Yamaha FZ6-SS, Service Manual

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Page 2: ...by Yamaha Motor Corporation U S A First edition November 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly pro...

Page 3: ...policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to i...

Page 4: ...e top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify par...

Page 5: ...rical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16...

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

Page 7: ...CK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2...

Page 8: ...3 11 ADJUSTING THE VALVE CLEARANCE 3 11 SYNCHRONIZING THE THROTTLE BODIES 3 17 ADJUSTING THE ENGINE IDLING SPEED 3 19 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 20 CHECKING THE SPARK PLUGS 3 22 MEASURI...

Page 9: ...HE LEVERS AND PEDALS 3 57 LUBRICATING THE SIDESTAND 3 57 LUBRICATING THE CENTERSTAND 3 57 LUBRICATING THE REAR SUSPENSION 3 58 ELECTRICAL SYSTEM 3 59 CHECKING AND CHARGING THE BATTERY 3 59 CHECKING TH...

Page 10: ...BRAKE CALIPERS 4 40 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4 41 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4 43 FRONT FORK 4 45 FRONT FORK LEGS 4 45 REMOVING THE FRONT FORK LEGS 4 48...

Page 11: ...TIMING CHAIN GUIDES 5 14 CHECKING THE TIMING CHAIN TENSIONER 5 14 INSTALLING THE CAMSHAFTS 5 15 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE CYLIN...

Page 12: ...1 CHECKING THE CLUTCH BOSS 5 51 CHECKING THE PRESSURE PLATE 5 51 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 52 INSTALLING THE CLUTCH 5 52 OIL PAN AND OIL PUMP 5 55 REMOVING THE OIL PAN 5 58 CHECKING...

Page 13: ...CRANKSHAFT JOURNAL BEARINGS 5 88 INSTALLING THE CRANKSHAFT 5 91 TRANSMISSION 5 92 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 92 REMOVING THE TRANSMISSION 5 98 CHECKING THE SHIFT FORKS 5 98 CH...

Page 14: ...FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 29 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 30 AIR INDUCTION SYSTEM 7 32 AIR INJECTION 7 32 AIR CUT OFF VALVE 7 32 AIR INDUCTION SYSTEM DIAGR...

Page 15: ...HECKING THE LIGHTING SYSTEM 8 31 SIGNALING SYSTEM 8 34 CIRCUIT DIAGRAM 8 34 TROUBLESHOOTING 8 36 CHECKING THE SIGNALING SYSTEM 8 36 COOLING SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 44 FUEL P...

Page 16: ...S 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 FAULTY LIGHTING OR SIGNALI...

Page 17: ...TORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is af...

Page 18: ...erating conditions such as acceleration deceleration or operating under a heavy load Carburetors that me ter the fuel through the use of jets have been provided with various auxiliary devices so that...

Page 19: ...e manifold only during the time the passage remains open Therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied Con versel...

Page 20: ...tachometer mode E is the following order ODO TRIP 1 TRIP 2 TRIP F E ODO When approximately 3 6 L of fuel remain in the fuel tank the bottom segment of the fuel meter will start flashing and the odome...

Page 21: ...ton together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET b...

Page 22: ...isassembly clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any s...

Page 23: ...are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the beari...

Page 24: ...Connect and disconnect sev eral times 3 Check Sall connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect Slead Scoupler Sconnector Make sure all...

Page 25: ...s used to remove the generator ro tor 90890 01701 YS 01880 A Sheave holder This tool is used to hold the generator rotor when removing or installing the generator ro tor bolt or pickup coil rotor bolt...

Page 26: ...on gauge Adapter These tools are used to measure engine compression 90890 03112 YU 3112 Pocket tester This tool is used to check the electrical sys tem Oil pressure gauge 90890 03153 YU 03153 Adapter...

Page 27: ...his tool is needed to remove and install the valve lifter 90890 04111 Valve guide remover 4 This tool is used to remove or install the valve guides 90890 04112 Valve guide installer 4 This tool is use...

Page 28: ...Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 095 mm 82 5 in 750 mm 29 5 in 1 215 mm 47 8 in 795 mm 31 3 in 1 440 mm 56 7 in 145 mm 5 71 in 2 800 mm 110 2 in SSS SSS SSS SSS...

Page 29: ...serve Reserve only Unleaded gasoline only 19 4 L 4 25 lmp gal 5 1 US gal 3 6 L 0 79 lmp gal 0 9 US gal SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filte...

Page 30: ...opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 0 L 1 76 lmp pt 2 11 US qt 93 3 X 122 7 kPa 0 93 X 1...

Page 31: ...be dimensions Measurement A Measurement B Max camshaft runout Chain drive right 23 008 X 23 029 mm 0 9058 X 0 9067 in 22 967 X 22 980 mm 0 9042 X 0 9047 in 0 028 X 0 062 mm 0 0011 X 0 0024 in 32 45 X...

Page 32: ...stem runout Valve seat width Intake Exhaust 24 9 X 25 1 mm 0 9803 X 0 9882 in 21 9 X 22 1 mm 0 8622 X 0 8701 in 1 14 X 1 98 mm 0 0449 X 0 0780 in 1 14 X 1 98 mm 0 0449 X 0 0780 in 0 9 X 1 1 mm 0 0354...

Page 33: ...in 32 5 mm 1 28 in 36 1 mm 1 42 in 69 0 X 79 0 N 7 03 X 8 05 kg 15 50 X 17 75 lb 114 0 X 132 0 N 11 62 X 13 46 kg 25 63 X 29 67 lb 160 X 184 N 16 32 X 18 76 kg 35 97 X 41 36 lb SSS SSS SSS Counter cl...

