reset a tripmeter select i...

Page 16: ...increments 11 the message HI flashes stop the vehicle then stop the engine and let the engine cool 1 7 FEATURES TIP When the coolant temperature is below 104 F LO will be displayed The coolant temperature varies with changes in the weather and engine load Air intake temperature display 1 11 1111i111l111 i1i 1 11J l11ii11 11 __ 1i1111 BQDfll 11111 s fi 6 16 1 tBBB I 1 Air intake temperature display...

Page 17: ... return to the original display D mode drive mode D mode is an electronically controlled engine performance system with three mode selections STD A and B Push the drive mode switch MODE to switch between modes 1 1 Drive mode switch MODE TIP Before using D mode make sure you under stand its operation along with the operation of 1 8 FEATURES the drive mode switch Mode STD Mode STD is suitable for va...

Page 18: ...espond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability A...

Page 19: ...c 0 II 3 2 4 5 6 7 8 9 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU engine control unit 5 Sensor input 6 Gear position sensor 7 Crankshaft position sensor 8 Speed sensor 9 Coolant temperature sensor 1 10 ...

Page 20: ...y from any source of fire REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality 1 11 IMPORTANT INFORMATION GASKETS OIL SEALS AND 0 RINGS 1 When overhauling the engine replace all gaskets seals and 0 rings All gasket surfac es oil seal lips...

Page 21: ...fore reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives 1 3c RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are sensitive to gasoline flammable oil gr...

Page 22: ...ewdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove a _ Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out BASIC SERVICE INFORMATION l 2 Install Quick fastener TIP To install the quick fastener insert the fastener into the part to be secured and tighten the screw a I I ELECTRICAL SYSTEM Electrical parts h...

Page 23: ...he electrical components _ ECA16770 NOTICE When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead If a tool or similar Item contacts the vehicle BASIC SERVICE INFORMATION while only the negative battery lead is con nected a spark could be generated which is extremely dangerous e NOTICE Turn the main switch to OFF before d...

Page 24: ...leads BASIC SERVICE INFORMATION a NOTICE For waterproof couplers never insert the tester probes directly into the coupler When performing any checks using a waterproof coupler use the specified test harness or a suitable commercially available test har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE When ...

Page 25: ...er Connector TIP When connecting a coupler or connector push both sections of the coupler or connector to gether until they are connected securely BASIC SERVICE INFORMATION Make sure all connections are tight 4 Check Continuity with the pocket tester Pocket tester 90890 03112 Analog pocket tester YU 03112 C TIP If there is no continuity clean the terminals When checking the wire harness perform st...

Page 26: ...lues shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown I Intake air temperature sensor re sistance 5 4o 6 60 kn at o C 32 F 290 390 n at 80 c 176 F I II M BASIC SERVICE INFORMATION 1 17 ...

Page 27: ... to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Ring nut wrench 90890 01 268 Spanner wrench YU 01268 Piston pin puller set 90890 01304 Piston pin puller YU 01304 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A Radiator cap tester adapte...

Page 28: ...0890 01423 Damping rod holder YM 01423 Oil filter wrench 90890 01426 YU 38411 Rod holder 90890 01434 Damper rod holder double ended YM 01434 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 11 90890 01436 YM A8703 1 19 Illustration 000 SPECIAL TOOLS Reference pages 5 32 3 18 4 61 4 52 4 53 3 23 4 51 4 56 4 57 4 55 4 56 4 57 ...

Page 29: ...driver 36 46 mm YM 01442 Pivot shaft wrench adapter 90890 01476 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Drive chain cut rivet tool 90890 01550 YM 01550 90890 01437 YM A8703 1 20 Illustration 000 0 SPECIAL TOOLS I Reference pages 4 55 4 56 4 57 4 51 4 56 4 57 4 54 4 55 5 7 5 8 5 7 5 7 5 8 4 71 4 73 ...

Page 30: ...6 Pocket tester 90890 031 12 Analog pocket tester YU 03112 C Oil pressure adapter H 90890 03139 Pressure gauge 90890 03153 YU 03153 Carburetor angle driver 2 90890 031 73 90890 03094 YU 44456 1 21 SPECIAL TOOLS Illustration M16XP1 5 Reference pages 5 32 5 33 5 1 3 8 1 16 1 17 8 91 8 92 8 93 8 97 8 98 8 99 8 100 8 101 8 1 03 8 104 8 105 8 106 8 107 8 108 8 1 10 8 111 3 24 3 24 7 11 3 9 ...

Page 31: ...890 03207 YU 03207 Test harness lean angle sensor 6P 90890 03209 YU 03209 Fuel injector pressure adapter 90890 03210 YU 03210 Yamaha diagnostic tool 90890 03215 Valve spring compressor 90890 04019 YM 04019 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 1 22 Illustration SPECIAL TOOLS Reference pages 5 37 8 102 8 1 03 8 109 7 11 3 5 5 20 5 43 8 105 8...

Page 32: ...ttachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Valve guide remover 04 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide installer 04 5 90890 04117 Valve guide installer 4 5 mm YM 04117 Valve guide reamer 04 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 Illustration 90890 04086 156 YM 91042 04 5 4 Smm 1 23 SPECIAL TOOLS Reference pages 6 11 5 42 5 45 3 6 5 23 5 ...

Page 33: ...l 90890 04161 YM 04161 Camshaft wrench 90890 04162 YM 04162 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 Yamaha bond No 1215 Three bond No 1215 90890 85505 1 24 Illustration SPECIAL TOOLS Reference pages 5 1 5 68 5 1 2 5 14 8 100 5 34 5 57 ...

Page 34: ...SPECIAL TOOLS 1 25 ...

Page 35: ...RQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 1 4 CHASSIS TIGHTENING TORQUES 2 1 8 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 41 ...

Page 36: ...ase Ground clearance Minimum turning radius Weight Curb weight Maximum load 2 1 GENERAL SPECIFICATIONS FZ09E 1RC4 FZ09EC 1RC5 2075 mm 81 7 in 815 mm 32 1 in 1135 mm 44 7 in 815 mm 32 1 in 1440 mm 56 7 in 135 mm 5 31 in 3037 mm 119 6 in FZ09E 188 kg 414 lb FZ09EC 189 kg 417 lb FZ09E 177 kg 390 lb FZ09EC 176 kg 388 lb ...

Page 37: ... up to the maxi mum level mark 2 2 ENGINE SPECIFICATIONS Liquid cooled 4 stroke DOHC 847 cm3 lnline 3 cylinder 78 0 x 59 1 mm 3 07 x 2 33 in 11 50 1 1530 kPa 680 r min 15 3 kgf cm2 680 r min 217 6 psi 680 r min 1330 171OkPa 680 r min 13 3 17 1 kgl cm2 680 r min 189 2 243 2 psi 680 r min Electric starter Premium unleaded gasoline Gasohol E10 ac ceptable 14 0 L 3 70 US gal 3 08 Imp gal 2 8 L 0 74 US...

Page 38: ...de inside diameter intake Limit 2 3 ENGINE SPECIFICATIONS 93 3 122 7 kPa 0 93 1 23 kgl cm2 13 5 17 8 psi 340 0 mm 13 39 in 222 6 mm 8 76 in 22 0 mm 0 87 in Single suction centrifugal pump 47 47 x 29 22 1 318 0 15 mm 0 006 in NGK CPR9EA9 O Hl 9 mm 0 031 0 035 in 19 09 20 69 cm3 1 16 1 26 cu in 0 10 mm 0 0039 in Chain drive right 24 500 24 521 mm 0 9646 0 9654 in 24 459 24 472 mm 0 9630 0 9635 in 0 ...

Page 39: ...ance Limit 2nd ring Ring type 2 4 ENGINE SPECIFICATIONS 4 500 4 512 mm 0 1772 0 1776 in 4 542 mm 0 1788 in 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 0032 in 0 025 0 052 mm 0 0010 0 0020 in 0 100 mm 0 0039 in 0 010 mm 0 0004 in 39 31 mm 1 55 in 37 34 mm 1 47 in 37 78 mm 1 49 in 35 89 mm 1 41 in 32 90 mm 1 30 in 32 00 mm 1 26 in 32 15 N mm 3 28 kgf mm 183 58 lbf in 43 93 N mm 4 48 kgf mm 250 84 lbf...

Page 40: ...3rd 4th 5th 6th Main axle runout limit Drive axle runout limit 2 5 ENGINE SPECIFICATIONS 0 30 0 45 mm 0 0118 0 01 n in 0 80 mm 0 0315 in 0 020 0 055 mm 0 0008 0 0022 in 0 115 mm 0 0045 in 0 10 0 40 mm 0 0039 0 0157 in 0 027 0 051 mm 0 0011 0 0020 in 1 Blue 2 Black 3 Brown 4 Green 0 030 mm 0 0012 in 0 160 0 262 mm 0 0063 0 0103 in 0 014 0 038 mm 0 0006 0 0015 in O White 1 Blue 2 Black 3 Brown 4 Gre...

Page 41: ...ngine idling speed COo o Al system OFF exhaust pipe Intake vacuum Water temperature Oil temperature Fuel line pressure at idling Throttle grip free play 2 6 ENGINE SPECIFICATIONS Shift drum and guide bar 0 050 mm 0 0020 in 5 76 5 89 mm 0 2 268 0 2319 in Oil coated paper element Electrical 3 3A 297500 1 110 3 FZ09E EACW41 61 1 FZ09EC EACW41 B3 1 FZ09E 1RC1 00 FZ09EC 1RC5 10 1 20 2 80 kn 0 63 0 73 v...

Page 42: ...Type Operation Front disc brake Disc outside diameter x thickness Brake disc thickness limit 2 7 CHASSIS SPECIFICATIONS Diamond 2S OO 0 103 mm 4 1 in Cast wheel 17M C x MT3 SO Aluminum 137 0 mm S 39 in 1 0 mm 0 04 in O S mm 0 02 in Cast wheel 17M C x MTS SO Aluminum 130 0 mm S 12 in 1 0 mm 0 04 in O S mm 0 02 in Tubeless 120 70 ZR17M C S8W BRIDGESTONE S20F DUNLOP D214F 1 0 mm 0 04 in Tubeless 180 ...

Page 43: ... Spring rate Kl Spring stroke K1 Inner tube outer diameter Inner tube bending limit Recommended oil Quantity left Quantity right Level left Level right Spring preload adjusting positions Minimum Standard Maximum 2 8 CHASSIS SPECIFICATIONS 0 10 mm 0 0039 in 4 5 mm 0 18 in 0 5 mm 0 02 in 4 5 mm 0 18 in 0 5 mm 0 02 in 15 00 mm 0 59 in 30 23 mm 1 19 in 27 00 mm 1 06 in DOT4 Single disc brake Right foo...

Page 44: ...of links Drive chain slack 15 link length limit Shift pedal Installed shift rod length 2 9 CHASSIS SPECIFICATIONS 3 tum s out 1 3 4 turn s out Adjusting screw fully turned in With the adjusting screw fully turned in Swingarm link suspension Coil spring gas oil damper 60 0 mm 2 36 in 191 4 mm 7 54 in 179 8 mm 7 08 in 99 96 N mm 10 19 kgf mm 570 77 lbf in O Q 60 0 mm 0 00 2 36 in 980 kPa 9 8 kgf cm2...

Page 45: ... type Bulb voltage wattage x quantity Headlight Auxiliary light Tail brake light Front tum signaVposition light Rear turn signal light License plate light Meter lighting Indicator light Neutral indicator light Tum signal indicator light Oil level warning light High beam indicator light Coolant temperature warning light Engine trouble warning light ELECTRICAL SPECIFICATIONS 12 v TCI 5 0 1200 r min ...

Page 46: ... output voltage Intake air temperature sensor resistance Coolant temperature sensor resistance Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Parking lighting fuse Fuel injection system fuse Auxiliary fuse Backup fuse Electronic throttle valve fuse Spare fuse Spare fuse Spare fuse ELECTRICAL SPECIFICATIONS Constant mesh 0 70 kW 0 0050 0 0150 n 12 0 mm 0 47 in ...

Page 47: ...ELECTRICAL SPECIFICATIONS Spare fuse 2 0A 2 12 ...

Page 48: ...t en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature 0 A Distance between flats B Outside thread diameter General tightening A nut B bolt torques Nm m kgf ft lbf 10mm 6mm 6 0 6 4 3 12 mm 8mm 15 1 5...

Page 49: ...ecting rod bolt MB 6 See TIP I Generator rotor bolt M12 1 7S Nm 7 S m kgf S4 ft lbf I Timing chain tensioner bolt M6 2 1ONm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 7 Nm 0 7 m kgf S 1 ft lbf Oil pump bolt M6 4 1ONm 1 0 m kgf 7 2 ft lbf Oil pump driven sprocket bolt M6 1 1S Nm 1 S m kgf 11 ft lbf Oil pump cover screw MS 1 3 B Nm 0 3B m kgf 2 B ft lbf Water pump housing cover bolt M...

Page 50: ... accessing bolt MB 1 15 Nm 1 5 m kgf 11 ft lbf Drive sprocket cover bolt M6 3 B Nm O B m kgf 5 B ft lbf Generator cover bolt M6 B 12 Nm 1 2 m kgf B 7 ft lbf Generator cover bolt M6 2 12 Nm 1 2 m kgf B 7 ft lbf G Main gallery bolt M16 2 B Nm O B m kgf 5 B ft lbf Sub gallery plug M14 1 6 Nm 0 6 m kgf 4 3 ft lbf Clutch cable holder bolt M6 2 12 Nm 1 2 m kgf B 7 ft lbf G Timing chain cover bolt M6 B 1...

Page 51: ...ap M20 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Starter motor assembly bolt M5 2 5 Nm 0 5m kgf 3 6 ft lbf Starter motor insulator nut M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Throttle position sensor screw M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Accelerator position sensor bolt M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Clutch cable and adjust nut MS 1 7 Nm 0 7 m kgf 5 1 ft lbf Throttle cable and throttle body M6 2 4 5 Nm 0 45 m k...

Page 52: ...olts to 20 Nm 2 0 m kgf 14 ft lbf 2 Tighten the bolts further to reach the specified angle 175 185 TIP Crankcase bolt main journal 1 Lubricate the bolt threads and both sides of the washers with engine oil 2 Tighten the bolts to 25 Nm 2 5 m kgf 18 fl lbf in the order shown in the illustration 3 Fully loosen the bolt 1 and then tighten the bolt again to the specified torque shown below Repeat this ...

Page 53: ...ly M10 1 44 Nm 4 4 m kgf 32 ft lbf nut upper Rear shock absorber assembly M10 1 44 Nm 4 4 m kgf 32 ft lbf nut lower Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Swingarm bracket left and M6 4 7 Nm 0 7 m kgf 5 1 ft lbf lt swingarm bolt Swingarm bracket right and M6 4 7 Nm 0 7 m kgf 5 1 ft lbf lt swingarm bolt Chain puller adjusting locknut MS...

Page 54: ...m kgf 5 1 fl lbf Fuel tank bracket and fuel tank M6 2 7 Nm 0 7 m kgf 5 1 fl lbf bracket assembly bolt Fuel tank cap bolt MS 4 6 Nm 0 6 m kgf 4 3 fl lbf Air scoop stay and frame bolt M6 4 7 Nm 0 7 m kgf 5 1 fl lbf Fuel tank bracket assembly and M6 4 7 Nm 0 7 m kgf 5 1 fl lbf rear frame bolt Seat bracket and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 fl lbf Seat lock assembly and battery M6 2 7 Nm 0 7 ...

Page 55: ...ht side Headlight unit side cover bolt M6 4 O S Nm O OS m kgf 0 59 ft lbf upper side Front brake lever pivot bolt M6 1 1 0 Nm 0 10 m kgf 0 72 ft lbl t Front brake lever pivot nut M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Front brake light switch screw M4 1 1 2 Nm 0 12 m kgf 0 S7 ft lbf Brake pedal nut MS 1 30 Nm 3 0 m kgf 22 ft lb Rear brake master cylinder lock MS 1 1S Nm 1 S m kgf 13 ft lbf nut Rear brake ...

Page 56: ...lt M6 2 1 5 Nm 0 15 m kgf 1 1 ft lb Canister bolt for California only M6 2 7 Nm 0 7 m kgf 5 1 fl lbf Canister bracket bolt for Califor M6 2 7 Nm 0 7 m kgf 5 1 fl lbf nia only TIP Lower ring nut 1 Tighten the ring nut to approximately 52 Nm 5 2 m kgf 38 ft lb with a torque wrench then loosen the lower ring nut completely 2 Tighten the lower ring nut to 18 Nm 1 8 m kgf 13 ft lbf 2 21 ...

Page 57: ...ce intake and exhaust Valve stems and stem ends intake and exhaust 1 Crankshaft big ends Piston surfaces Piston pins Connecting rod bolts 1 Crankshaft journals Balancer shaft journals Generator rotor assembly Water pump impeller shaft Oil pump rotors inner and outer oa Oil pump assembly Oil cooler bolts Oil filter cartridge union bolt oaor Oil nozzle 0 rings Main gallery bolt 0 ring or 1 Oil coole...

Page 58: ...maha bond No 1215 Stator coil assembly lead grommet Three bond No 1215 CHASSIS Lubrication point Lubricant Steering bearings seal lip and ball race lip o a Tube guide throttle grip inner surface and throttle cables o a Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts and clutch cable end o a Swingarm collar outer surface oil seal lip o a Pi...

Page 59: ...al moving parts o a Shift shaft joint rod moving parts o a Front wheel oil seal left and right o a Rear wheel oil seal o a Rear wheel drive hub oil seal o a Rear wheel drive hub mating surface o a Brake caliper piston seal I Master cylinder inside 1 Brake caliper piston dust seal Caliper bracket slide pins and or retaining bolts 2 24 ...

Page 60: ...MS EA 203510 LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART 17 IL L 16 b I 11 I l l l 14 JI I 15 13 13 13 yin illfn IZI 12 L I R 11 l_ Jl IZI r 6 2 v uL L l 1 4 3 5 10 iooooon 7 I I H u DDDDL _J DC 10 10 10 51 9 2 25 ...

Page 61: ...ump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Drive axle 8 Main axle 9 Shitt fork upper 1O Mission shower 11 Crankshaft 12 AC magneto 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft 2 26 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS EASo20 10 LUBRICATION DIAGRAMS 4 3 2 1 2 27 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Oil level switch 2 Oil filter cartridge union bolt 3 Oil filter cartridge 4 Crankshaft 2 28 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 0 2 29 ...

Page 65: ...BRICATION SYSTEM CHART AND DIAGRAMS 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket 2 30 ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 0 0 3 6 2 1 2 31 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Main gallery bolt 2 32 ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 1 0 0 0 0 0 2 3 4 5 I I f J 6 2 33 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Balancer shaft 2 Crankshaft 3 Main axle 4 Shift fork guide bar shift forl C side 5 Drive axle 6 Sub gallery bolt 7 Shift fork 2 34 ...

Page 70: ...1 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 3 2 35 0 0 0 7 8 ...

Page 71: ...Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil passage to the timing chain tensioner 5 Oil passage to the cylinder head 6 Oil passage to the clutch chamber 7 Oil return passage from the cylinder head 8 Crankshaft 9 Main gallery 2 36 ...

Page 72: ... COOLING SYSTEM DIAGRAMS 3 2 1 1 I COOLING SYSTEM DIAGRAMS 2 37 I j____ _ 1 7 i ...

Page 73: ...COOLING SYSTEM DIAGRAMS 1 Water pump 2 Thermostat 3 Radiator 2 38 ...

Page 74: ...COOLING SYSTEM DIAGRAMS 1 2 3 6 5 2 39 ...

Page 75: ...COOLING SYSTEM DIAGRAMS 1 Water jacket 2 Thermostat 3 Radiator 4 Water pump 5 Oil cooler 6 Coolant reservoir 2 40 ...

Page 76: ...CABLE ROUTING CABLE ROUTING Handlebar top view 2 41 ...

Page 77: ... the rubber cover silicone water or soapy water may be applied to the inside of the rubber cover B Detailed drawing of around the front brake master cylinder C Straight line parallel to the front brake master cyl inder reservoircap D 3 13 E Center of the metal fitting tor the front brake hose CABLE ROUTING 2 42 ...

Page 78: ...CABLE ROUTING Handlebar front view 5 H 1 3 u 2 43 ...

Page 79: ...Fasten the horn lead to the stay with the clamp so that the mating section faces downward H Align the horn lead and the brake hose with the brake hose protector and fasten them to the stay with the clamp I Fasten the brake hose and the horn lead with the headlight clamp J Clamp the wire harness and then fasten it to the stay Hook the either catch of the clamp onto the stay K Outtine drawing of aro...

Page 80: ...Radiator front side view and right side view p 2 2 45 CABLE ROUTING c 4 ...

Page 81: ...t the tip of the hose contacts the rib of the water jacket joint H Install the radiator inlet hose with its yellow paint mark facing downward I Point the hose clamp installation bolt upward J Install the radiator inlet hose up to the base of the bend in the radiator pipe K Install the radiator inlet hose with its white paint mark facing inward L Install the radiator hose up to the base of the bend...

Page 82: ...CABLE ROUTING Fuel tank left and bottom view 2 2 7 5 0 0 6 2 47 ...

Page 83: ...faces the rearward B Install the clip so that the end is on the paint mark Do not put it on the clip spool guard Point the end to the rear and store it inside to the fuel hose C Align the fuel pump positioning to the inner panel marking visual guide during installation D Insert the fuel tank breather hose up to the section where the fuel tank pipe increases in diameter Install it so that the yello...

Page 84: ...Canister for California only cg 6 5 Q p Q 4 s _ _ 2 49 CABLE ROUTING 4 ID c c 1 2 3 4 IQ E F 3 ...

Page 85: ...te paint mark on the hose upward F Install the hose up to the base of the bend in the hose lilting of canister G Route the fuel tank drain hose between the canis ter and the frame H Install the fuel tank breather hose to the rollover valve making sure that the fuel tank breatherhose contacts the rollover valve I To fuel tank J Point the end of the clip toward right Make sure not to install the cli...

Page 86: ...CABLE ROUTING Air filter case and throttle body top view and left side view c 1 2 51 ...

Page 87: ...the pipe of the cylinder head Install the breather hose on the white paint mark side to the engine Install the breather hose so that the white paint mark is in the rear of the vehicle and parallel to the cylinder head mating surfaces Install the clip so that the end is in the rear of the vehicle and parallel to the cylinder head mating surfaces C Install the ECU harness by storing it in the recess...

Page 88: ...CABLE ROUTING Air cut off valve left side view 2 8 2 53 ...

Page 89: ...of the hose con tacts the air filter case B Insert the protrusion on the radiator fan cover into the hole in the aircut off valve holder C Point the end of the clip for the air induction sys tem hose air cut off valve to reed valve cover 2 3 forward D Point the end of the clip for the air induction sys tem hose air filter case to air cut off valve to the teft E Point the end of the clip for the ai...

Page 90: ...CABLE ROUTING Frame and engine right side view D 1 l I J 7 b M 4 2 55 ...

Page 91: ...ute the rear brake light switch lead outside brake Huid reservoir hose J It does not matter whether the 0 2 sensor lead or the rear brake light switch lead is on top bottom in the area shown in the illustration K Connect the radiator fan motorcoupler L Insert the rubber bracket for the headlight relay so that it touches the rib of the air scoop stay on the vehicle M Install the fuse box to the rub...

Page 92: ...CABLE ROUTING Frame and en I g ne left side view 2 3 4 6 Q s Q 11 4 13 2 57 ...

Page 93: ...and breather hose with the bending edge of the hose and then install them Face the clamp opening to the rearward H 30 50 mm 1 18 1 97 in I Point the tips of fuel tank drain hose and breather hose as shown in the illustration J Place the stator coil assembly lead so that bare copper wires do not protrude from the boots K Route the intake air temperature sensor lead above the throttle cable in the l...

Page 94: ...CABLE ROUTING Frame top view 5 D 2 E 1 8 9 1 3 10 1 fill 3 _ 11 2 59 ...

Page 95: ... B Insert the clamp into the fuel rail hole C Fold back the injector lead 1 by the coupler and then fasten tt with tape D Connect the sub lead to the injector coupler 2 Fasten the injector coupler on the wire harness side with tape E For the air cut off valve lead ignition coil lead 3 and fuel injector lead 3 it does not matter which is routed above the others F Route the coolant temperature senso...

Page 96: ...CABLE ROUTING Frame top view 10 m 3 QJ 0 0 8 7 IRl 1 1 J 2 61 ...

Page 97: ...e wire harness side of the oil level switch lead to the battery box D Fasten the rear brake light switch lead on the wire harness with tape E Fasten the sidestand switch lead of the wire har ness to the battery box F Route the negative battery lead inside to the branch of the 02 sensor lead and the rear brake light switch lead and through between the wire harness and the frame For rear side of the...

Page 98: ...CABLE ROUTING Frame top view 4 5 6 Im 7 1 IE 13 1 E F III 2 63 ...

Page 99: ...ard relay in the battery box D Install the clamp into the hole in the battery box E Connect each rear turn signal coupler to the cou pier with the same color After connecting the license plate light connector store the turn signal light coupler left right furthest to the bottom of the vehicle After connecting the other couplers store them below the taiVbrake light lead F Route the tail brake light...

Page 100: ...CABLE ROUTING Front brake right side view and left side view I 2 5 2 2 65 ...

Page 101: ...uches the projection on the brake caliper Install brake hose from the master cylinder so that it aligned with the direction of the brake pipe to the right brake caliper E Install the brake pipe so that it contacts the projec tion on the brake caliper F Face the catch of the clamp backward and then close the clamp until three clicks or more are heard G Same for three clamps H Insert the clamp into ...

Page 102: ...CABLE ROUTING Rear brake 3 3 2 67 ...

Page 103: ...ion B Make sure to install the clamp all the way in the rear frame C Fasten the protector of the brake hose with the clamp Install the mating section on the top of the vehicle D Make sure to install the clamp all the way in the swingarm assembly E Install the brake pipe so that it aligned with the cut out in the caliper CABLE ROUTING 2 68 ...

Page 104: ...CABLE ROUTING 2 69 ...

Page 105: ...ADS 3 13 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 13 CHECKING THE FRONT BRAKE HOSES 3 14 CHECKING THE REAR BRAKE HOSE 3 14 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 1 5 CHECKING THE WHEEL BEARINGS 3 1 6 CHECKING THE SWINGARM OPERATION 3 1 6 LUBRICATING THE SWINGARM PIVOT 3 1 6 ADJUSTING THE DRIVE CHAIN SLACK 3 1 6 LUBRICATING THE DRIVE CHAIN 3 1 7 CHECKING AND ADJUSTING THE STEERING HEAD 3 1 8 LU...

Page 106: ...6 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 27 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 27 CHECKING AND LUBRICATING THE CABLES 3 28 CHECKING THE THROTTLE GRIP 3 28 CHECKING AND CHARGING THE BATTERY 3 29 CHECKING THE FUSES 3 29 REPLACING THE HEADLIGHT BULB 3 29 ADJUSTING THE HEADLIGHT BEAM 3 30 ...

Page 107: ...A 1AC1301 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS No ITEM ROUTINE 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi 1000 km 7000 km 13000 km 19000 km 25000 km 31000 km or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months Check fuel hoses forcracks or 1 Fuel line damage Replace it necessary Check condrtion 2 Spark plugs Adjust gap a...

Page 108: ...lace If necessary Check tread depth and tor damage 8 TIres Replace If necessary Check air pressure Correc1if necessary Check bearings for smooth 9 Wheel bearings operation Replace II necessary Check operation and for Swingarm pivot excessive play 0 bearings Moderately repack with lith um soap based grease Every 32000 mi 50000 km Check chain slack alignment and condition Every 500 mi 800 km and aft...

Page 109: ...place itnecessary Change coolant 6 Front and rear brake switches Check operation Apply Yamaha cable lubricant 7 Control cables or other suitable cable lubri cant thoroughly Check operation Check throttte grip free play 8 Throttle grip and adjust if necessary Lubricate cable and grip housing 29 Lights signals Check operation and switches Adjust headllgh1 beam TIP Air filter This model s air filter ...

Page 110: ...on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 3 4 PERIODIC MAINTENANCE 2 Remove Ignition coils Spark plugs NOTICE 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 3 Check Spark plug type Incorrect Change 4 Check Manu...

Page 111: ...er to CAMSHAFTS on page 5 9 3 Remove Timing mark accessing bolt 1 Crankshaft end cover 2 4 Measure Valve clearance Out of specification Adjust 3 5 PERIODIC MAINTENANCE Valve clearance cold Intake 0 11 0 20 mm 0 0043 0 0079 in Exhaust 0 26 0 30 mm 0 0102 0 0118 in TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the T...

Page 112: ...3 3 6 PERIODIC MAINTENANCE 1 Valve lapper 90890 04101 Valve lapping tool YM A8998 TIP Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place 1 3 EX IN 2 1 b Calculate the difference between the speci lied valve clearance and the measured...

Page 113: ...r and the valve pad in the correct place 3 7 PERIODIC MAINTENANCE The valve lifter must turn smoothly when rotat ed by hand g Install the exhaust and intake camshafts tim ing chain and camshaft caps Camshaft cap bolt 10 Nm 1 0 m kgf 7 2 ft lbf TIP Refer to CAMSHAFTS on page 5 9 Lubricate the camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshafts marks with the ...

Page 114: ...tle body synchronization 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 3 Remove Caps 1 3 8 PERIODIC MAINTENANCE 4 Install Vacuum gauge 1 5 Install Vacuum gauge 90890 03094 Vacuummate VU 44456 Air filter case Refer ...

Page 115: ... throttle bodies If the throttle body synchronization can not be adjusted using the bypass air screw clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg Carburetor angle driver 2 90890 03173 3 9 PERIODIC MAINTENANCE 2 Stop the engine and remove the measuring equipment 3 Install Caps 4 Install Air filter case Refer to...

Page 116: ...ilter case cover 2 Refer to GENERAL CHASSIS on page 4 1 PERIODIC MAINTENANCE 3 Check Air filter element 1 Air filter seal Damage Replace TIP Replace the air filter element every 37000 km 24000 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Air filter case cover ECU engine control unit EC A 14401 NOTICE Never...

Page 117: ...e specified clutch lever free play is ob 3 11 PERIODIC MAINTENANCE tained Direction a Clutch lever free play Is Increased Direction b Clutch lever free play is decreased c Tighten the locknut 1 Locknut 7 Nm 0 7 m kgf 5 1 ft lbf E ASIFOC1307 CHECKING THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check the brake system Refer to FRONT BRAKE on page 4 20 and REAR BRAKE on page...

Page 118: ...e pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever hold er Position 1 Distance a is the largest Position 5 Distance a is the smallest A WARNING After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in...

Page 119: ... will consid erably reduce braking performance NOTICE After adjusting the brake pedal position make sure there is no brake drag PERIODIC MAINTENANCE 2 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 27 EA 212 0 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicator groov...

Page 120: ...hen release the brake lever or brake pedal PERIODIC MAINTENANCE 1 Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose J Tighten the bleed screw to specification Brake caliper bleed screw 5 Nm 0 5 m kgf 3 6 ft lbf k Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid Refer to CHE...

Page 121: ...the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE PERIODIC MAINTENANCE Tire air pressure measured on cold v tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 k gflcm2 42 psi Loading condition FZ09E 90 ln kg 198 390 lb FZ09EC 90 176 kg 198 388 lb Front 250 kPa 2 50 kg...

Page 122: ...ion of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point PERIODIC MAINTENANCE E ASIFOC1308 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 10 and CHECKING THE REAR WHEEL on page 4 17 eAS1AC1309 CHECK...