Page 34: ...004 X 0 0014 in 65 475 X 65 490 mm 2 5778 X 2 5783 in 4 mm 0 16 in 16 002 X 16 013 mm 0 6300 X 0 6304 in 0 5 mm 0 0197 in Intake side 15 991 X 16 000 mm 0 6296 X 0 6299 in 0 002 X 0 022 mm 0 0001 X 0...

Page 35: ...rown 4 Green SSS SSS 0 03 mm 0 0012 in SSS SSS SSS 0 10 mm 0 0039 in SSS Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clu...

Page 36: ...02 mm 0 0008 in 0 02 mm 0 0008 in Shifting mechanism Shift mechanism type Max shift fork guide bar bending Shift drum Guide bar SSS SSS 0 05 mm 0 002 in Air filter type Oil coated paper element SSS F...

Page 37: ...vel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 M C MT5 50 Aluminum 130 mm 5 12 in SSS SSS SSS SSS SSS SSS 1 mm 0 04 in 0 5 mm 0 02 in Front tire Tire type Size Model m...

Page 38: ...ss Max deflection Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm 11 73 0 20 in SSS SSS 6 0 mm 0 24 in 1...

Page 39: ...uantity each front fork leg Level from the top of the inner tube with the inner tube fully compressed and without the fork spring Telescopic fork Coil spring oil damper 130 mm 5 12 in 354 0 mm 13 94 i...

Page 40: ...d adjusting positions Minimum Standard Maximum Swingarm monocross Coil spring gas oil damper 50 mm 1 97 in 185 0 mm 7 28 in 172 0 mm 6 77 in 127 4 N mm 12 99 kg mm 727 45 lb in 0 X 50 mm 0 00 X 1 97 i...

Page 41: ...harging system System type Model manufacturer Normal output Stator coil resistance color A C magneto F5VX MORIC 14 V 310 W at 5 000 r min 0 22 X 0 34 at 20_C 68_F W W SSS SSS SSS SSS Rectifier regulat...

Page 42: ...7 16 X 9 52 N 730 X 971 g 25 77 X 34 27 oz 0 0012 X 0 0022 at 20_C 68_F 28 mm 1 1 in 0 7 mm 0 03 in SSS SSS SSS 3 5 mm 0 14 in SSS SSS 27 mm 1 06 in SSS Starter relay Model manufacturer Amperage Coil...

Page 43: ...Fuel level sender Model manufacture Sender unit resistance full Sender unit resistance empty 5VX DENSO 20 X 26 134 X 140 SSS SSS SSS Starting circuit cut off relay Model manufacture Coil resistance G8...

Page 44: ...0 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 ftSlb 4 3 11 22 40 61 94 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specific...

Page 45: ...pump Bolt M6 2 12 1 2 8 7 Thermo sensor Bolt M12 1 18 1 8 13 Coolant hose drain bolt water pump Bolt M6 1 10 1 0 7 2 Radiator and frame Bolt M6 2 7 0 0 7 5 1 Radiator stay and crankcase Bolt M6 1 10 1...

Page 46: ...eather hose cover Bolt M6 4 12 1 2 8 7 Oil pipe Bolt M6 2 12 1 2 8 7 Crankshaft position sensor Bolt M6 2 10 1 0 7 2 Starter clutch Screw M8 3 32 3 2 23 Starter motor cover bolt Bolt M6 2 3 4 0 34 2 5...

Page 47: ...2 20 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence...

Page 48: ...0 See NOTE 2 Engine mount self locking nut upper M10 55 5 5 40 Engine mount self locking nut lower M10 55 5 5 40 Fornt frame and rear frame upper M10 41 4 1 30 Front frame and rear frame lower M10 41...

Page 49: ...2 Rear brake caliper bolt front and rear brake caliper bracket M8 27 2 7 20 Rear brake caliper bolt rear and rear brake caliper bracket M8 22 2 2 16 Rear wheel sprocket and rear wheel drive hub M10 10...

Page 50: ...pump rotors inner and outer Oil pump housing Oil strainer Clutch pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main ax...

Page 51: ...ivoting point and metal to metal moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point...

Page 52: ...2 25 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Oil cooler COOLING SYSTEM DIAGRAMS...

Page 53: ...2 26 COOLING SYSTEM DIAGRAMS SPEC 1 Water pump 2 Oil cooler 3 Radiator...

Page 54: ...2 27 COOLING SYSTEM DIAGRAMS SPEC 1 Oil cooler 2 Water pump...

Page 55: ...2 28 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Thermostat...

Page 56: ...2 29 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART...

Page 57: ...2 30 LUBRICATION DIAGRAMS SPEC 1 Oil level switch 2 Oil cooler 3 Relief valve LUBRICATION DIAGRAMS...

Page 58: ...2 31 LUBRICATION DIAGRAMS SPEC 1 Oil pump 2 Exhaust camshaft 3 Intake camshaft 4 Oil strainer...

Page 59: ...2 32 LUBRICATION DIAGRAMS SPEC 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump...

Page 60: ...2 33 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Oil pump 3 Relief valve...

Page 61: ...2 34 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft...

Page 62: ...2 35 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Drive axle...

Page 63: ...down to the length of 1 to 5 mm 0 04 to 0 20 in C Route the horn lead by the headmost side D Pass the throttle cables wire harness lead clutch cable main switch and immobilizer lead and left handleba...

Page 64: ...nner tube Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm 0 04 to 0 20 in G Pass the throttle cables through the wire guide Route the right...