Page 123: ...hain Is tightened Direction b Drive chain is loosened TIP To maintain the properwheel alignment adjust both sides evenly There should be no clearance between the ad justing block and adjusting bolt c Tighten the wheel axle nu1 to specification Wheel axle nut 150 Nm 15 m kgf 108 ft lbf d Tighten the locknuts to specification Locknut 16 Nm 1 6 m kgf 12 ft lbf EA 21440 LUBRICATING THE DRIVE CHAIN The...

Page 124: ...nd right a couple of times to check that it moves smoothly PERIODIC MAINTENANCE 5 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 Lower ring nut initial tightening torque 52 Nm 5 2 m kgf 38 ft lbf c Loosen the lower ring nut 6 completely then tighten it to specification EWA13 0 AwARNJ NG Do not overtighten the lower ring nut Lower ring nut final tightening torque 18 Nm 1 8 m kgf...

Page 125: ...t Lithium soap based grease LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal l Recommended lubricant Lithium soap based grease PERIODIC MAINTENANCE ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length 256 9 258...

Page 126: ...nt 4 Repair Refer to FRONT FORK on page 4 48 EA 1AC13 1 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs EWAl31 0n AwARNING Securely support the vehicle so that there Is PERIODIC MAINTENANCE no danger of it falling over Spring preload EWAIRC 303 A WARNING Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of...

Page 127: ... adjustment it would be advisable to check the number of turns of each damping force adjusting mechanism and to modify the specifications as necessary 3 21 PERIODIC MAINTENANCE E A 1AC1311 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface E WA13 20 A wARNING Securely support the vehicle so that there is no danger of it falling over 2 Check Rear shock absorber assembl...

Page 128: ...ction b Standard 1 1 2 turn s in direction b Maximum hard Adjusting screw fully turned In direction a With the adjusting screw fully turned in direction a TIP To obtain a precise adjustment it is advisable to check the actual total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match the spec ifications listed due to small differences in production ...

Page 129: ...g the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EA 201 l1 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off PERIODIC MAINTENANCE 2 Place a co...

Page 130: ...long with the 0 ring IH 11 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL PERIODIC MAINTENANCE LEVEL on page 3 22 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 2 Start the engine warm ...

Page 131: ...mum level mark a and minimum level PERIODIC MAINTENANCE mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE Adding water Instead of coolant lowers the antifreeze concentration of the coolant If water Is used Instead of coolant check and if necessary correct the antifreeze concen tration of the coolant Use only distilled water However if dis tilled water is no...

Page 132: ...turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 2 Remove Coolant reservoir bolts 1 PERIODIC MAINTENANCE Coolant reservoir cover 2 Coolant reservoir 3 Collars 4 3 Remove Coolant reservoir cap 1 4 Drain Coolant from the coolant reservoir 5 Rem...

Page 133: ...r is used instead of coolant check and if necessary correct the antifreeze concen tration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze PERIODIC MAINTENANCE 1O lnstall Radiator cap stopper Radiator cap Radiator ...

Page 134: ...k Throttle grip free play a Out of specification Adjust Throttle grip free play 3 0 5 0 mm 0 12 0 20 In The following procedure applies to all of the in ner and outer cables EWA 3VO AwARNING Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation R...

Page 135: ... Refer to CHECKING THE FUSES on page 8 93 EAW700 REPLACING THE HEADLIGHT BULB 1 Remove Headlight unit side cover bolts 1 TIP Lift up the headlight unit 2 and then remove it from the headlight stay 3 PERIODIC MAINTENANCE 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb cover 1 4 Unhook Headlight bulb holder 1 5 Remove Headlight bulb 2 A WARNING 3 29 Since the headlight bulb gets extremely h...

Page 136: ...ht unit 1 TIP lnstall the headlight unit as shown 1 11 lnstall Headlight unit side cover bolts EA 181 0 Headlight unit side cover bolt 7 Nm 0 7 m kgf 5 1 ft lbf ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically PERIODIC MAINTENANCE TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Tum the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam Is lowere...

Page 137: ...PERIODIC MAINTENANCE 3 31 ...

Page 138: ...PERIODIC MAINTENANCE 3 32 ...

Page 139: ...RONT BRAKE 4 20 INTRODUCTION 4 25 CHECKING THE FRONT BRAKE DISCS 4 25 REPLACING THE FRONT BRAKE PADS 4 26 REMOVING THE FRONT BRAKE CALIPERS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 29 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 30 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 3...

Page 140: ...TALLING THE STEERING HEAD 4 62 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 64 DISPOSING OF A REAR SHOCK ABSORBER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE CONNECTING ARM AND RELAY ARM 4 64 INSTALLING THE RELAY ARM 4 65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 SWINGARM 4 67 REMOVING THE SWINGARM 4...

Page 141: ...seat and battery 2 2 Nm 0 22 m kg 1 6 It lbf Order 1 2 3 4 5 6 4 o 5 Job Parts to remove Rider seat Battery band Negative battery lead Positive battery lead Battery Spacer GENERAL CHASSIS 1 Q ty Remarks 1 1 1 Disconnect 1 Disconnect 1 1 4 1 ...

Page 142: ... r Order Job Parts to remove Q ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 1 Rear side cover left 1 2 Rearside cover right 1 3 Seat bracket 1 4 Tail brake light coupler 1 Oisconnect 5 Tail brake light 1 6 License plate light connector 2 Oisconnect 7 Rear turn signal light coupler 2 Disconnect 8 Mudguard assembly 4 2 ...

Page 143: ...t unit side cover left Turn signal position light coupler left Headlight unit side cover right Turn signal position light coupler right Auxiliary light coupler Headlight coupler Headlight assembly Headlight unit cover Meter assembly Meter assembly coupler Meter braeket 4 3 GENERAL CHASSIS 1 7 Nm 0 7 m kgf 5 1 ft tbf Q ty Remarks 1 1 Disconnect 1 1 Disconnect 1 Disconnect 1 Disconnect 1 1 1 1 Disco...

Page 144: ... scoop and fuel tank cover 1 5 Nm 0 15 m kgf 1 1 ft lbl 5 j 1 1 5 Nm 0 15 m kgf 1 111 lbl Order Job Parts to remove Q ty Remarks Air scoop left 2 Air scoop right 1 3 Fuel tank cover 4 Fuel tank mole left 1 5 Fuel tank mole right 1 4 4 ...

Page 145: ...the projection c on the air scoop into the hole d b Install the air scoop bolt and quick fastener screws and then tighten the bolts to specifi cation Air scoop bolt 1 5 Nm 0 15 m kgf 1 1 ft lbf 4 5 GENERAL CHASSIS 2 Install Air scoop right 1 TTYTTTYYTTTYTTTYYTTTYTTTYTTTYYTT a Insert the projection a on the air scoop into the grommet b and insert the projection c on the air scoop into the hole d b ...

Page 146: ...1 a 2 Install Fuel tank mole right 1 YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY a Install the hole a in the fuel tank mole onto the projection b on the air scoop stay 1 a GENERAL CHASSIS 4 6 ...

Page 147: ...ver 4 Air filter element 5 Air filter case joint clamp screw 6 Air induction system hose 7 Cylinder head breather hose 8 Air filtercase 4 Q ty 1 2 1 1 3 1 1 1 4 7 GENERAL CHASSIS 1 1 6 Nm 0 16 m kgf 1 2 ft fbf 2 8 Nm 0 28 m kgf 2 0 ft lbf Remarks Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 1 Refer to FUEL TANK on page 7 1 Disconnect l oosen Disconnect Disconnect ...

Page 148: ...f i 65 Nm 6 5 m kgf 47 It lbf it 18 Nm 1 8 m kgf 13 It lbl 7 5 Order Job Parts to remove 1 Reflector 2 Front brake caliper 3 Wheel axle pinch bOlt 4 Wheel axle 5 Front wheel 6 Collar 7 Front brake disc 7 Q ty 2 2 1 1 1 2 2 4 8 FRONT WHEEL 2 i 35 Nm 3 5 m kgl 25 It lbl i 18 Nm 1 8 m kgf 13 It lbf 6 Remarks Loosen ...

Page 149: ...Disassembling the front wheel Order Job Parts to remove 1 Oil seal 2 Wheel bearing 3 Spacer Q ty 2 2 1 4 9 FRONT WHEEL 2 mm 1 Remarks ...

Page 150: ...YYYYYYYYYYY a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface 0 I c Remove the wheel bearings 3 with a gener al bearing puller FRONT WHEEL CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace EWA13 4 0 AwARNING Do no...

Page 151: ... a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals EAS21970 ADJUSTING THEFRONT WHEELSTATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front ...

Page 152: ...ned as shown x 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 FRONT WHEEL is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown x x x b If the front wheel does not remain stationary at all of the positions rebalance it INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS...

Page 153: ...ning the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly TIP Check that wheel axle end a is flush with front folk surface b and then tighten the wheel axle pinch bolt If end a is not flush with surface b align the ends manually or with a plastic ham mer b a 6 Install Front brake calipers Front brake caliper bolt 35 Nm 3 5 m kgf 25 ft lbf EWAll...

Page 154: ...6 Nm 1 6 m kgl 12 It lbl Order Job Parts to remove Q ty Remarks Rear brake caliper Refer to REAR BRAKE on page 4 32 1 Locknut 2 Loosen 2 Adjusting bolt 2 Loosen 3 Wheel axle nut 1 4 Washer 1 5 Wheel axle 1 6 Adjusting block left 1 7 Adjusting block right 1 8 Rear wheel 1 9 Brake caliper bracket 1 4 14 ...

Page 155: ...Nm 8 0 m kgf 58 ft lb I 2 11 10 4 Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Bracket 1 3 Rear wheel sprocket 1 4 Collar 1 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Collar 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 4 15 ...

Page 156: ...REAR WHEEL Disassembling the rear wheel 2 Order Job Parts to remove Q ty Remarks 1 Oil seal 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 4 16 ...

Page 157: ... wheel forward and remove the drive chain from the rear wheel sprocket REAR WHEEL DISASSEMBLING THE REAR WHEEL 1 Remove Oil seal Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 10 CHECKING THE REAR WHEEL 1 Check Wheel axle Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 1 0 2 Check Tire Rear wheel Damage wear Replace Reier to CHECKING THE TIRES on page 3 1 5 an...

Page 158: ...ket nut 80 Nm 8 0 m kgf 58 ft lbf TIP Tighten the rear wheel sprocket nuts in stages and in a crisscross pattern REAR WHEEL ASSEMBLING THE REAR WHEEL 1 Install Wheel bearings l IM Oil seal lllM Refer to ASSEMBLING THE FRONT WHEEL on page 4 11 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP Alter replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel sta...

Page 159: ...f the vehicle REAR WHEEL A Left side B Right side 5 Install Rear brake caliper Rear brake caliper bolts 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 16 Drive chain slack 5 0 15 0 mm 0 20 0 59 in 7 Tighten Wheel axle nut Rear brake caliper bolts Wheel axle nut 150 Nm 15 m kgf 108 ft lbf Rear brake caliper bolt front 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bolt ...

Page 160: ...e pad clip 2 Brake pad pin 3 Brake pad spring 4 Brake pad 5 Reflector 6 Front brake caliper 7 Bleed screw 4 20 FRONT BRAKE II 5 Nm 0 5 m kgl 3 6 It lbl Q ty 2 1 1 2 1 1 1 7 J___ __ 4 3 II 35 Nm 3 5 m kgl 2511 lbl Remarks The following procedure applies to both of the front brake calipers ...

Page 161: ...m holder Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead connector Front brake light switch Brake hose union bott Brake hose gasket Brake hose Front brake master cylinder holder Front brake master cylinder assembly FRONT BRAKE 10 Nm 1 0 m kgf 7 2 ft lbf 6 Nm 0 6 m kgf 4 3 ft lbf 5 1 2 Nm 0 12 m kgf 0 87 ft lbf Q ty 1 1 1 1 2 1 1 2 1 1 1 Remarks Refer to HANOLEBA...

Page 162: ...FRONT BRAKE Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder ktt 1 2 Brake master cylinder body 1 4 22 ...

Page 163: ...1 Brake hose union bolt 1 2 Brake hose gasket 1 3 Brake hose 2 4 Brake hose gasket 2 5 Reflector 1 6 Front brake caliper 1 4 23 FRONT BRAKE 35 Nm 3 5 m kgf 25 ft 0 lbf 5 6 Remarks The following procedure applies to both of the front brake calipers Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 13 ...

Page 164: ...rts to remove 1 Brake pad Clip 2 Brake pad pin 3 Brake pad spring 4 Brake pad 5 Brake caliper piston 6 Brake caliper piston dust seal 7 Brake caliper piston seal 8 Bleed screw mm 6 Q ty 2 1 1 2 4 4 4 4 24 FRONT BRAKE 3 6 5 mm Remarks The following procedure applies to both of the front brake calipers ...

Page 165: ...FRONT WHEEL on page 4 8 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Brake disc runout limit as mea sured on wheel 0 10 mm 0 0039 in a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebarto the left or right to ...

Page 166: ...per 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 2 Remove Brake pads 1 3 1 FRONT BRAKE 1 3 Measure Brake pad wear limit a Ou1 of specification Replace the brake pads as a set Brake pad lining thickness inner 4 5 mm 0 18 In Limit 0 5 mm 0 02 in Brake pad llnlng thickness outer 4 5 mm 0 18 in Limit 0 5 mm 0 02 In 1 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring...

Page 167: ...RAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully 7 Check 1 Wr rn Brake fluid level Below the minimum level mark a Add the spe...

Page 168: ...ery four years Brake fluid Every two years and whenever the brake is disassembled 1 Check Brake caliper pistons 1 Rust scratches wear 4 Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear 4 Replace the brake caliper assembly Brake caliper body 3 Cracks damage 4 Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction 4 Blow out with com...

Page 169: ...lbf Refer to REPLACING THE FRONT BRAKE PADS on page 4 26 4 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid E WA13000 Specified brake fluid DOT4 AwARNING 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...

Page 170: ...RONT BRAKE Obstruction t Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear t Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir diaphragm holder 2 Cracks damage t Replace Brake master cylinder reservoir diaphragm 3 Damage wear t Replace 4 Check Brake hoses Cracks damage wear t Replace ASSEMBLING THE FRONT BRAKE MASTER CYLINDER AwARN...

Page 171: ...RONT BRAKE with the specified amount of the specified brake fluid Specified brake fluid DOT4 AwARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake per...

Page 172: ... pad retaining bolt 3 Rear brake caliper 4 Brake pad 5 Brake pad shim 6 Brake pad insulator 7 Brake pad spring 8 Bleed screw REAR BRAKE II 5 Nm 0 5 m k f 3 6 ft lb 27 Nm 2 7 m kg 20 ft lb 3 22 Nm 2 2 m kgf 16 ft lbf 17 Nm 1 7 m kgf 12 ft bf c 2 5 Nm 0 25 m kgf 1 8 ft lb 5 Q ty Remarks 1 1 1 2 2 2 1 1 4 32 ...

Page 173: ...Drain Brake fluid Refer to BLEEDING THE HYORAULIC BRAKE SYSTEM on page 3 13 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 holder 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Rear brake light switch coupler 1 Disconnect 11 Right footr...

Page 174: ... 110 Nm 11 m kgf 80 ft 0 lbf t 55 Nm 5 5 m kgf 40 ft 0 lbf 23 Nm 2 3 m kgf 17 ft lbf Order Job Parts to remove Q ty Remarks 13 Brake pedal 14 Rear brake master cylinder assembly 1 15 Rear brake light switch 1 4 34 ...

Page 175: ...sembling the rear brake master cylinder 5 2 mm 2 mm 1 4 3 mm Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 2 Brake master cylinder kit 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 4 35 ...

Page 176: ...ear brake caliper 30 Nm 3 0 m kgf 22 ft lbf 4 22 Nm 2 2 m kgf 16 ft lbf 27 Nm 2 7 m kgf 20 ft lbf Order Job Parts to remove Q ty Remarks 1 Brake hose union bott 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 4 36 ...