Page 65: ...hoses 2 pieces under the cover 2 E Route the crank shaft position sensor lead inner side of the radiator hose F Pull down the mark painted sections of the fuel tank breather hose fuel tank drain hose...

Page 66: ...l the right handlebar switch lead coupler through the hole of the bracket 2 from the downside L Route the starter motor lead by the inner side of the air cut off valve hose M Pass the ignition coil le...

Page 67: ...able pull side 25 Radiator fan motor lead 26 Oil level gauge lead 27 Sidestand switch lead 28 A C magneto lead 29 Speed sensor lead 1 Main switch lead 2 Stay assembly 3 Left handlebar switch lead 4 Cl...

Page 68: ...he leads are not crossed K Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the brack et Pull out the lead sufficiently to the frame side and route it along...

Page 69: ...the tip to be between 1 and 5 mm 0 04 and 0 20 in R To the rear turn signal light left S Pass the fuel tank drain hose through the clamp lo cated under the coolant reservoir tank T Route it behind the...

Page 70: ...24 Spark plug lead 25 Air cut off valve hose 1 Right handlebar switch lead 2 Throttle cables 3 Battery positive lead 4 Coolant reservoir tank hose 5 Battery cover 6 Connecter cover 7 Fuel tank breathe...

Page 71: ...or lead and crank shaft posi tion sensor lead Point the projected part of the tip to the inner side of the vehicle G Pass the radiator hose coolant reservoir hose wire harness and starter motor lead i...

Page 72: ...3 under the air cut off valve hose AK Route the spark plug lead 2 behind the air cut off valve hose CABLE ROUTING SPEC S To the license plate light T To the tail brake light U Insert the enwinding cla...

Page 73: ...2 46 CABLE ROUTING SPEC AL Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 AM Route the spark plug leads 2 and 3 behind the air cut off valve hose...

Page 74: ...e used at the time of work E It prevents that this portion falls out 2 The clamp is attached from the bottom after the work of 1 It checks being completely equipped with and section A B C 1 Fuel pump...

Page 75: ...close to direction of which All notches gear at the time of attachment G Pass the coolant reservoir tank hose inside of the clamp H Insert in certainly I To the fuel tank drain tube J Air opening K T...

Page 76: ...b of the clip upward The application of water is possible at the time of attachment G Pass the balance hose under the canister hose H Insert this portion securely I Spittle is turned back J Insert to...

Page 77: ...drain hose inside of the clamp N Point the knob of clamp downward O Point the knob of clamp upward P Insert in certainly Q To the fuel tank drain tube R Point the paint marking both white front side...

Page 78: ...onization 6 Exhaust system See page 3 36 S Check for leakage S Tighten if necessary S Replace gasket s if necessary 7 Evaporative emission control system For California only S Check control system for...

Page 79: ...ary 17 Front fork See page 3 53 S Check operation and for oil leakage S Replace if necessary 18 Shock absorber assembly See page 3 54 4 65 S Check operation and for oil leakage S Replace if necessary...

Page 80: ...3 3 SEAT CHK ADJ Order Job Part Q ty Remarks 1 Removing the seat Seat 1 Remove the parts in the order listed For installation reverse the removal procedure EAS00038 SEAT...

Page 81: ...coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose except for CAL Canister hose for CAL Fuel tank Fuel pump 1 1 1 1 1 1 1 Remove the parts in the order listed Disconnect Refer to...

Page 82: ...K CHK ADJ Order Job Part Q ty Remarks 8 Roll over valve for CAL 1 For installation reverse the removal procedure Refer to the CABLE ROUTING for how to attach a hose 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mS...

Page 83: ...n ing in it STo remove the fuel hose from the fuel injection pipe slide the cover a on the end of the hose in the direction of the arrow shown and then re move the hose SBefore removing the hoses plac...

Page 84: ...uel hose make sure that it is securely connected and that the fuel hose holders are in the correct position otherwise the fuel hose will not be properly installed Install the fuel hose connector secur...

Page 85: ...nt cowling Rear view mirrors left and right Windshield Rear cowling Frame side cover 2 2 1 2 1 1 2 Remove the parts in the order listed Refer to SEAT Disconnect For installation reverse the removal pr...

Page 86: ...oosen Disconnect Disconnect Disconnect For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb Removing the air filter case Seat Front cowling inner panel left and right Fuel tank Intak...

Page 87: ...ery box Battery box bracket Ignition coil assembly 1 3 2 Remove the parts in the order listed This part has to be set properly For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb 7...

Page 88: ...inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sbattery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Sair filter case Refer to AIR FILTER CASE Sbattery box Sbatt...

Page 89: ...on stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading...

Page 90: ...ve pad from falling into the crankcase SMake a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the fol...

Page 91: ...ect is the new valve pad number The new valve pad number is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorre...

Page 92: ...SFirst install the exhaust camshaft SAlign the camshaft marks with the camshaft cap marks STurn the crankshaft counterclockwise several full turns to seat the parts g Measure the valve clearance again...

Page 93: ...215 220 225 230 235 240 0 96 X 1 00 200 205 210 215 220 225 230 235 240 1 01 X 1 05 205 210 215 220 225 230 235 240 1 06 X 1 10 210 215 220 225 230 235 240 1 11 X 1 15 215 220 225 230 235 240 1 16 X 1...

Page 94: ...ould be checked 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand 2 Remove Sseat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank R...

Page 95: ...the air screws 1 1 2 2 3 3 4 4 5 SAfter each step rev the engine two or three times each time for less than a second and check the synchronization again SIf the air screw is removed turn the screw 3...

Page 96: ...et it warm up for several minutes 2 Check Sengine idling speed Out of specification Adjust Engine idling speed 1250 X 1350 r min 3 Adjust Sengine idling speed a Turn the idle adjusting screw 1 in dire...

Page 97: ...ght Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE Sbattery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 3 Adjust Sthrottle cable free play When t...

Page 98: ...e cable free play is decreased c Tighten the locknut 4 Install Sbattery assembly Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Sair filter case Refer to AIR FILTER CASE Sfuel tank Refer to F...

Page 99: ...ay any dirt accumulated in the spark plug wells with compressed air to prevent it from fal ling into the cylinders 3 Check Sspark plug type Incorrect Change Spark plug type manufacturer CR9EK NGK 4 Ch...

Page 100: ...pressure will result in a loss of performance 1 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and the...

Page 101: ...inimum 1 350 kPa 13 50 kg cm2 13 50 bar 191 87 psi Standard 1 550 kPa 15 50 kg cm2 15 50 bar 220 46 psi Maximum 1 736 kPa 17 36 kg cm2 17 36 bar 246 92 psi a Turn the main switch to ON b With the thro...

Page 102: ...out oil Piston ring s wear or damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly defective Repair 7 Install Sspark plug 8 Install Sspark plug caps Signition coils...

Page 103: ...he engine warm it up for several min utes and then turn it off 3 Check Sengine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum leve...

Page 104: ...turn it off 5 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled EAS00074 CHANGING THE ENGINE OIL 1 Start the engine warm it up for sev...

Page 105: ...g 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Oil filter cartridge 17 Nm 1 7 mSkg 12 ftSlb 6...

Page 106: ...ine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off When the engine is cold the engine...

Page 107: ...essure as its own data may fluctuate depending on the oil temperature and viscosity the oil pressure may fluctuate when measuring The following data should be used only as a reference when measuring t...

Page 108: ...ble free play is increased Direction Clutch cable free play is decreased If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engi...

Page 109: ...l left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK 2 Remove Sair filter case cover 1 Sair filter element 2 3 Clean Sair filter element 2 4 Check Sair filter element Damage Replace 5 Inst...

Page 110: ...ll Sfuel tank Refer to FUEL TANK Sfront cowling inner panel left and right Refer to COWLINGS Srider seat Refer to SEAT EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all...

Page 111: ...rly SBefore removing the fuel hose place a few rags in the area under where it will be re moved SThere is a white mark on the fuel tank breather hose Refer to CABLE ROUTING in chapter 2 3 Install Sfue...

Page 112: ...ove Sradiator Refer to RADIATOR in chapter 6 2 Check Sexhaust pipe 1 Scatalyst pipe 2 Smuffler 3 Cracks damage Replace Sgasket 4 Exhaust gas leaks Replace 3 Check Stightening torque Exhaust pipe nut 5...

Page 113: ...elow the minimum level mark Add the recommended coolant to the proper level SAdding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and...

Page 114: ...oler inlet hose 5 Soil cooler outlet hose 6 Swater jacket outlet joint 7 Swater jacket hose 8 Swater pump outlet pipe 9 Swater pump outlet hose 10 Cracks damage Replace Refer to COOLING SYSTEM in chap...

Page 115: ...he radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his...

Page 116: ...t reservoir capacity 0 27 L 0 24 Imp qt 0 29 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care SIf coolant splashes in your eyes thorough ly wash...

Page 117: ...Sradiator cap 14 Fill Scoolant reservoir tank with the recommended coolant to the maxi mum level mark a 15 Install Scoolant reservoir cap 16 Start the engine warm it up for several min utes and then...

Page 118: ...on 1 Distance is the largest Position 5 Distance is the smallest SAfter adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjust ing...

Page 119: ...pedal is raised Direction Brake pedal is lowered After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specificat...

Page 120: ...the recommended brake fluid to the proper level Recommended brake fluid DOT 4 A Front brake B Rear brake SUse only the designated brake fluid Other brake fluids may cause the rubber seals to deterior...

Page 121: ...to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS00118 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all...

Page 122: ...ody 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on s...

Page 123: ...gthening the bleeding procedure SIf bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappe...

Page 124: ...servoir to the proper lev el with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake operation EAS00136 ADJUSTING THE SHIFT P...

Page 125: ...ace Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel several times and fi...

Page 126: ...serviced especially when the motorcycle is used in dusty areas This motorcycle has a drive chain with small rubber O rings between each side plate Steam cleaning high pressure washing certain sol ven...

Page 127: ...the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Supper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4 4 Adjust Ssteerin...

Page 128: ...hten the upper ring nut 8 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 9 Make sure...

Page 129: ...ove procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head EAS00149 CHEC...

Page 130: ...Adjust the spring preload with a ring nut wrench Ring nut wrench 90890 01268 YU 01268 b Turn the adjusting ring 1 in direction a or b c Align the desired position on the adjusting ring with the stopp...

Page 131: ...ht with oil and a full fuel tank 207 kg 456 lb 208 kg 459 lb for CAL Maximum load 190 kg 419 lb 189 kg 417 lb for CAL Cold tire pressure Front Rear Up to 90 kg 198 lb load 225 kPa 2 25 kgf cm2 2 25 ba...

Page 132: ...ure the wheel rim band and tube are centered in the wheel groove SPatching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as po...

Page 133: ...until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed be fore any high speed riding is done For tires with a direction of rotation mark 1 SInstall the t...

Page 134: ...ricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171...

Page 135: ...CATING THE REAR SUSPENSION CHK ADJ EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfi...

Page 136: ...lectrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL SSkin Wash with water SEyes Flush with water for 15 minutes and get immediate medical atten...