Page 177: ...l 1 2 5 Nm 0 25 m k I 1 8 ft lbf 4 5 0 Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 4 37 ...

Page 178: ...ion Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 Brake disc runout limit as mea sured on wheel 0 15 mm 0 0059 in 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 5 Adjust REAR BRAKE Brake disc thickness limit ...

Page 179: ...n of the brake caliper piston REAR BRAKE 3 Lubricate Rear brake caliper bolts NOTICE Recommended lubricant Siiicone grease Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug s Check Rear brake caliper bolt front 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bolt rear 22 Nm 2 2 m kgf 16 ft lbf LOCTITE Brake pad ret...

Page 180: ...is ton REAR BRAKE b Remove the brake caliper piston dust seal and brake caliper piston seal CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Piston dust seal Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1 Check Brake caliper piston 1 Rust scratches ...

Page 181: ...1 temporarily Brake hose gaskets l tiWJ Brake hose 2 Brake hose union bolt 3 Brake hose union bolt 30 Nm 3 0 m kgf 22 fl lbf 4 41 REAR BRAKE A WARNING Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 41 NOTICE When Installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake cali...

Page 182: ... 13 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 13 REAR BRAKE REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gasket...

Page 183: ...uid DOT4 AwARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservo...

Page 184: ...e Q ty Remarks Meter bracket Refer to GENERAL CHASSIS on page 4 1 1 Rearview mirror 2 2 Front brake light switch connector 2 Disconnect 3 Front master cylinder holder 1 4 Front brake master cylinder assembly 1 5 Right handlebar switch 1 6 Throttle cable housing 2 7 Throttle cable 2 Disconnect 8 Grip end 2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handleb...

Page 185: ...erously weaken it HANDLEBAR INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface AwARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 ECAIRC1407 NOTICE Upper handlebar holder bolt 22 Nm 2 2 m kgf 16 fl lbf First tighten the bolts on the front side of the upper handlebar hol...

Page 186: ...er cylinder assembly Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4 30 7 Install Clutch lever holder 1 HANDLEBAR Clutch cable Clutch lever holder pinch bolt 11 Nm 1 1 m kgf 8 0 ft lbf TIP Align the center of slit on the clutch lever holder with the punch mark a on the handlebar 8 Install Handlebar grip 1 Grip end 2 Grip end 26 Nm 2 6 m kgf 19 ft lbf a Apply a thin coat of rubber adh...

Page 187: ...dlebar switch with the hole b in the handlebar 1O Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 28 11 Adjust Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Clutch lever free play Referto ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 Clutch lever free play 10 0 15 0 mm 0 39 Q 59 in 4 47 HANDLEBAR ...

Page 188: ...Parts to remove Front wheel 1 Front fender 2 Upper bracket pinch bolt 3 Cap bolt 4 Lower bracket pinch bolt 5 Front fork leg 4 48 Q ty 1 1 1 2 1 FRONT FORK 23 Nm 2 3 m kgf 17 ft 0 lbf r 3 l 5 Remarks The following procedure applies to both of the front fork legs Refer to FRONT WHEEL on page 4 8 Loosen Loosen Loosen ...

Page 189: ...Order Job Parts to remove Q ty Remarks 1 Cap bolt 1 2 0 ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Oust seal 1 8 Oil seal clip 1 9 Outer tube 1 10 Oil seal 1 11 Washer 1 12 Outer tube bushing 1 13 Inner tube bushing 1 14 Damper rod assembly boll 1 15 Copper washer 1 16 Damper rod assembly 1 17 Inner tube 1 4 49 ...

Page 190: ... d a m id 0 t 15 1 123 Nm 2 3 m kQf 17 ft lbf I Order Job Parts to remove Q ty Remarks 1 Cap bolt 1 2 O ring 3 Washer 4 Spacer 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 8 Oust seal 1 9 Oil seal clip 1 10 Outer tube 1 11 Oil seal 1 12 Washer 1 13 Outer lube bushing 1 14 Inner tube bushing 1 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 4 50 ...

Page 191: ...RNING Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 4 51 FRONT FORK Spacer 3 Locknut 4 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Press down on the spacer with the fork spring compressor 5 b...

Page 192: ...ght side is used for the rebound operation Pay atten tion not to mistake the right and left TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt 1 FRONT FORK Damper rod holder 90890 01423 Damping rod holder VM 01423 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage ...

Page 193: ...ith the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Oil seal Oil seal clip Dust seal FRONT FORK Copper washer 0 ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 NOTICE Allow the damper rod assembly to sllde slowly d...

Page 194: ...ithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation FRONT FORK 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Fork seal driver 90890 01442 Adjustable fork seal driver ...

Page 195: ... oil NOTICE Recommended oil Suspension oil 01 Quantity left 472 0 cm3 15 96 US oz 16 65 Imp oz Quantity right 458 0 cm3 15 48 US oz 16 15 Imp oz Be sure to use 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 ma terial to enter the front fork 12 After filling the front fork leg slo...

Page 196: ... facing up A FRONT FORK A 1 _ _ Ja _ A A V I c Install the locknut all the way onto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 Rod puller 90890 01437 Unive...

Page 197: ... smaller diameter a facing up A FRONT FORK A 1 _ _ Ja _ A l V I c Install the locknut all the way onto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 Rod pulle...

Page 198: ...ly tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with th...

Page 199: ...mp 5 Main switch coupler 6 Wire harness clamp 7 Horn lead connector 8 Horn 9 Front brake hose 10 Headlight stay 11 Horn bracket 0 0 4 59 STEERING HEAD 1 1 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf Q ty Remarks Refer to FUEL TANK on page 7 1 Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 1 Refer lo GENERAL CHASSIS on page 4 1 Refer to HANDLEBAR on page 4 4...

Page 200: ...wer bracket cap 13 Steering stem nut 14 Upper bracket 15 Lock washer 16 Upper ring nut 17 Rubber washer 18 Lower ring nut 19 Lower bracket 20 Bearing cover 21 Lower bearing dust seal 22 Upper bearing 23 Lower bearing 4 60 STEERING HEAD 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf 21 Q ty Remarks 1 1 1 1 1 1 1 1 1 1 1 1 ...

Page 201: ... haust flange nut wrench YU A9472 CHECKING THE STEERING HEAD 1 Wash Bearings Bearing races 2 Check Recommended cleaning solvent Kerosene Bearings 1 Bearing races 2 4 61 STEERING HEAD Damage pitting Replace the bearings and bearing races as a set 2 1 2 3 Replace Bearings tg J 2 SS 1 E j 2 Bearing races TTYTTTYYTTTYTTTYYTTTYTTTYTTTYYTT a Remove the bearing races from the steering head pipe 1 with a ...

Page 202: ...wer ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 18 4 2 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 48 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Steering stem nut 11ONm 11 m kgf...

Page 203: ...scoop Fuel tank cover Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm lower nuVbolt 1 1 2 Relay arm nuVcollar bolt 111 1 3 Rear shock absorber assembly upper nuVwasher bolt 1 1 1 4 Rear shock absorber assembly lower nuVwasher bolt 1 211 5 Rear shock absorber assembly 1 6 Connecting arm upper nuVbolt...

Page 204: ...n from its end as shown AwARNING Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 20 25 mm 0 79 0 98 in I Q REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface AwARNING Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Connec...

Page 205: ...the relay arm face the 1RC mark of the connecting arms outside 3 Relay arm d d b i 4 Connecting arm 5 Rear shock absorber assembly A Left side B Right side INSTALLING THE REAR SHOCK ABSORBER ASSEMBLV 1 Install Rear shock absorber assembly 5 Rear shock absorber assembly upper bolt Rear shock absorber assembly upper nut Relay arm bolt Relay arm nut Connecting arm lower bolt Connecting arm lower nut ...

Page 206: ...REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly upper nut 44 Nm 4 4 m kgf 32 ft lbf Relay arm nut 61 Nm 6 1 m kgf 44 ft lbf Connecting arm lower nut 55 Nm 5 5 m kgf 40 ft lbf 4 66 ...

Page 207: ... on page 4 32 Rear wheel Refer to REAR WHEEL on page 4 14 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Chain Refer to CHAIN DRIVE on page 4 70 Connecting arm lower nut 2 Connecting arm lower bolt 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Washer 1 6 Swingarm 1 7 Drive chain guard 1 8 Drive chain guide 1 9 Rear fender 1 10 Dust cover 4 11 Collar 3 12 Oil seal 4 13 Bearing 4 4 67 ...

Page 208: ... by moving the swingarm from side to side If the swingarm has side to side play check the spacer bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collar bearings and dust covers SWINGARM AA AAAA AAA AAAA AAA AA _ AAAA A 4 Remove Drive chain Refer to REMOV...

Page 209: ...epth e 1 5 2 5 mm 0 06 0 1Oin TIP When installing the oil seals to the swingarm face the character stamp of the oil seals outside SWINGARM e e fl A Left side B Right side 3 Install Swingarm Pivot shaft Pivot shaft nut 11ONm 11 m kgf 80 ft Ibf 4 Install Drive chain Refer to INSTALLING THE DRIVE CHAIN on page 4 73 Connecting arm lower bolt Connecting arm lower nut Connecting arm lower nut 55 Nm 5 5 ...

Page 210: ...e drive chain 14 Nm 1 4 m kgf 10 ft lbf Order Job Parts to remove Q ty Remarks 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive chain guide 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive sprocket 1 9 Drive chain 4 70 ...

Page 211: ...een the inner sides of the pins and the length c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length a of the 15 link section of the drive chain using the following formula Drive chain 15 link section length a 4 71 CHAIN DRIVE length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link ...

Page 212: ... I 1 4 Check 0 rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain L L 1 DD 1 5 Lubricate Drive chain Recommended lubricant l Chain lubricant suitable for 0 rlng chains CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear whe...

Page 213: ... 2 b c After riveting make sure the space c which is inside of the connecting link 3 and inside of the connecting plate 1 is 14 1 14 3 mm 0 56 Q 65 in 3 c 1 CHAIN DRIVE 2 Lubricate Drive chain Recommended lubricant Chain lubricant suitable for 0 ring chains 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 l W Drive sprocket nut 95 Nm 9 5 m kgf 69 ft lbf TIP While applying the rear brake tigh...

Page 214: ...5 0 15 0 mm 0 20 0 59 In NOTICE A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 4 74 CHAIN DRIVE ...

Page 215: ... INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 GENERATOR AND STARTER CLUTCH 5 30 REMOVING THE GENERATOR 5 32 REMOVING THE STARTER CLUTCH 5 32 CHECKING THE STARTER CLUTCH 5 32 INSTALLING THE STAR...

Page 216: ... PAN 5 55 CHECKING THE OIL STRAINER 5 55 INSTALLING THE OIL PAN 5 55 CRANKCASE 5 56 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 60 REMOVING THE CONNECTING RODS AND PISTONS 5 61 CHECKING THE CYLINDER AND PISTON 5 61 CHECKING THE PISTON RINGS 5 62 CHECKING THE PISTON PIN 5 63 CHECKING THE CONNECTING RODS 5 63 INSTALLING THE...

Page 217: ...CHECKING THE SHIFT DRUM ASSEMBLY 5 81 CHECKING THE TRANSMISSION 5 81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 81 INSTALLING THE TRANSMISSION 5 82 ...

Page 218: ...ession gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04136 5 1 ENGINE INSPECTION 1 2 5 Measure Compression pressure Out of specification Refer to steps c and d Standard compression pressure at sea level 1530 kPa 680 r min 15 3 kgf cm2 680 r min 217 6 psi 680 r min Minimum maximum 1330 171OkPa 680 r min 13 3 17 1 kgf cm2 680 r min 189 2 243 2 psi 680 r min a Set the main swit...

Page 219: ...head gasket pos sibly defective Repair 6 Install Spark plugs Spark plug 13 Nm 1 3 m kgf 9 4 fl lbf 7 Install Ignition coils Refer to CAMSHAFTS on page 5 9 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 ENGINE INSPECTION 5 2 ...

Page 220: ...e muffler and exhaust pipe 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 3 Order Job Parts to remove Q ty Remarks 1 0 2 sensor coupler bracket 1 2 0 2 sensor coupler 1 Disconnect 3 Muffler assembly 1 4 Exhaust gasket 3 5 Muffler protector 1 5 3 ...

Page 221: ...e 4 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Fuel rail Refer to THROTTLE BODIES on page 7 5 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Right footrest assembly Refer to REAR BRAKE on page 4 32 Drive sprocket Refer to CHAIN DRIVE on page 4 70 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Negative battery lead 1 ...

Page 222: ...d hoses 12 Nm 1 2 m kgf 8 7 ft 0 lbl 9 8 10 7 Nm 0 7 m kgf 5 1 ft lbl Order Job Parts to remove Q ty Remarks 8 Gear position sensor coupler 2 Disconnect 9 Crankshatt position sensor coupler 1 Disconnect 10 Stator coil coupler 1 Disconnect 5 5 ...

Page 223: ...unting bott right front upper side 1 2 Adapter bolt right 1 3 Engine mounting bolt right front lower side engine mounting bott left front lower side engine mounting bolt lett front upper side 1 1 1 4 Adapter bott left 1 5 Engine mounting bolt rear lower side engine mounting nut rear lower side 1 1 6 Engine mounting bolt rear upper side engine mounting nut rear upper side 1 1 7 Engine 1 8 Engine mo...

Page 224: ... mounting adjust bolts rear 2 temporarily tighten 2 Install Engine 3 Install Engine mounting bolt rear upper side 3 Engine mounting bolt rear lower side 4 4 Install Adapter bolt left 5 temporarily tighten 5 Install Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 Temporarily tighten the engine mounting bolts 6 T...

Page 225: ...ter bolt right 9 temporarily tighten 9 Install Engine mounting bolt right front upper side 1O 1O Tighten Engine mounting nut rear lower side 11 Engine mounting nut rear upper side 12 Engine mounting nut 45 Nm 4 5 m kgf 33 ft lbf 11 Tighten Engine mounting bolt right front upper side 1O Engine mounting bolt left front upper side 6 Engine mounting bolt left front lowerside 7 Engine mounting bolt rig...

Page 226: ...coop Fuel tank cover Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Reier to GENERAL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide to...

Page 227: ... chain tensioner 4 Timing chain tensioner gasket 5 Intake camshaft cap 6 Exhaust camshaft cap 7 Camshaft cap 8 Intake camshaft 9 Exhaust camshaft 10 Intake camshaft sprocket 11 Exhaust camshatt sprocket 12 Timing chain bolt 13 Dowel pin 14 Timing chain guide intake side 15 Timing chain 5 10 14 Q ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CAMSHAFTS 10 Nm 1 0 m kgf 7 2 ft lbf 8 10 I f tm mU T i L l J 1 U 11 9...

Page 228: ... be found when the camshaft lobes are turned away from each other J 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket a 5 11 4 Remove Camshaft cap 1 Intake camshaft cap 2 CAMSHAFTS Exhaust camshaft cap 3 NOTICE To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Int...

Page 229: ... mm 1 4063 1 4102 in Limit 35 620 mm 1 4024 in Base circle diameter Exhaust 27 978 28 078 mm 1 1015 1 1054 in Limit 27 878 mm 1 0976 in a 1 I CAMSHAFTS 3 Measure Camshaft runout Ou1 of specification Replace Camshaft runout limit 0 030 mm 0 0012 in 4 Measure Camshaft journal to camshaft cap clearance Ou1 of specification Measure the camshaft journal diameter Camshaft journal to cam shaft cap cleara...

Page 230: ...mage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set CAMSHAFTS 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set a b a 1 4 tooth b Correct 1 Timing chain 2 Camshaft sprocket 1 2 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Che...

Page 231: ... mark b a Turn the crankshaft counterclockwise b When piston 1 is at BTDC1 25 on the com pression stroke align the BTDC1 25 mark a on the generator rotor with the generator rotor cover mark b CAMSHAFTS 3 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 Camshaft sprocket bolt 24 Nm 2 4 m kgf 17 ft lbf NOTICE Be sure to tighten the camshaft sprocket bolts to the specified torque to avo...