Page 137: ...der seat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative ba...

Page 138: ...e bat tery lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery c...

Page 139: ...checking steps If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current af...

Page 140: ...ging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for m...

Page 141: ...ry leads to the battery terminals First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Sbattery terminals Dirt Clean with a wire brush Loose con nection Connect prope...

Page 142: ...the pocket tester selector to 1 Pocket tester 90890 03112 YU 3112 b If the pocket tester indicates replace the fuse 3 Replace Sblown fuse a Set the main switch to OFF b Install a new fuse of the corr...

Page 143: ...ting other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction a...

Page 144: ...s and your hands away from the bulb until it has cooled down 5 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light...

Page 145: ...adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left...

Page 146: ...ollar left and right Front wheel Front brake disc left and right 2 2 1 2 1 1 2 1 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loo...

Page 147: ...CHAS Order Job Part Q ty Remarks Disassembling the front wheel Oil seal left and right Wheel bearing left and right Spacer 2 2 1 Disassemble the parts in the order listed For assembly reverse the disa...

Page 148: ...the front wheel is elevated 2 Remove Sleft brake caliper Sright brake caliper Do not apply the brake lever when removing the brake calipers 3 Elevate Sfront wheel Place the motorcycle on a suitable st...

Page 149: ...place Radial wheel runout limit 1 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in 4 Check Swheel bearings Front wheel turns roughly or is loose Re place the wheel bearings Soil seals Damage wear...

Page 150: ...all of the brake discs 1 Check Sbrake disc Damage galling Replace 2 Measure Sbrake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflecti...

Page 151: ...ten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 18 Nm 1 8 mSkg 13 ftSlb LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps...

Page 152: ...d in the handlebar several times and check if the front fork rebounds smoothly 6 Install Sbrake calipers left and right Make sure that there is enough space between the brake pads before installing th...

Page 153: ...all the marks come to rest is the front wheel s heavy spot X 3 Adjust Sfront wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X Start with the lightest...

Page 154: ...eel axle Washer Drive chain puller left and right Rear wheel Rear brake caliper bracket 1 2 2 1 1 1 1 2 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the re...

Page 155: ...procket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel 1 1 2 2 2 1 6 1 Remove the parts in the order listed For installation re...

Page 156: ...CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Collar Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly...

Page 157: ...orcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sbrake caliper 1 Do not depress the brake pedal when removing the brake caliper 3 Loosen Slocknut 1 Sadjusting nut 2 4 Remove Sw...

Page 158: ...Measure Sradial wheel runout Slateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Srear wheel drive hub 1 Cracks damage Replace Srear wheel drive...

Page 159: ...heel sprocket self locking nut 100 Nm 10 mSkg 72 ftSlb Tighten the self locking nuts in stages and in a crisscross pattern EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate Swheel axle Swheel bearings So...

Page 160: ...IC BALANCE SAfter replacing the tire wheel or both the rear wheel static balance should be adjusted SAdjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjus...

Page 161: ...ke pad Brake pad spring Bleed screw 1 2 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers For installation reverse the removal procedure NOTE...

Page 162: ...ke pad pin Rear brake caliper Brake pad shim Brake pad Brake screw Brake pad spring 1 1 1 4 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure 3 Nm 0 3 mSkg 2 2...

Page 163: ...ust be disassembled drained cleaned properly filled and bled after reas sembly SNever use solvents on internal brake com ponents SUse only clean or new brake fluid for clean ing brake components SBrak...

Page 164: ...tor 1 Sside reflector bracket left side only 2 Sbrake hose holder 3 Sbrake caliper 4 2 Remove Sbrake pads 1 along with the brake pad shims Sbrake pad shims onto the brake pads Sbrake pad spring 3 Meas...

Page 165: ...ith your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 mSkg 4 3 ftSlb d Install a new brake pad shim onto each new brake pad 5 Install Sbrake caliper 6 Check Sbrake fluid level Below the minim...

Page 166: ...pad spring 4 2 Remove Sbrake pads 1 along with the brake pad shims 3 Measure Sbrake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 1 0 mm 0 04 in 4 Install...

Page 167: ...ew 6 Nm 0 6 mSkg 4 3 ftSlb d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Sbrake pad cover Sbrake caliper front rear Sbrake pad pin Sscrew plug 6 Check Sbrake fluid level Below t...

Page 168: ...older Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead coupler Front brake light switch Union bolt Copper washer Master cylinder holder 1 1 1 1 1 1 1 2 1 Remove the...

Page 169: ...FRONT AND REAR BRAKES CHAS Order Job Part Q ty Remarks 10 Master cylinder assembly 1 For installation reverse the removal procedure 2 Nm 0 2 mSkg 1 4 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 10 Nm 1 0 mSkg 72 f...

Page 170: ...ty Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly revers...

Page 171: ...ear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt Copper washer Brake hose Master cylinder assembly 1 1 1 1 1 1 1 1 1 Remove the parts in the order l...

Page 172: ...rt Q ty Remarks Disassembling the rear brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse...

Page 173: ...der the master cylinder and the end of the brake hose 3 Remove Sbrake lever Smaster cylinder bracket Smaster cylinder assembly 4 Remove Scirclip from the master cylinder assembly Smaster cylinder kit...

Page 174: ...s Cracks damage wear Replace Refer to CHECKING THE FRONT AND REAR BRAKE HOSES in chapter 3 EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove Sunion bolt 1 Scopper washers 2 Sbrake hose 3...