Page 232: ...Tighten the camshaft cap bolts in the tightening sequence as shown ECA 1RC11Wt1 NOTICE Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 7 Tighten Camshaft cap bolts 1 Camshaft cap ...

Page 233: ...ming chain tensioner rod by hand remove the hexagon wrench and then insert the hexagon wrench 2 Parts No 1RC 1 2228 00 into the timing chain ten sioner rod d Install the timing chain tensioner gasket 3 the timing chain tensioner 4 and the timing chain tensioner bolts 5 on the cylinder block TIP Face the section b of the gasket inward 4 I e Tighten the timing chain tensioner bolts to the specified ...

Page 234: ...tor rotorcover mark b Camshaft punch mark c Make sure the punch mark c on the cam shaft is aligned with the camshaft cap align ment mark d Out of alignment Adjust Refer to the installation steps above 5 17 CAMSHAFTS 12 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 13 lnstall Timing mark accessing bolt 1 Timing mark accessing bolt 15 Nm 1 5 ...

Page 235: ... head gasket 1 to the cylinder head cover cut off the a section a 15 lnstall Spark plugs Ignition coils 1 Spark plug 13 Nm 1 3 m kgf 9 4 fl lbf TIP lnstall the ignition coils 1 in the direction shown in the illustration CAMSHAFTS 5 18 ...

Page 236: ...amshaft 1 Coolant temperature sensor 2 Cylinder head 3 Cylinder head gasket 4 Dowel pin 5 Timing chain guide exhaust side Q ty 1 1 1 2 1 5 19 CYLINDER HEAD 1st 25 Nm 2 5 m kgf 18 ft dbl 2nd 16 Nm 1 6 m kgl 12 ft lbf Specified angle 90 ii 10 Nm 1 0 m kgf 7 2 ft lbf Remarks Refer to ENGINE REMOVAL on page 5 3 Refer to CAMSHAFTS on page 5 9 Refer to CAMSHAFTS on page 5 9 ...

Page 237: ...rp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace CYLINDER HEAD Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification 4 Resurface the cylinder head Warpage limit 0 10 mm 0 0039 in a Place a straightedge 1 and a thickness gauge 2 across the cylinder head Thicknes...

Page 238: ...ne oil 3 Tighten Cylinder head bolts 1 8 Cylinder head bolts 9 12 Cylinder head bolt 1 8 1st 25 Nm 2 5 m kgf 18 ft lbf 2nd 16 Nm 1 6 m kgf 12 ft lbf 90 Cylinder head bolt 9 12 10 Nm 1 0 m kgf 7 2 ft lbf Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as s...

Page 239: ...e 5 19 1 Intake valve lifter 6 2 Intake valve pad 6 3 Intake valve cotter 12 4 Intake valve spring reiainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 15 Exhaust valve 6 16 Exhaust val...

Page 240: ...he valves properly seal TIP There should be no leakage at the valve seat 1 1 3 Remove Valve cotters VALVES AND VALVE SPRINGS TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapter 22mm YM 0...

Page 241: ...on and to maintain the correct fit heat the cylinder head to 100 c 212 F in an oven YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY a Remove the valve guide with the valve guide remover 1 VALVES AND VALVE SPRINGS b Install the new valve guide with the valve guide installer 2 and valve guide remover 11 1 Valve guide position 13 3 13 7 mm 0 52 0 54 in a Valve guide position c After installing the valve guide bore ...

Page 242: ...G THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat VALVES AND VALVE SPRINGS 2 Check Valve seat Pitting wear 4 Replace the cylinder head 3 Measure Valve seat width a Ou1 of specification 4 Replace the cylinder head Valve seat width Valve seat width intake 0 90 1 10 mm 0 0354 0 0433 In Limit 1 60 mm 0 ...

Page 243: ...ply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face VALVES AND VALVE SPRINGS h Install the valve into the cylinder head 1 Press the valve through the valve guide and onto the valve seat to make a clear impres sion J...

Page 244: ...e spring tilt a Out of specification 4 Replace the valve spring Spring tilt intake 1 7 mm 0 07 in Spring tilt exhaust 1 6 mm 0 06 in VALVES AND VALVE SPRINGS a CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Valve lifter Damage scratches 4 Replace the valve lift ers and cylinder head INSTALLING THE VALVES The following procedure applies to all of the ...

Page 245: ...and the valve spring compressor attachment 3 1 VALVES AND VALVE SPRINGS Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapter 22mm YM 04108 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valv...

Page 246: ...TIP The valve lifter must move smoothly when ro lated with a finger Each valve lifter and valve pad must be rein stalled in its original position VALVES AND VALVE SPRINGS 5 29 ...

Page 247: ...oupler 3 Holder fuel tank overflow hose and breather hose 4 5 6 7 8 Generator cover Generator cover gasket Dowel pin Stator coil lead holder Stator coil assembly stator coil crankshaft posi lion sensor 5 30 Q ty 1 1 1 1 1 2 1 1 id 3 8 14 Nm 1 4 m kgl 10 ft lbf 6 12 Nm 1 2 m kgf 8 7 ft lbl 12 Nm 1 2 m kgf 8 7 ft lbf Remarks Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 1 R...

Page 248: ... 12 Nm 1 2 m kgf 8 7 ft lbf 12 Nm 1 2 m kgf 8 7 ft 0 lbf Order Job Parts to remove Q ty Remarks 9 Generator rotor 1 10 Starter clutch 1 11 Starterclutch gear 1 12 Woodruff key 1 13 Starter clutch idle gear shaft 1 14 Starter clutch idle gear 1 15 Crankshaft end cover 1 16 Timing mark accessing bolt 1 17 Water pump outlet pipe 1 5 31 ...

Page 249: ...tch Make sure the flywheel puller is centered over the generator rotor Flywheel puller 90890 01362 Heavy duty puller YU 33270 B REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts 1 Sheave holder 90890 01701 Primary clutch holder YS 01880 A CHECKING THE STARTER CLUTCH 1 Check Start...

Page 250: ...the generator rotor 2 While holding the generator rotor with the sheave holder 3 tighten the starter clutch bolts Sheave holder 90890 01701 Primary clutch holder YS 01880 A 500 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer lf ii Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the...

Page 251: ...cover gasket l Mi Generator cover Generator cover bolt 1 12 Nm 1 2 m k gf 8 7 ft lbf LOCTITE Generator cover bolt 2 12 Nm 1 2 m k gf 8 7 ft lbf TIP Tighten the generator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TI P To route the stator coil lead refer to CABLE ROUTING on page 2 41 5 34 ...

Page 252: ...ver Fuel tank Air filter case Throttle bodies 1 Starter motor lead 2 Negative battery lead 3 Starter motor 5 35 Q ty 1 1 1 ELECTRIC STARTER 3 Remarks Reier to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 1 Refer to FUEL TANK on page 7 1 Refer to GENERAL CHASSIS on page 4 1 Refer to THROTTLE BODIES on page 7 5 Disconnect Disconnect ...

Page 253: ...e starter motor 7 3 sl t4ta s l tw 11 2 11 tm I s Nm 0 5 m kgf 3 6 ft lbf Order Job Parts to remove Q ty Remarks 1 0 ring 1 2 Front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Rearcover 1 5 36 ...

Page 254: ...T a Measure the armature assembly resistances with the digital circuit tester Digital circuit tester 90890 03174 Model 88 Multimeter with tachom eter YU A1927 Armature coil resistance 0 0050 0150 n Insulation resistance Above 1 Mn at 20 C 68 F b If any resistance is out of specification re place the starter motor ELECTRIC STARTER 2 1 1 Commutator resistance 2 Insulation resistance Iii o 4 Measure ...

Page 255: ...1 Starter motor yoke 2 Front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover b a b 0 0 1 2 3 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Negative battery lead 2 Starter motor bolts 3 TIP lnstall the negative battery lead as shown in the illustration Starter motor bolt 12 Nm 1 2 m kgf 8 7 ft lbf ELECTRIC STARTER 2 Connect S...

Page 256: ...1 1 ft bf 12 Nm 1 2 m kgf 8 7 ft lbf Order Job Parts to remove Engine oil 1 Clutch cable 2 Cover 3 02 sensor coupler bracket 4 Clutch cover 5 Clutch cover gasket 6 Dowel pin 7 Oil filler cap CLUTCH 4 Q ty Remarks Drain Refer to CHANGING THE ENGINE Oil on page 3 23 1 Disconnect 1 1 1 2 1 5 39 ...

Page 257: ... Removing the p ull lever shaft 8 7 5 LS 3 1mm Order Job Parts to remove Q ty Remarks 1 Circlip 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 5 40 ...

Page 258: ...CLUTCH 125 Nm 12 5 m kgf 90 ft 0 lbf 16 14 I 13 12 10 mm 8 5 41 ...

Page 259: ... driven sprocket 1 Refer to OIL PUMP on page 5 50 3 Remove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 4 Remove Friction plate 1 1 CLUTCH 5 Remove Clutch plate 1 Friction plate 2 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 5 42 Universal clutch hol...

Page 260: ...in Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 In Wear limit 2 82 mm 0 111 in CLUTCH A Friction plate 1 B Friction plate 2 eA 2l 11 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clu...

Page 261: ... sprocket 1 Cracks damage wear Replace 1 CLUTCH 3 Check Bearing Damage wear Replace the bearing and clutch housing CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace 2 1 CHE...

Page 262: ...g Damage wear 4 Replace INSTALLING THE CLUTCH 1 Install Oil pump drive chain 1 Clutch housing 2 TIP lnstall the oil pump drive chain onto the oil pump drive sprocket a CLUTCH 2 a 2 Install Thrust plate Clutch boss 1 Washer Conical spring washer 2 Clutch boss nut 3 IH4W Clutch boss nut 125 Nm 12 5 m kgf 90 ft lbf LOCTITE TIP Install the conical spring washer on the main axle with the OUT mark a fac...

Page 263: ...OCTITE TIP Tighten the clutch spring bolts in stages and in a crisscross pattern Apply lithium soap based grease onto the pull rod Position the pull rod so that the teeth a face towards the hole b Then install the clutch cover 5 Install Dowel pins Clutch cover gasket IH j Clutch cover Cover Clutch cover bolt CLUTCH 12 Nm 1 2 m kgf 8 7 ft lbf TIP Apply engine oil onto the bearing Tighten the clutch...

Page 264: ...7 Adjust Clutch lever free play Referto ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in CLUTCH 5 47 ...

Page 265: ...to remove Q ty Remarks Clutch assembly Refer to CLUTCH on page 5 39 Shift arm Refer to CHAIN DRIVE on page 4 70 1 Circlip 1 2 Washer 1 3 Shilt shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 8 Stopper lever spring 9 Collar 10 Shilt shaft spring 1 11 Shilt shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 5 48 ...

Page 266: ...y Stopper lever spring 2 Shift shaft spring stopper 22 Nm 2 2 m kgf 16 ft lbf LOCTITE TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal lllf 111 l4 t I Washer 1 SHIFT SHAFT Circlip 2 ll...

Page 267: ... the oil pump 0 ii 10 Nm 1 0 m kgf 7 2 ft lbf 0 10 Nm 1 0 m kgf 7 2 ft lbf 15 Nm 1 5m kgf 11 ft lbf Order Job Parts to remove Q ty Remarks Clu ch cover Refer 1 0 CLUTCH on page 5 39 1 Oil pump driven sproekel 1 2 Oil pump assembly 1 5 50 ...

Page 268: ...3 2 1 0 I OJ 4 8 q 5 9 j m Q _ Order Job Parts to remove Q ty Remarks 1 Oil pump cover 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Circlip 1 Hold down the washer when removing the circlip 7 Washer 1 8 Spring 9 Relief valve 10 Dowel pin 2 5 51 ...

Page 269: ...learance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and out er rotor clearance c Out of specification Replace the defective part s OIL PUMP Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 19 mm 0 0035 0 0075 In Limit 0 21 mm 0 0083 in Oii pump housing to in ner and oute...

Page 270: ...e pin 3 in the oil pump shaft with the groove in the inner rotor 2 OIL PUMP 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 52 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 Oil pump bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump driven sprocket 3 ECA1ACl508 NOTICE 011 pump driven sprocket bolt 15 Nm 1 5 m kgf 11 ft lbf LOCTITE After installing the oil pump drive chain...

Page 271: ...uel lank Muffler assembly Engine oil Oil level switch lead coupler 1 Oil level switch lead holder 1 Oil level switch 1 0 2sensor lead holder 1 Oil pan 1 Oil pan gasket 1 Oil strainer 1 5 54 OIL PAN 7 Remarks Refer lo GENERAL CHASSIS on page 4 1 Refer lo GENERAL CHASSIS on page 4 1 Refer lo FUEL TANK on page 7 1 Refer lo ENGINE REMOVAi on page 5 3 Drain Refer to CHANGING THE ENGINE Oil on page 3 23...

Page 272: ...ge Replace 1 Contaminants Clean with solvent 1 INSTALLING THE OIL PAN 1 Install Gasket l ll Oil pan 1 Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil level switch 2 Oil level switch bolt 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt 3 OIL PAN Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf A wARNING Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lu...

Page 273: ...idge 2 Oil filtercartridge union bolt 3 Gear position sensor 4 Speed sensor 5 Clutch cable holder 6 Lower crankcase 7 Dowel pin Q ty 1 1 1 1 3 5 56 CRANKCASE 1st 25 Nm 2 5 m k f 18 ft lbf ii 2nd 18 Nm 1 8 m kgf 13 ft lbf 3rd Specified angle 60 II 17 Nm 1 7 m kgf 12 ft lbf II 70 Nm 7 0 m k f 51 ft 0 lbf Remarks Refer to ENGINE REMOVAL on page 5 3 Refer to CYLINDER HEAD on page 5 19 Refer to WATER P...

Page 274: ...l lower bearing Balancer shaft journal bearings from the lower crankcase TIP ldentify the position of each part very carefully so that it can be reinstalled in its original place CRANKCASE CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passa...

Page 275: ...36 in bolts 13 14 M6 x B5 mm 3 35 in bolt 1B M6 x 65 mm 2 56 in bolts 1 5 16 M6 x 65 mm 2 56 in bolt 26 M6 x 50 mm 1 97 in bolts 17 19 21 23 25 271 30 M6 x 40 mm 1 57 in bolt 22 19 20 21 22 CRANKCASE 7 Tighten Crankcase bolts 1 B Crankcase bolts 1 S 1st 25 Nm 2 5 m kgf 18 ft lbf 2nd 15 Nm 1 5 m kgf 11 ft lbf 3rd so Crankcase bolts 7 8 1st 25 Nm 2 5 m kgf 18 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf 3rd...

Page 276: ...hten Crankcase bolts 9 30 Crankcase bolts 9 14 24 Nm 2 4 m kgf 17 fl lbf Crankcase bolts 15 30 10 Nm 1 0 m kgf 7 2 fl lbf TIP Tighten the bolts in the tightening sequence cast on the crankcase CRANKCASE 5 59 ...

Page 277: ...2 0 m kgl 14 It lbl 2nd Specified angle 175 185 Order Job Parts to remove Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 56 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 5 60 ...

Page 278: ... put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 61 3 Remove Top ring 2nd ring Oil ring 4 TIP When removing a piston ring ope...

Page 279: ...eplace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 150 mm 0 0059 in f If out of specification replace the cylinder and replace the piston and piston rings as a set CHECKING THE PISTON RINGS 1 Measu...

Page 280: ... 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 16 990 16 995 mm 0 6689 0 6691 in Limit 16 970 mm 0 6681 in 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 17 ...

Page 281: ...A1ACISOI NOTICE Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod After installing the big end bearing assemble th...

Page 282: ...ap 3 2 1 3 i Tighten the connecting rod bolts further to reach the specified angle 175 185 Connecting rod bolt final Specified angle 175 185 A WARNING If the connecting rod bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again NOTICE Do not use a torque wrench to tighten th...

Page 283: ...of the con necting rods and pistons 1 Install Big end bearings Connecting rod cap onto the connecting rod TIP Be sure to reinstall each big end bearing in its original place Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Make sure that the projection c on the con necting rod cap faces the same direction as the Y mark d on the conn...

Page 284: ...ing rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips...

Page 285: ...projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and seats into the cylinder 2 and onto the crankshaft b pin NOTICE Piston installing tool 90890 04161 YM 04161 If the projection a of the piston installing tool damages you cannot use it Please han dle with care TIP Fit the projection a of the pi...

Page 286: ... the specified angle do not loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again ECAIW 0 NOTICE Do not use a torque wrench to tighten the connecting rod bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface EWAIAC15 JG AwARNING If the connecting rod...

Page 287: ...ve Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 56 Connecting rod Refer to REMOVING THE CONNECTING RODS ANO PISTONS on page 5 61 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzfe 3 5 70 ...

Page 288: ...faces Crankshaft pin surfaces Bearing surfaces Scratches wear t Replace the crankshaft 3 Measure Crankshaft journal to crankshaft jour nal bearing clearance Out of specification t Replace the crank shaft journal bearings ECA 13920 NOTICE Journal oil clearance 0 014 0 038 mm 0 0006 0 0015 In Do not interchange the crankshaft journal bearings To obtain the correct crank shaft journal to crankshaft j...

Page 289: ... journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine...

Page 290: ...ancer shaft jour nal bearings To obtain the correct balancer shaft journal to balancer shaft journal bear ing clearance and prevent engine damage the balancer shaft journal bearings must be installed in their original positions TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Clean the balancer shaft journal bearings balancer shaft journals and bearing portions of the crankcase b Place the upper crankcase upsid...

Page 291: ...ification select replacement balancer shaft journal bearings 1v a lJ 4 Select Balancer shaft journal bearings J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration If J J2 are t...

Page 292: ...alancer journal upper bearings into the upper crankcase Balancer journal lower bearings into the lower crankcase TIP Align the projections a on the balancerjournal bearings 1 with the notches b in the crank cases Be sure to install each balancer journal bearing in its original place 2 Install Balancer shaft TIP lnstall by aligning the crankshaft match mark a and the balancer shaft match mark b 5 7...

Page 293: ...t 0 lbf 6 0 1 9 ii 10 Nm 1 0 m kgf 7 2 ft lbf Order Job Parts to remove Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 56 1 Drive axle assembly 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift drum retainer 2 6 Shift fork guide bar 2 7 Shilt fork L 1 8 Shilt fork R 1 9 Shilt drum assembly 1 10 Shilt fork C 1 Main axle assembly 12 Bearing 5 76 ...

Page 294: ...on gear thed lock washer 2 Too d lock washer retainer 3 Toothe 4 6th pinion gear 5 Collar 6 Washer 7 Circlip 8 3rd pinion gear 9 Circlip 10 washer 11 Sth pinion gear 12 Collar 13 Bearing housing 14 Bearing 15 Main axle TRANSMISSION 1 Q ty Remarks 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 77 ...

Page 295: ...Parts to remove Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear TRANSMISSION Q ty Remarks 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 78 ...

Page 296: ...TRANSMISSION Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 21 Collar 1 22 Bearing 23 Circlip 24 Drive axle 5 79 ...

Page 297: ...ening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Bearing 1 TRANSMISSION 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 2 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace EWA128 1 A...

Page 298: ... 5 81 TRANSMISSION Ou1 of specification 4 Replace the drive axle 3 Check Drive axle runout limit 0 08 mm 0 0032 In 1 Transmission gears Blue discoloration pitting wear 4 Replace the defective gear s Transmission gear dogs Cracks damage rounded edges 4 Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect 4 Reassemble the transmiss...

Page 299: ...r in the groove a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer TRANSMISSION 1 a c 2 1 a A Main axle B Drive axle INSTALLING THE TRANSMISSION 1 Install 2 Bearing 1 TIP Face the seal side of bearin...

Page 300: ...t drum retainers 3 Bearing Oil seal llllll l M I Circlip 4 ll i Drive axle assembly 5 Shift drum retainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward TRANSMISSION Touch the protrusion d on the shif...

Page 301: ...IATOR 6 2 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 302: ...r 4 Coolant reservoircap 5 Radiator cap 6 Radiator fan motor coupler 7 Radiator hose cylinder head to radiator 8 Radiator inlet hose 9 Radiator outlet hose 10 Radiator 11 Radiator fan cover 12 Radiator fan 13 Radiator stay 6 1 Q ty 1 1 1 1 1 1 1 1 1 1 1 1 1 RADIATOR Remarks Refer to GENERAL CHASSIS on page 4 1 Drain Refer to CHANGING THE COOLANT on page 3 26 Disconnect Disconnect Disconnect Discon...

Page 303: ...tem tester kit YU 24460 A Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 2 RADIATOR b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended cool...

Page 304: ...essure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Reier to CHECKING THE RADIATOR on page 6 2 RADIATOR 6 3 ...

Page 305: ...ant reservoir Muffler assembly Coolant Engine oil 1 Radiator inlet hose 2 Oil cooler inlet hose 3 Oil cooler outlet hose 4 Oil cooler union bott 5 Washer 6 Oil cooler 7 Water jacket joint 1 1 1 1 6 4 Refer to RADIATOR on page 6 1 Refer to ENGINE REMOVAL on page 5 3 Drain Refer to CHANGING THE COOLANT on page 3 26 Drain Refer to CHANGING THE ENGINE Oil on page 3 23 ...

Page 306: ...soap based grease to the 0 ring Make sure the 0 ring is positioned properly Align the projection a on the oil coolerwith the slot b in the crankcase After installing the oil cooler union bolt bend the tab c of the washer 6 5 OIL COOLER 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 Crankcase with the specified amount of the re...

Page 307: ... 2 ft lbf Order Job Parts to remove Q ty Remarks Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Drain Coolant Refer to CHANGING THE COOLANr on page 3 26 1 Radiator outlet hose 1 2 Water pump inlet hose 1 3 Oil cooler outlet hose 1 Disconnect 4 Thermostat assembly 1 6 6 ...

Page 308: ...specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 2 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 THERMOSTAT 6 7 ...

Page 309: ...Removing the water pump Order Job Parts to remove Coolant 1 Water pump inlet hose 2 Water pump assembly Q ty 1 1 6 8 WATER PUMP 12 Nm 1 2 m kgf 8 7 ft lbf Remarks Drain Refer to CHANGING THE COOLANr on page 3 26 Disconnect ...

Page 310: ... 8 9 10 s mm 9 mm 10 Job Parts to remove Water pump housing cover 0 ring Circlip Water pump driven gear Pin Washer Impeller shalt Mechanical seal Bearing Oil seal WATER PUMP mm 8 7 mm 2 1 10 Nm 1 0 m kgf 7 2 ft lbl Q ty Remarks 1 1 1 1 1 1 1 1 1 1 6 9 ...

Page 311: ...Do not scratch the impeller shaft 1 WATER PUMP CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the water pump assembly 2 2 Check Bearing 3 Rough movement Replace 3 Check Water pump inlet pipe Cracks damage wear Replace ASSEMBLING THE WATERPUMP 1 Install Installed depth a 0 5 1 0 mm 0 02 0 04 In 1 TIP l...

Page 312: ... pump housing 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down 3 Install Mechanical seal impeller side 1 U 4 ll TIP Before installing the mechanical seal impeller side apply tap water or coolant onto its outer surface If the top of the mechanical seal is dirty clean it 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 6 11 WATER PUMP 4 NOTICE Make su...

Page 313: ...7 8 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 REPLACING THE THROTTLE BODIES 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 10 CHECKING THE FUEL PRESSURE 7 11 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE ACCELERATOR POSITI...

Page 314: ...k drain hose Fuel tank Fuel pump bracket Fuel pump Fuel pump gasket Wire harness assembly intake air temperature sensor Air scoop stay left Wire harness assembly headlight relay fuse box I radiator Ian motor coupler Air scoop stay right 7 1 Q ty 1 1 1 1 1 1 1 1 1 1 1 1 FUEL TANK 7 7 Nm 0 7 m kgf 5 1 ft lbl Remarks Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 1 Disconnect...

Page 315: ...CHASSIS on page 4 1 Air scoop Fuel tank cover Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister purge hose hose joint to canister 1 2 Fuel tank breather hose fuel tank to rollover 1 valve 3 Rollover valve 1 4 Fuel tank breather hose rollover valve to canis 1 ter 5 Canister 1 6 Canister breather hose 1 7 Canister bracket 1 7 2 ...

Page 316: ...re it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings t 2 4 Remove Fuel tank TIP 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 up right position 7 3 FUEL TANK REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE Do not drop the fuel pump or give It a strong shock Do...

Page 317: ...1AC1104 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE 0 0 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose on...

Page 318: ...anister purge hose Refer to FUEL TANK on page 7 1 For California only 1 Fuel hose 1 2 Intake air pressure sensor 1 coupler 1 Disconnect 3 Intake air pressure sensor 2 coupler 1 Disconnect 4 Accelerator position sensor coupler Disconnect 5 Throttle servo motor coupler Disconnect 6 Throttle position sensor coupler Disconnect 7 Throttle cable accelerator cable 1 Disconnect Black 8 Throttle cable dece...

Page 319: ...8 7 5 2 __J Order Job Parts to remove Q ty Remarks 1 Negative pressure hose 6 2 Hose joint 2 3 Canister purge hose 5 For California only 4 Hose joint 3 For California only 5 Intake air pressure sensor 2 1 6 Intake air pressure sensor 1 1 7 Throttle position sensor 1 8 Accelerator position sensor 1 7 6 ...

Page 320: ... 2 m kgf 8 7 ft Ibf Order Job Parts to remove Q ty Remarks Throttle bodies Throttle body joint Refer to THROTTLE BODIES on page 7 5 1 Fuel rail 1 2 Injector 3 3 Injector coupler 2 Disconnect 4 Injector lead 1 5 Injector lead coupler 1 Disconnect 6 Wire harness 1 7 Adapter 1 7 7 ...

Page 321: ... free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure In the fuel 7 8 THROTILE BODIES hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF...

Page 322: ...tall the caps 895 14169 00 onto the hose fittings a 7 9 THROTILE BODIES a a c Hold the throttle valves in the open position EWA1FCl104 AwARNING When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies ECA1ACl700 NOTICE Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools t...

Page 323: ...ES on page 3 8 5 Place the vehicle on a suitable stand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed Engine idling speed 1100 1300 r min INSTALLING THE INJECTORS ECAIRCl702 NOTICE Always use new 0 rings When installing the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails...

Page 324: ...heck the pressure gauge and adapter Check the seals and 0 rings and then rein stall Out of specification Replace the fuel injec tors EA 1AC17 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure 7 11 THROTILE BODIES TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Remove the rider seat air scoop and fuel tank cover Refer to GENERAL CHASSIS on page 4 1 b Remove the fuel tank bolt and hold up the fuel tank c Disconne...

Page 325: ...If the throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to CHECKING THE THROTILE PO SITION SENSOR on page 8 107 THROTILE BODIES 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sensor screws b Check that the throttle valves are fully closed c T...

Page 326: ...ator position sensor to the wire harness e Connect the throttle cables to the throttle bod ies f Simultaneously press and hold the SE LECT button 1 and RESET button 2 tum the main switch to ON and continue to press the buttons for 8 seconds or more 0 THROTILE BODIES c llRC TIP dlAG appears on the display g Simultaneously press the SELECT button 1 and RESET button 2 for 2 seconds or more to set the...

Page 327: ... 10 24 adjust the acceler ator position sensor angle q Tum the throttle grip to the fully open position r Check the meter display value If the meter display value is not 95 109 adjust the accel erator position sensor angle s Repeat steps h to r until the meter display values are within the specified ranges t If the meter display values are not within the specified ranges after repeating steps h to...

Page 328: ...AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 3 4 7 15 ...

Page 329: ...1 Air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose aircut off valve to reed valve cover AIR INDUCTION SYSTEM 7 16 ...

Page 330: ... valve cover Air induction system hose air cut off valve to reed valve cover Air induction system hose air filter case to air cut off valve Air cut off valve Air cut off valve holder Reed valve cover Reed valve assembly 1 Reed valve plate Reed valve cover Reed valve assembly 2 Reed valve plate 7 17 Q ty 1 1 1 1 1 1 1 1 1 1 1 2 4 7 8 Remarks Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHA...

Page 331: ... during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value A From the air filter case B To the cylinder head 1 Check Hoses Loose connections t Connect properly Cracks dama...

Page 332: ...en side turns to the exhaust side of the en gine Install the reed valve assembly 2 so that the open side turns to the intake side of the engine A Reed valve assembly 1 B Reed valve assembly 2 C Exhaust side 3 Install Reed valve cover Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE 7 19 AIR INDUCTION SYSTEM ...

Page 333: ... 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 35 DIAGNOSTIC MODE 8 36 YAMAHA DIAGNOSTIC TOOL 8 37 TROUBLESHOOTING DETAILS 8 38 FUEL PUMP SYSTEM 8 81 CIRCUIT DIAGRAM 8 81 TROUBLESHOOTING 8 83 ELECTRICAL COMPONENTS 8 85 CHECKING THE SWITCHES 8 89 CHECK...

Page 334: ...E FUEL SENDER 8 104 CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT 8 105 CHECKING THE OIL LEVEL WARNING LIGHT 8 105 CHECKING THE SPEED SENSOR 8 105 CHECKING THE RADIATOR FAN MOTORS 8 106 CHECKING THE COOLANT TEMPERATURE SENSOR 8 106 CHECKING THE THROTTLE POSITION SENSOR 8 107 CHECKING THE ACCELERATOR POSITION SENSOR 8 107 CHECKING THE THROTTLE SERVO MOTOR 8 108 CHECKING THE AIR INDUCTION SYSTEM ...

Page 335: ......

Page 336: ... IGNITION SYSTEM EA 27110 CIRCUIT DIAGRAM Ill I l i I I I I I e I 9 I Ii I I I_ _ 1 t 1 mi ml Ill m I i i u _ 1 i 0 IGNITION SYSTEM G l1 T r El jl t llll i o i J 8 1 ...

Page 337: ...t connector 19 Joint coupler 20 Relay unit 23 ECU engine control unit 24 lgnition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 Spark plug 33 Crankshaft position sensor 38 Lean angle sensor 58 Gear position sensor 61 Sidestand switch 62 Right handlebar switch 64 Start engine stop switch IGNITION SYSTEM 8 2 ...

Page 338: ...ntinues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position sensor is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position sensor is closed and the sides tand is down the sidestand switch circuit is open 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5...

Page 339: ...nition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 100 NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 100 OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 101 OK 7 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 OK 8 Check the starVengine stop switch Refer to CHECKING THE SWITCH...

Page 340: ... OKt 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 101 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Replace the ECU Refer to REPLACING THE ECU en gine control unit on page 8 93 NG NG NG NG NG 8 5 IGNITION SYSTEM Replace the gear position sensor Replace the sidestand switch Replace the relay unit Replace the lean angle sensor P...

Page 341: ...IGNITION SYSTEM 8 6 ...

Page 342: ...RCUIT DIAGRAM Ill i e I I e 0 I I I I I I I I t f Ii_ fl i I I j I I gi 1 e I I I 1 J__f 2 1 w 0 I El ti U 1 J e tlil cr i e l ti 6 t___B e J 8 7 C 1 _ 6 El 8 e 1 _ If i lfl 4 I p c i ____ ___ I i e H8 i i f ll J G fiJ jo ai i l li1 ei JI Ii ffi j 1 1 ff II il illl gi 9 1 ...

Page 343: ...njection system fuse 16 Starter relay 17 Starter motor 18 Joint connector 19 Joint coupler 20 Relay unit 21 Starting circuit cut off relay 58 Gear position sensor 61 Sidestand switch 62 Right handlebar switch 64 StarVengine stop switch 70 Clutch switch ELECTRIC STARTING SYSTEM 8 8 ...