Page 175: ...er kit Scirclip New Sbrake master cylinder 1 SInstall the brake master cylinder holder with the UP mark facing up SAlign the end of the brake master cylinder holder with the punch mark a on the handle...

Page 176: ...e system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the brake master cylinder reser voir Wate...

Page 177: ...re the brake pipe touches the projection a as shown 3 Fill Sbrake fluid reservoir to the maximum level mark a Recommended brake fluid DOT 4 SUse only the designated brake fluid Other brake fluids may...

Page 178: ...hapter 3 5 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust Sbrake pedal positi...

Page 179: ...bracket 1 2 1 1 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For instal...

Page 180: ...rake pad Brake caliper piston Brake caliper piston seal Brake pad spring Bleed screw 2 2 4 1 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake cali...

Page 181: ...id Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal p...

Page 182: ...e pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw 1 1 2 4 1 1 2 1 Disassemble the parts in the order listed For assembly reverse the disass...

Page 183: ...hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blo...

Page 184: ...e end of the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper piston 1 Sbrake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a...

Page 185: ...embled 1 Check Sbrake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Sbrake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Sbrake caliper body 3 Cracks...

Page 186: ...ever use solvents on internal brake com ponents as they will cause the piston seals to swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended br...

Page 187: ...e SWhen refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock Brake fluid...

Page 188: ...swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper 1 front rear Sbrake pad pin Sscrew plug Scopp...

Page 189: ...brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean u...

Page 190: ...bracket pinch bolt Under bracket pinch bolt Front fork leg 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT AND REAR BRAKES Loosen Loosen Loosen For i...

Page 191: ...ring Dust seal Oil seal clip Damper rod assembly bolt Copper washer Damper rod assembly Oil seal Washer 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The following the procedure ap...

Page 192: ...der Job Part Q ty Remarks Inner tube Outer tube bushing Inner tube bushing Oil flow stopper Outer tube 1 1 1 1 1 For assembly reverse the disassembly procedure 13 14 15 16 17 24 Nm 2 4 mSkg 17 ftSlb 2...

Page 193: ...le on a suitable stand so that the front wheel is elevated 2 Loosen Supper bracket pinch bolt 1 Scap bolt 2 Sunder bracket pinch bolt 3 Before loosening the upper and under bracket pinch bolts support...

Page 194: ...mper rod holder 90890 01294 T handle 90890 01326 5 Remove Sinner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tu...

Page 195: ...ication Replace Spring free length 354 mm 13 94 in Limit 347 mm 13 66 in 3 Check Sdamper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Soil flow stopper 2...

Page 196: ...seal before assembling the front fork leg make sure all of the components are clean 1 Install Sinner tube busing Souter tube busing Soil flow stopper Sdamper rod assembly 1 Scopper washer New Always...

Page 197: ...1 with the fork seal driver weight and fork seal driver attachment Make sure the numbered side of the oil seal faces up SBefore installing the oil seal lubricate its lips with lithium soap based grea...

Page 198: ...commended fork oil Other oils may have an adverse effect on front fork performance SWhen disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 Me...

Page 199: ...cap bolt lubricate its O ring with grease b Larger pitch EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Sfront fork leg Temporarily t...

Page 200: ...r switch Throttle grip Throttle cable Front brake light switch connector Front brake master cylinder holder Front brake master cylinder Upper handlebar holder Handlebar 2 1 1 1 1 1 1 1 2 1 1 1 2 1 Rem...

Page 201: ...r grip and gradually push the grip off the handlebar 3 Disconnect Sclutch switch connector 4 Remove Sleft handlebar switch 1 Sclutch cable 2 Sclutch lever holder 3 5 Remove Sgrip end Sfront brake ligh...

Page 202: ...with the fuel tank adjust the handlebar position Align the match marks a on the handlebar with the upper surface of the lower handlebar hold ers 3 Install Sthrottle cables Sright handlebar switch 1 St...

Page 203: ...he handlebar 8 Adjust Sclutch cable free play Refer to ADJUST THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 X 15 mm 0 39 X 0 59 in 9 Install Sleft ha...

Page 204: ...Main switch coupler Steering stem nut Washer Upper bracket Horn stay Lock washer 2 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to HANDLEBAR Refer to COWLI...

Page 205: ...r ring nut Rubber washer Lower ring nut Under bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race 1 1 1 1 1 2 1 1 1 2 For installation reverse the removal...

Page 206: ...washer Sring nut 1 with the steering nut wrench 2 Hold the lower ring nut with the exhaust and steering nut wrench and then remove the upper rung nut with the ring nut wrench Steering nut wrench 90890...

Page 207: ...rly the steering head pipe could be damaged SAlways replace the bearing balls and bearing races as a set SWhenever the steering head is disassembled replace the dust seal 4 Check Supper bracket Slower...

Page 208: ...4 63 STEERING HEAD CHAS 110 Nm 11 mSkg 80 ftSlb 3 Install Supper bracket Swasher Ssteering stem nut 4 Install Sfront fork legs Refer to INSTALLING THE FRONT FORK LEGS...

Page 209: ...r bolt Swingarm rear shock absorber Self locking nut washer bolt Frame rear shock absorber Rear shock absorber Oil seal bearing 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to REAR WHE...

Page 210: ...danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Srear wheel Refer to REAR WHEEL AND BRAKE DISC 3 Remove Srear shock absorber assembly lo...

Page 211: ...ce of high heat High heat can cause an explosion due to excessive gas pressure SDo not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping perfor...

Page 212: ...ASSEMBLY 1 Lubricate Scollar Sbearings Soil seals Recommended lubricant Lithium soap based grease 2 Install Scollar Srear shock absorber assembly When installing the rear shock absorber assem bly lift...

Page 213: ...Adjusting nut Rear fender Pivot shaft nut washer Pivot shaft Swingarm Drive chain 2 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL AND BRAKE DISC Refer to REAR SHOCK ABSORBER A...

Page 214: ...E CHAIN CHAS Order Job Part Q ty Remarks 8 9 10 11 Drive chain guide Dust cover Bearing Spacer 1 2 2 1 For installation reverse the removal procedure 120 Nm 12 mSkg 87 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 16...

Page 215: ...AS SEMBLY 3 Measure Sswingarm side play Sswingarm vertical movement a Measure the tightening torque of the pivot shaft nut Pivot shaft nut 120 Nm 12 mSkg 87 ftSlb b Measure the swingarm side play A by...

Page 216: ...the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sdrive chain with the drive chain cutter EAS00707 CHECKING THE SWINGARM 1 Check Sswingarm Bends cracks damage Replace 2 C...

Page 217: ...arings Sspacer Sdust covers Spivot shaft Recommended lubricant Lithium soap based grease 2 Install Sswingarm 1 Spivot shaft nut 2 3 Install Srear shock absorber assembly Srear wheel Refer to INSTALLIN...

Page 218: ...tiffness Clean and lubricate or replace 3 Clean Sdrive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the...

Page 219: ...d make sure that the battery breather hose is proper ly routed away from the drive chain and be low the swingarm 5 Lubricate Sdrive chain Recommended lubricant Engine oil or chain lubricant suitable f...

Page 220: ...ver Nut Lock washer Drive sprocket 2 1 1 1 1 1 1 Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Loosen For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 m...

Page 221: ...bly Muffler 1 4 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 20 Nm 2 0 mSkg 15 ftSlb 16 Nm 1 6 mSkg 11 6 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ft...

Page 222: ...t the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Refer to AIR FILTER CA...

Page 223: ...Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler 1 1 1 1 1 1 1 1 1 Refer to COOLING SYSTEM in chapter 6 Refer t...

Page 224: ...nut Rear engine mounting bolt Engine 1 2 2 2 1 Remove the parts in the order listed Place a suitable stand under the frame and engine For installation reverse the removal procedure NOTE Refer to INSTA...

Page 225: ...ne mounting bolts 1 Lubricate the rear engine mounting bolt threads with lithium soap based grease 2 Install Sright front engine mounting bolt 2 Sleft front engine mounting bolts 3 Do not fully tighte...

Page 226: ...kg 7 2 ftSlb NOTE 5 Tighten Sright front engine mounting bolts 6 6 Install Sshift arm 7 SAlign the punch mark a in the shift shaft with the slot in the shift arm SAlign the bottom edge of the shift pe...

Page 227: ...uide top side 4 4 1 1 1 Remove the parts in the order listed Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to BATTERY BOX AND BATTERY BOX BRACKET...

Page 228: ...ft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft 4 1 1 1 3 6 3 6 1 Remove the parts in the order listed Refer to CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR Loosen During removal the do...

Page 229: ...1 12 13 Exhaust camshaft Pin Timing chain guide intake side Cam sprocket 1 1 1 2 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb...

Page 230: ...lign the T mark a on the pick up rotor with the crankcase mating surface b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Scamshaft sprocke...

Page 231: ...discoloration pitting scratches Re place the camshaft 2 Measure Scamshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 32 45 X 32...

Page 232: ...lastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps STighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out SDo not...

Page 233: ...a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check Stiming chain guide exhaust side 1 Stiming chain guide intake side 2 Stiming chain guide top side 3 Damage wear Replace the def...

Page 234: ...aluminum washer New Sgasket New Damage wear Replace the defective part s EAS00215 INSTALLING THE CAMSHAFTS 1 Align S T mark a on the pickup rotor with the crankcase mating surface b a Turn the cranksh...

Page 235: ...and in a crisscross pattern working from the inner caps out I1 I2 Intake side camshaft cap mark E1 E2 Exhaust side camshaft cap mark SLubricate the camshaft cap bolts with the engine oil SThe camshaf...

Page 236: ...in tensioner bolt 12 Nm 1 2 mSkg 8 7 ftSlb d Remove the screwdriver make sure that the timing chain tensioner rod releases and then tighten the cap bolt to the specified torque Cap bolt 7 Nm 0 7 mSkg...

Page 237: ...5 18 CAMSHAFTS ENG 10 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3...

Page 238: ...bracket Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to CAMSHAFTS Refer to ENGINE For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ft...

Page 239: ...plug bore threads Svalve seats 2 Check Scylinder head Damage scratches Replace Scylinder head water jacket Mineral deposits rust Eliminate 3 Measure Scylinder head warpage Out of specification Resurf...

Page 240: ...avity 3 Tighten Scylinder head bolts 1 X 10 1st 2nd Scylinder head bolts 11 12 SLubricate the cylinder head bolts with engine oil STighten the cylinder head bolts in the proper tightening sequence as...

Page 241: ...seat Intake valve spring outer Intake valve spring inner Intake valve stem seal Intake valve lower spring seat Intake valve Intake valve guide Exhaust valve lifter Exhaust valve pad Exhaust valve cot...

Page 242: ...14 15 16 17 18 19 Exhaust valve upper spring seat Exhaust valve spring Exhaust valve stem seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 8 8 8 8 For installation reverse t...

Page 243: ...position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check Svalve sealing Leakage at the valve seat Check the valve face valve seat and valve seat wid...

Page 244: ...ly so that it can be reinstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valv...

Page 245: ...talling the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide re...