Page 344: ...pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting...

Page 345: ...PULLED TO THE HAN DLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Gear position sensor neutral circuit 11 Diode 12 Starter relay 13 Starter motor ELECTRIC STARTING SYSTEM 8 10 ...

Page 346: ...arter motor Refer to CHECKING THE START ER MOTOR on page 5 37 OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 97 OK 6 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 99 OK 7 Check the starter relay Refer to CHECKING THE RE LAYS on page 8 97 OK 8 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 OK NG NG OK...

Page 347: ... 89 OKt 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 89 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 The starting system circuit is OK ELECTRIC STARTING SYSTEM NG t NG t NG t NG t NG t 8 12 Replace the gear position sensor Replace the sidestand switch Replace the clutch switch Replace the right handlebar switch Properly connect...

Page 348: ...CHARGING SYSTEM EA 27 CHARGING SYSTEM EAS2 121 0 CIRCUIT DIAGRAM m 1 e l I Em I _ f J11H t Y t fi ir 1 d 1 8 13 l8iiJ3l 1 1 ...

Page 349: ...1 AC magneto 2 Rectifier regulator 4 Main fuse 13 Battery 14 Engine ground CHARGING SYSTEM 8 14 ...

Page 350: ...heck the stator coil Refer to CHECKING THESTA TOR COIL on page 8 102 OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 102 OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 OK The charging system circuit is OK NG NG NG NG NG 8 15 Replace the fuse Clean the battery terminals Recharge or replace the battery Replace the stator c...

Page 351: ...CHARGING SYSTEM 8 16 ...

Page 352: ...EA 272 CO LIGHTING SYSTEM EA 272 50 CIRCUIT DIAGRAM Ill I l i I I I I I e I 9 I Ii I I i 8 17 LIGHTING SYSTEM C T El jl t llll 1 ...

Page 353: ...3 ECU engine control unit 45 Meter assembly 47 Meter light 54 High beam indicator light 69 Left handlebar switch 74 Pass switch 75 Dimmer switch 78 Front right turn signal position light 79 Front left turn signal position light 80 Headlight 81 Auxiliary light 82 License plate light 83 TaiVbrake light 84 Headlight relay LIGHTING SYSTEM 8 18 ...

Page 354: ... 93 OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 OK I 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 89 OK 6 Check the pass switch Refer to CHECKING THE SWITCHES on page 8 89 OK I 7 Check the headlight relay on off Refer to CHECKING THE RE LAYS on page 8 97 OK NG NG NG NG NG...

Page 355: ...ystem s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 93 NG t 8 20 LIGHTING SYSTEM Properly connect or repair the lighting sys tem s wiring ...

Page 356: ...EA 27VO SIGNALING SYSTEM EA 27W CIRCUIT DIAGRAM Ill I l i I I I I I e I 9 I I Ii I 1 i _ 0 8 21 SIGNALING SYSTEM 1 El 1 Q 8 ...

Page 357: ...ngine trouble warning light 53 Coolant temperature warning light 55 Left turn signal indicator light 56 Right turn signal indicator light 57 0il level switch 58 Gear position sensor 59 Fuel sender 62 Right handlebar switch 65 Hazard switch 66 Front brake light switch 67 Rear brake light switch 68 Turn signal hazard relay 69 Left handlebar switch 71 Horn 72 Horn switch 73 Turn signal switch 76 Rear...

Page 358: ...NG AND CHARGING THE BATIERY on page 8 94 OKJ 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 OKJ 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 OKJ This circuit is OK Check the signaling system The horn fails to sound 1 Check the horn switch Refer to CHECKING THE SWITCHES on page 8 89 OKJ 2 Check the horn Refer to CHECKING THE HORN on page 8 ...

Page 359: ...ake light switch Properly connect or repair the signaling system s wiring The tum signal light tum signal indicator light or both fail to blink 1 Check the front tum signal position light bulbs rear turn signal light bulbs and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 92 OK I 2 Check the tum signal switch Refer to CHECKING THE SWITCHES on page 8 89 3 Check the hazard switch Ref...

Page 360: ...t fails to come on 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 89 OKi 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 OKi Replace the meter assembly The fuel level warning light fails to come on 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 104 OKi NG t NG t NG t NG t NG t NG t NG t 8 25 SIGNALING SYSTEM Properly co...

Page 361: ...trol unit on page 8 93 NG t NG t NG t The coolant temperature warning light fails to come on 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 106 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 93 NG t NG t 8 26 SIGNALING ...

Page 362: ...EA 27300 COOLING SYSTEM EA 27310 CIRCUIT DIAGRAM Ill I l i I I I I I e I 9 I Ii I I i _ 0 Gl fu 1 J e g k 5 e t vi W J 1 l l _ R_lll_ LB e i COOLING SYSTEM C T I 8 27 ...

Page 363: ...ain fuse 7 Radiator fan fuse 9 Ignition fuse 13 Battery 14 Engine ground 18 Joint connector 23 ECU engine control unit 35 Coolant temperature sensor 85 Radiator fan motor relay 86 Radiator fan motor COOLING SYSTEM 8 28 ...

Page 364: ... FAN MOTORS on page 8 106 OKJ 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 97 OK 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 106 OKJ 7 Check the entire cooling system s wmng Refer to CIRCUIT DIAGRAM on page 8 27 OKJ Replace the ECU Reier to REPLACING THE ECU en gine control unit on page 8 93 NG t NG t NG t NG t...

Page 365: ...COOLING SYSTEM 8 30 ...

Page 366: ... I ail I l i 1 i t I I I eo1 2 leI I Jf I i l gi 1 I I i J h m ti 1 1r 0 I S El U_ J ti I I I I e i e r5 l t lil W ti I _ fa e J 8 31 FUEL INJECTION SYSTEM C q l CJ L a IEl ID 6 1 1 I 11 I I I u i lf i 1 p c i I 6 e H8 i i f G iJ je ai i l li1 ei JI Ii m 1 1 ff II il illl gi 9 1 ...

Page 367: ...sensor 33 Crankshaft position sensor 34 lntake air temperature sensor 35 Coolant temperature sensor 36 Intake air pressure sensor 1 37 lntake air pressure sensor 2 38 Lean angle sensor 39 Speed sensor 40 Throttle servo motor 41 Accelerator position sensor 42 Throttle position sensor 43 Yamaha diagnostic tool connector 44 Yamaha diagnostic tool coupler 45 Meter assembly 49 Multi function meter 52 E...

Page 368: ...red in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation Warning light ECU operation Fuel injection Vehicle operation indication operation Warning provided Flashing when unable to start Operation stopped Cannot be operated engine Operated with substi tute characteristics in Can or cannot be oper Remains on Malfunction detected acc...

Page 369: ...ght and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions ...

Page 370: ...r is displayed TIP If another fault code number is displayed repeat steps 1 to 4 until no fault code number is dis played 5 Erase the malfunction history in the diagnos tic mode code No 62 Refer to SELF DIAG NOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 FUEL INJECTION SYSTEM TIP Setting the main switch to OFP will not erase the malfunction history The engine operation is not normal but the...

Page 371: ...pressing the SE LECT and RESET buttons TIP The diagnostic code number appears on the display 1 70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1 second or longer to automatic...

Page 372: ...play on the computer The displayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool Fault diagnosis mode Function diagnostic mode Inspection mode CO adjustment mode Monitoring mode Logging mode View log ECU rewrite Fault codes recorded on the ECU are read and the contents are displayed The freeze frame data FFD is the operatio...

Page 373: ...ly Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 8 36 Fault code No 12 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of Maintenance job Confirm...

Page 374: ...lue Between joint connector and ECU coupler black blue black blue 4 Installed condition of crank Improperly installed sensor Crank the engine shaft position sensor t Reinstall or replace the Fault code number is not dis Check for looseness or sensor played t Service is finished pinching Refer to GENERATOR AND Fault code number is dis Check the gap 0 85 mm STARTER CLUTCH on played t Go to item 5 0 ...

Page 375: ...rn the main switch to ON ECU coupler Connect the coupler securely Fault code number is not dis Check the locking condition or replace the wire harness played Service is finished of the coupler Fault code number is dis Disconnect the coupler and played Go to item 3 check the pins bent or bro ken terminals and locking condition of the pins 3 Wire harness continuity Open or short circuit Turn the mai...

Page 376: ...e is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor 1 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 1 09 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 TIP If fault code numbers 13 and 14 are both indicated take the actions...

Page 377: ...sensor 1 mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking ...

Page 378: ...ck the pins bent or bro ken terminals and locking condition of the pins 2 Connection of wire harness Improperly connected Turn the main switch to ON ECU coupler Connect the coupler securely Fault code number is not dis Check the locking condition or replace the wire harness played Service is finished of the coupler Fault code number is dis Disconnect the coupler and played Go to item 3 check the p...

Page 379: ... fully closed A value of 11 21 is indicated When throttle valves are fully open A value of 96 106 is indi cated Check throttle position sen sor signal 2 Execute the diagnostic mode Code No 13 When the throttle valves are fully closed A value of 9 23 is indicated When the throttle valves are fully open A value of 94 108 is indi cated An indicated value is out of the specified range Replace the thro...

Page 380: ...n of main switch Improperly connected Turn the main switch to ON coupler Connect the coupler securely and then extend and retract Check the locking condition or replace the wire harness the sidestand of the coupler Fault code number is not dis Disconnect the coupler and played Service is finished check the pins bent or bro Fault code number is dis ken terminals and locking played Go to item 4 cond...

Page 381: ... sensor 2 Item when the main switch is turned to ON the intake air pres sure sensor 1 voltage and intake air pressure sensor 2 volt age differ greatly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 04 03 Meter display Displays the intake air pressure Procedure Shift the transmission into gear extend the sidestand and then operate the throttle while pushing the si...

Page 382: ... 0 mmHg 20 7 inHg Displayed value is incorrect Check the intake air pres sure sensor 1 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 109 2 Defective intake air pressure Execute the diagnostic Turn the main switch to ON sensor 2 mode Code No 04 Fault code number is not dis When engine is stopped played Service is finished Atmospheric pressure at the Fault code numb...

Page 383: ...connected Turn the main switch to ON ECU coupler Connect the coupler securely Fault code number is not dis Check the locking condition or replace the wire harness played Service is finished of the coupler Fault code number is dis Disconnect the coupler and played Go to item 3 check the pins bent or bro ken terminals and locking condition of the pins 3 Wire harness continuity Open or short circuit ...

Page 384: ... No 05 Meter display Displays the air temperature Procedure Compare the actually measured air temperature with the meter display value Item Probable cause of Maintenance job Confirmation of service malfunction and check completion 1 Connection of intake air tern Improperly connected Turn the main switch to ON perature sensor coupler Connect the coupler securely Fault code number is not dis Check t...

Page 385: ... is not dis Check for looseness or sensor played Service is finished pinching Fault code number is dis played Go to item 5 5 Defective intake air tempera Execute the diagnostic Turn the main switch to ON ture sensor mode Code No 05 Fault code number is not dis When engine is cold played Service is finished Displayed temperature is Fault code number is dis close to the ambient temper played Go to i...

Page 386: ...ode number is dis condition of the pins played Go to item 3 3 Connection of wire harness Improperly connected Start the engine warm it up ECU coupler Connect the coupler securely and then race it or execute Check the locking condition or replace the wire harness the diagnostic mode Code of the coupler No 63 Disconnect the coupler and Fault code number is not dis check the pins bent or bro played S...

Page 387: ... unit on page 8 93 Fault code No 25 Item Intake air pressure sensor 2 open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 04 Meter display Displays the intake air pressure Procedure Shift the transmission into gear extend the sidestand and then operate the throttle while pushing the i side of the starVengine stop switch If the display value...

Page 388: ...ntinuity Open or short circuit Turn the main switch to ON Replace the wire harness Fault code number is not dis Between intake air pressure played Service is finished sensor 2 coupler and ECU Fault code number is dis coupler played Go to item 4 pink white pink white Between intake air pressure sensor 2 coupler and joint connector blue blue black blue black blue Between joint connector and ECU coup...

Page 389: ... Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor 2 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 109 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 TIP If fault code numbers ...

Page 390: ...is played Go to item 2 2 Defective intake air pressure Execute the diagnostic sensor 2 mode Code No 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 It above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 It above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ...

Page 391: ...switch to ON angle sensor and condition of the sensor then to OFP and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor Execute the diagnostic Turn the main switch to ON mode Code No 08 then to OFP and then back Replace if defective to ON Refer to CHECKING THE Fault code number is not dis LEAN ANGLE SE...

Page 392: ...ocking condition or replace the wire harness Fault code number is not dis of the coupler played t Service is finished Disconnect the coupler and Fault code number is dis check the pins bent or bro played t Go to item 3 ken terminals and locking condition of the pins 3 Wire harness continuity Open or short circuit t Start the engine and let it idle Replace the wire harness for approximately 5 secon...

Page 393: ...ly connected Start the engine and let it idle ignition coil coupler Connect the coupler securely for approximately 5 seconds Check the locking condition or replace the wire harness Fault code number is not dis of the coupler played Service is finished Disconnect the coupler and Fault code number is dis check the pins bent or bro played Go to item 2 ken terminals and locking condition of the pins 2...

Page 394: ...CU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 35 Item Cylinder 3 ignition coil open or short circuit detected in the primary lead of the cyllnder 3 Ignition coll Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 32 Actuation Actuates the cylinder 3 ign...

Page 395: ...d let it idle der 3 ignition coil coil Reinstall or replace for approximately 5 seconds Check for looseness or the ignition coil Fault code number is not dis pinching played t Service is finished Fault code number is dis played t Go to item 5 5 Defective cylinder 3 ignition Measure the primary coil Start the engine and let it idle coil resistance of the cylinder 3 for approximately 5 seconds ignit...

Page 396: ...n page 8 111 2 Connection of injector 1 2 Improperly connected Execute the diagnostic and or injector 3 coupler Connect the coupler securely mode Code Nos 36 37 Check the locking condition or replace the wire harness 38 of the coupler No operating sound Go to Disconnect the coupler and item 3 check the pins bent or bro Operating sound Go to ken terminals and locking item 7 condition of the pins 3 ...

Page 397: ...lt code number is not displayed Fault code No 41 Item Lean angle sensor open or short circuit detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 08 Meter display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of Maintenance job Confirmation of...

Page 398: ...en played Service is finished Between lean angle sensor Fault code number is dis coupler and joint connector played Go to item 4 blue blue black blue black blue Between joint connector and ECU coupler blue blue black blue black blue 4 Defective lean angle sensor Execute the diagnostic Turn the main switch to ON mode Code No 08 then to OFP and then back Replace if defective to ON Refer to CHECKING ...

Page 399: ...rrect indication 4 Go to gear with the clutch lever item 2 in section C for the squeezed and the sidestand clutch switch retracted ON 2 Connection of speed sensor Improperly connected 4 Execute the diagnostic coupler Connect the coupler securely mode Code No 07 Check the locking condition or replace the wire harness Rotate the rear wheel by of the coupler hand and check that the indi Disconnect th...

Page 400: ...oes not increase Between joint connector and Go to item 5 ECU coupler blue blue black blue black blue 5 Malfunction in ECU Replace the ECU Go to item 6 and delete the Refer to REPLACING THE fault code ECU engine control unit on page 8 93 6 Delete the fault code Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the ve...

Page 401: ...di cated value increases Execute the diagnostic Incorrect indication t Go to mode Code No 21 item 2 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF When the transmission is in Incorrect indication Go to gear with the clutch lever item 2 in section C for the squeezed and the sidestand clutch switch is retracted ON 2 Connection of neutral sw...

Page 402: ... No 21 Between relay unit coupler When the transmission is in and gear position sensor neutral ON coupler When the transmission is in sky blue sky blue gear with the clutch lever Between relay unit coupler released OFF and ECU coupler Correct indication t Go to black yellow black yellow item 9 Incorrect indication t Go to item 5 5 Defective relay unit Check the relay unit Execute the diagnostic Re...

Page 403: ...n page 8 93 9 Delete the fault code Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 19 mi h The fault code can also be delete by activating the diag nostic mode and selecting diagnostic code number 63 Fault code No 42 A Speed sensor no normal signals are received from the speed sensor I...

Page 404: ... neutral ON When the transmission is in gear with the clutch lever released OFF When the transmission is in Incorrect indication Go to gear with the clutch lever item 2 squeezed and the sidestand retracted ON 2 Clutch lever adjustment Refer to ADJUSTING THE Execute the diagnostic CLUTCH LEVER FREE mode Code No 21 PLAY on page 3 11 When the clutch lever is released OFF When the clutch lever is sque...

Page 405: ...en ECU coupler and When the clutch lever is relay unit coupler released OFP black yellow black yellow When the clutch lever is Between relay unit coupler squeezed ON and clutch switch coupler Correct indication Go to black yellow black yellow item 9 black red black red Incorrect indication t Go to item 6 6 Defective relay unit Check the relay unit Execute the diagnostic Refer to CHECKING THE mode ...

Page 406: ...ge Approximately 12 0 Procedure Set the start engine stop switch to and then compare the actually measured battery voltage with the meter display value If the actually measured battery voltage is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals Illuminates the engine trouble warning light Procedure Check that the relay unit is actuated five times by ...

Page 407: ...ed played t Go to item 4 Between starter relay fuel injection system fuse and relay unit coupler red red Between relay unit coupler and ECU coupler red blue red blue blue yellow blue yellow 4 Defective relay unit Execute the diagnostic Start the engine and let it idle mode Code No 50 for approximately 5 seconds No operating sound Fault code number is not dis Replace the relay unit played t Service...

Page 408: ...ot dis EEPROM data error for ISC played Service is finished idle speed control learning Fault code number is dis values played Repeat item 1 If the same number is indi cated go to item 3 3 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagn...

Page 409: ...rform this proce dure with the main switch turned to ON Fault code No 59 Item Accelerator position sensor open or short circuit detected Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 14 15 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully open position Procedure Check with throttle grip in fully closed posi...

Page 410: ... the pins bent or bro ken terminals and locking condition of the pins 3 Wire harness continuity Open or short circuit Turn the main switch to ON Replace the wire harness Fault code number is not dis Between accelerator posi played Service is finished tion sensor coupler and ECU Fault code number is dis coupler played Go to item 4 black blue black blue white white black black blue blue 4 Installed ...

Page 411: ...ted Check accelerator position sensor signal 2 Execute the diagnostic mode Code No 15 When the throttle grip is fully closed A value of 10 24 is indicated When the throttle grip is fully open A value of 95 109 is indi cated An indicated value is out of the specified range Replace the accelerator posi tion sensor 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on...

Page 412: ...ve fuse Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Wire harness continuity Open or short circuit Turn the main switch to ON Replace the wire harness Fault code number is not dis Between throttle servo motor played Service is finished coupler and ECU coupler Fault code number is dis yellow red yellow red played Go to item 5 yellow white ye...

Page 413: ...ion of wire harness Improperly connected Turn the main switch to ON ECU coupler Connect the coupler securely Fault code number is not dis Check the locking condition or replace the wire harness played Service is finished of the coupler Fault code number is dis Disconnect the coupler and played Go to item 3 check the pins bent or bro ken terminals and locking condition of the pins 3 Wire harness co...

Page 414: ...agnostic tool Err multi function meter display Item Multi function meter signals cannot be transmitted between the ECU and the multi function meter 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 8 79 ...

Page 415: ...FUEL INJECTION SYSTEM 8 80 ...

Page 416: ...EA 27S50 FUEL PUMP SYSTEM EA 275e0 CIRCUIT DIAGRAM Ill I l i I I I I I e I 9 I Ii I I 8 81 FUEL PUMP SYSTEM C T ...

Page 417: ...tion fuse 13 Battery 14 Engine ground 15 Fuel injection system fuse 18 Joint connector 20 Relay unit 22 Fuel pump relay 23 ECU engine control unit 60 Fuel pump 62 Right handlebar switch 64 StarVengine stop switch FUEL PUMP SYSTEM 8 82 ...

Page 418: ...engine stop switch Refer to CHECKING THE SWITCHES on page 8 89 OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 97 OK 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP OPERATION on page 7 3 OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 81 OK Replace the ECU Refer to REPLACING THE ECU en gine control unit on page 8 93 NG NG...

Page 419: ...FUEL PUMP SYSTEM 8 84 ...

Page 420: ...ELECTRICAL COMPONENTS EA 27973 ELECTRICAL COMPONENTS 4 5 1 7 17 8 16 10 14 13 8 85 ...

Page 421: ... Fuse box 2 6 Main fuse 7 Fuel injection system fuse 8 Starter relay 9 Rectifier regulator 10 Rear brake light switch 11 Gear position sensor 12 Sidestand switch 13 0 2 sensor 14 0il level switch 15 Ignition coil 16 Radiator fan motor 17 Horn ELECTRICAL COMPONENTS 8 86 ...

Page 422: ...ELECTRICAL COMPONENTS 2 3 4 6 20 19 7 8 10 12 13 8 87 ...

Page 423: ... hazard relay 8 Relay unit 9 Speed sensor 10 Stator coil 11 Crankshaft position sensor 12 Cootant temperature sensor 13 Throttle servo motor 14 Acceterator position sensor 15 Throttle position sensor 16 Intake air pressure sensor 1 17 lntake air pressure sensor 2 18 Injector 19 Air induction system solenoid 20 Fuse box 1 ELECTRICAL COMPONENTS 8 88 ...

Page 424: ...F i4 N L J 5 I I i I SIR Bf 1 J 6 I f 11 1 I 7 I I us 4 B I I 6 I i it I I B I L J 8 89 ELECTRICAL COMPONENTS 8 9 Dg Br W Ch OFF ON MV VII B Bl Bili RN RIB L W B OFF RUN START Dg B Ch B l 10 W t G Btw FREE PUSH ________________________________ J 11 BJ 8Jl I I 12 11 111 13 I Br 1 1 MYlt Br y __________J y I J ...

Page 425: ...gnal switch 4 Horn switch 5 Clutch switch 6 Oil level switch 7 Sidestand switch 8 Hazard switch 9 Start engine stop switch 10 Drive mode switch 11 Front brake light switch 12 Main switch 13 Rear brake light switch ELECTRICAL COMPONENTS 8 90 ...

Page 426: ...ge When checking for continuity switch back and forth between the switch positions a few times a oo The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch posi...

Page 427: ...lb gets extremely hot ELECTRICAL COMPONENTS keep flammable products and your hands away from the bulb until it has cooled down NOTICE Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the lif...

Page 428: ... C b If the pocket tester indicates oo replace the fuse ELECTRICAL COMPONENTS 3 Replace Blown fuse YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Fuses Amperage Q ty rating Main 50A 1 Headlight...

Page 429: ...he balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VALA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VALA ELECTRICAL COMPONENTS Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged th...

Page 430: ...cle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads 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 ch...

Page 431: ...Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging ELECTRICAL COMPONENTS c Make sure th...

Page 432: ... 3 1 2 A 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 8 97 ELECTRICAL COMPONENTS Relay unit starting circuit cut off relay 3 1 2 4 I I I I Ill II R LAV I I RS I tJYIRW L0 BR Sb 1 Posttive battery terminal 2 Negative battery terminal 3 Posttive tester probe 4 Negative tester probe Result Continui...

Page 433: ...ired Turn signaVhazard relay input voltage DC 12V ELECTRICAL COMPONENTS TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Connect the pocket tester DC 20 V to the tum signal hazard relay terminal as shown Pocket tester 90890 03112 Analog pocket tester VU 03112 C Positive tester probe blue red 1 Negative tester probe Ground UR 1 b Turn the main switch to ON c Measure the tum signal hazard relay input voltage 2 Ch...

Page 434: ...tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blue 1 Continuity Positive tester probe blue black 5 Ne...

Page 435: ...heck Secondary coil resistance Out of specification Replace ELECTRICAL COMPONENTS Secondary coil resistance 9 35 12 65 kn TTYTTTYTTTTTTTTYTTTTTTTTYTTTYTTT a Connect the pocket tester n x 1 k to the ig nition coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe red black 1 Positive tester probe spark plug terminal 2 D b Measure the secondary coil resistance ...

Page 436: ...ster 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gray 1 Negative tester probe black 2 ELECTRICAL COMPONENTS 1 y B 2 b Measure the crankshaft position sensor re sistance CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the fuel tank bracket 2 Check Lean angle sensor output voltage Out of specification Replace Lean angle sensor output voltage Less than 65 0 4 1 4 ...

Page 437: ...ble gas or fluid is in the vicinity b Check the starter motor operation ELECTRICAL COMPONENTS CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil Stator coil resistance 0 152 0 228 n W W a Connect the digital circuit tester to the stator coil coupler as shown Digital circuit tester 90890 03174 M...

Page 438: ...ator Regulated voltage DC 14 3 14 7 v TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a Set the engine tachometer to the ignition coil of cylinder 1 b Connect the pocket tester DC 20 V to the battery as shown ELECTRICAL COMPONENTS Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe 4 positive battery terminal 1 Negative tester probe 4 negative battery terminal 2 s C c Start the engine...

Page 439: ...nector gray 1 Negative tester probe Body earth 2 ELECTRICAL COMPONENTS Maximum level position B Positive tester probe Connector gray 1 Negative tester probe Body earth 2 ID 2 1 b Measure the oil level switch resistance CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler from the fuel pump 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance Out of specificati...

Page 440: ...cuit 1 Check Oil level warning light 1 Tum the main switch to ON Warning light comes on for a few seconds then goes off 4 Warning light is OK Warning light does not come on 4 Replace the meter assembly Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunc tion detected in oil level switch 4 Replace the oil level switch CHECKING THE SPEED SENSOR 1 Check Speed sen...

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Page 442: ... tester probe 4 black blue 2 ELECTRICAL COMPONENTS b Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor TIP When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle bodies EWA1FCl106 A WA...

Page 443: ... operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor ELECTRICAL COMPONENTS 3V 3V A Check that the throttle valves 2 open B Check that the throttle valves 2 fully close CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification t Replace Solenoid resistance 20 24 0 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a...

Page 444: ...tive tester probe pink wire harness color intake air pres sure sensor 1 pink white wire harness color intake air pressure sensor 2 Negative tester probe black blue wire harness color ELECTRICAL COMPONENTS A Intake air pressure sensor 1 B Intake air pressure sensor 2 c Set the main switch to ON d Measure the intake air pressure sensor out put voltage CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Rem...

Page 445: ...specification Replace the gear posi tion sensor Pocket tester 90890 03112 Analog pocket tester YU 03112 C 8 110 ELECTRICAL COMPONENTS Result Neutral position Continuity Positive tester probe sky blue 1 Negative tester probe Sensor terminal a 1st position Continuity Positive tester probe white 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe pink 3 Negative te...

Page 446: ...ification Replace the fuel injec tor l I Resistance 12 0 Q a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket tester Q x 10 to the fuel injector coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 1 2 c Measure the fuel injector resistance 8 111 ELECTRICAL COMP...

Page 447: ...EED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 EVENT CODE TABLE 9 12 ...

Page 448: ...Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 9 1 TROUBLESHOOTING 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary c...

Page 449: ...orks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog 9 2 TROUBLESHOOTING FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Unevenly t...

Page 450: ... Bent or damaged damper rod 9 3 TROUBLESHOOTING Incorrect oil viscosity Incorrect oil level UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork leg...

Page 451: ...rness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect tum signal bulb Turn signal remains lit Faulty turn signal hazard relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect tum signal bulb Faulty turn signal hazard relay Burnt out turn signal ...

Page 452: ...the 0 2 sensor 8 50 25 Intake air pressure sensor 2 open or short circuit detected 8 52 26 Intake air pressure sensor 2 hose system malfunction clogged or 8 54 detached hose 30 Latch up detected 8 56 33 Cylinder 1 ignition coil open or short circuit detected in the primary 8 56 lead of the cylinder 1 ignition coil 34 Cylinder 2 ignition coil open or short circuit detected in the primary 8 58 lead ...

Page 453: ...ignal 1 Fully closed position 11 21 Check with throttle valves fully closed Fully open position 96 106 Check with throttle valves fully open 03 Intake air pressure 1 Displays the intake air Shilt the transmission into pressure gear extend the sides tand and then operate the throttle while pushing the J side of the start engine stop switch If the display value changes the perfor mance is OK 04 Inta...

Page 454: ...5 degrees Overturned 3 7 4 4 09 Fuel system voltage Fuel system voltage Set the start engine stop battery voltage Approximately 12 0 switch to and then compare the actually mea sured battery voltage with the meter display value If the actually measured bat tery voltage is low recharge the battery 13 Throttle position sensor signal 2 Fully closed position 9 23 Check with throttle valves fully close...

Page 455: ...r is ON squeezed with the transmission in gear and when the sides tand is retracted Clutch lever is OFF squeezed with the transmission in gear and when the sides land is extended 60 EEPROM fault code dis play No history 00 No malfunctions detected If the sell diagnosis fault code 44 is indicated the ECU is defective History exists 01 03 Cylinder fault code If more than one cylin der is defective t...

Page 456: ...plays the total num To erase the history set bar of malfunctions the start engine stop including the current switch from l l to malfunction that have occurred since the his tory was last erased For example if there have been three mal functions 03 is dis played 63 Malfunction code rein statement for fault code No 24 42 only No malfunction code 00 Malfunction code exists Fault code 24 42 To reinsta...

Page 457: ...31 Cylinder 2 ignition coil Actuates the cylinder 2 Check that a spark is gen ignition coil five times at erated five times one second intervals Connect an ignition Illuminates the engine checker trouble warning light 32 Cylinder 3 ignition coil Actuates the cylinder 3 Check that a spark is gen ignition coil five times at erated five times one second intervals Connect an ignition Illuminates the e...

Page 458: ...lay unit is times at one second inter actuated five times by lis vals tening for the operating 1 lluminates the engine sound trouble warning light 51 Radiator fan motor relay Actuates the radiator fan Check that the radiator fan motor relay five times at motor relay is actuated five second intervals five times by listening for 1 lluminates the engine the operating sound trouble warning light 52 He...

Page 459: ...U black red No 19 lead input line 196 Coolant temper Brief abnormality Same as fault code 21 Perform the inspection ature sensor detected a in the items listed for fault code coolant tempera No 21 ture sensor 197 Intake air tern Brief abnormality Same as fault code 22 Perform the inspection perature sensor detected in the items listed for fault code intake air tempera No 22 ture sensor 199 Intake ...

Page 460: ... to lower limit for ment is maintained ness between the that first adjustment at the lower limit sensor and ECU Rarely Code 241 Drop in fuel pres occurs even when the sure system is functioning Clogged fuel injec properly tor Fault in sensor Malfunction in ECU Malfunction in the fuel injection sys tern 242 ISC During idling the Idling engine speed is Implement diagnosis Stuck at the adjustment is ...

Page 461: ... in ECU 244 Poor start Poor starting inabil No gasoline If a fault code is ing inability to ity to start detected Malfunction in the occurring respond to start fuel injection sys that first tem Rarely Code 244 Dirty or worn spark occurs even when the plug system is functioning Malfunction in the properly battery Malfunction in ECU 245 Engine stop Engine stop No gasoline If a fault code is detected...

Page 462: ...EVENT CODE TABLE 9 15 ...

Page 463: ... Right turn signal indicator light 57 Oil level switch 58 Gear position sensor 59 Fuel sender 60 Fuel pump 61 Sidestand switch 62 Right handlebar switch 63 Drive mode swttch 64 Start engine stop switch 65 Ha2ard switch 66 Front brake light switch 67 Rear brake light switch 68 Turn signal hazard relay 69 Left handlebar switch 70 Clutch switch 71 Horn 72 Horn switch 73 Turn signal switch 74 Pass swi...

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