Page 246: ...mm 0 0016 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Scarbon deposits from the valve face and valve seat 2 Check Svalve seat...

Page 247: ...o the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping res...

Page 248: ...th Intake valve spring inner 37 0 mm 1 46 in Limit 35 2 mm 1 39 in Intake valve spring outer 38 4 mm 1 51 in Limit 36 5 mm 1 44 in Exhaust valve spring 41 8 mm 1 65 in Limit 39 7 mm 1 56 in 2 Measure...

Page 249: ...ve lifters 1 Check Svalve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related component...

Page 250: ...ressor attachment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 YM 01253 5 To secure the valve cotters onto the valve stem lightly tap the valve tip wit...

Page 251: ...l assembly lead holder 1 1 1 2 1 Remove the parts in the order listed Refer to SEAT and FUEL TANK in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect 32 Nm 3 2 mSkg 23 ftSlb 12...

Page 252: ...asher Generator rotor Starter clutch assembly Idler gear shaft Idler gear Starter clutch drive gear 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE GENE...

Page 253: ...n chapter 3 Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 3 Remove Sgenerator rotor cover Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bo...

Page 254: ...set s center bolt and the crank shaft Make sure the flywheel puller is centered over the generator rotor Flywheel puller 90890 01362 YU 33270 Flywheel puller attachment 90890 04089 YM 33282 REMOVING...

Page 255: ...er clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the...

Page 256: ...an the tapered portion of the crankshaft and the generator rotor hub SReplace the washer with a new one 2 Tighten Sgenerator rotor bolt 1 SWhile holding the generator rotor 2 with the sheave holder 3...

Page 257: ...n a crisscross pattern 6 Fill Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 Scoolant Refer to CHANGING THE COOLANT in chapter 3 7 Install Sfuel tank Refer to FUEL TANK in chapter 3 Sfront...

Page 258: ...cover Shift shaft cover gasket Dowel pin Oil seal Shift shaft Shift shaft spring Collar Stopper lever spring Circlip Washer 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Dra...

Page 259: ...SHAFT ENG Order Job Part Q ty Remarks 11 12 13 14 Stopper lever Collar Washer Shift shaft spring stopper 1 1 1 1 For installation reverse the removal procedure 22 Nm 2 2 mSkg 16 ftSlb 12 Nm 1 2 mSkg...

Page 260: ...ace Roller turns roughly Replace the stopper lever EAS00332 INSTALLING THE SHIFT SHAFT 1 Install Sshift shaft spring stopper 1 Swashers Sshift shaft 2 SApply LOCTITE to the threads of the shift shaft...

Page 261: ...r cover gasket Dowel pin 1 1 1 2 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Drain Refer to CHANGING THE ENGINE OIL i...

Page 262: ...OTOR ENG Order Job Part Q ty Remarks 5 6 7 Crankshaft position sensor Pickup rotor Plug screw 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 35 N...

Page 263: ...olts are fully loosened remove them 2 Remove Spickup rotor bolt 1 Swasher 2 Spickup rotor 3 While holding the generator rotor 4 with the ro tor holding tool 5 loosen the pickup rotor bolt Sheave holde...

Page 264: ...bolt Sheave holder 90890 01701 YS 01880 A 3 Apply Ssealant onto the crankshaft position sensor lead grommet Yamaha bond No 1215 90890 85505 ACC 11001 5 01 4 Install Spickup rotor cover Sgasket New SW...

Page 265: ...h cover gasket Dowel pin 1 1 1 1 1 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect For...

Page 266: ...sassembling the clutch cover Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer 2 1 1 1 1 1 2 1 1 Disassemble the parts in the order listed For assembly revers...

Page 267: ...Friction plate Brown Clutch plate t 2 0 mm 0 08 in Friction plate Clutch plate t 2 3 mm 0 09 in Clutch boss nut Lock plate Clutch boss Thrust plate 6 1 1 1 6 7 2 1 1 1 1 1 Remove the parts in the orde...

Page 268: ...essure plate 2 Spull rod 3 Sfriction plates Sclutch plates 3 Straighten the lock washer tab 4 Loosen Sclutch boss nut 1 While holding the clutch boss 2 with the univer sal clutch holder loosen the clu...

Page 269: ...TES The following procedure applies to all of the clutch plates 1 Check Sclutch plate Damage Replace the clutch plates as a set 2 Measure Sclutch plate warpage with a surface plate and thickness gauge...

Page 270: ...utch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Sbearing Damage wear Replace the bearing and clutch housing EAS00285 CHE...

Page 271: ...ull rod bearing Damage wear Replace EAS00299 INSTALLING THE CLUTCH 1 Install Sthrust plate 1 Sclutch boss 2 Slock washer 3 New Sclutch boss nut 4 While holding the clutch boss 2 with the clutch holdin...

Page 272: ...s shown in the illustration Clutch plate 1 t 2 3 mm 0 09 in Clutch plate 2 t 2 0 mm 0 08 in Friction plate 3 Friction plate 4 Color Brown 5 Install Spressure plate 1 Align the punch mark b in the pres...

Page 273: ...bdenum disulfide grease onto the pull rod SWhen installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure t...

Page 274: ...l strainer gasket 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to CHANGING THE COOLANT in chapter 3 Refer to ENGINE Refer to WATER PUM...

Page 275: ...y Dowel pin Relief valve assembly 1 1 1 2 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 43 Nm 4 3 mSkg 31 ftSlb 12 Nm 1 2...

Page 276: ...pump assembly Oil pump cover Pin Oil pump inner rotor Oil pump outer rotor Pin Washer Oil pump rotor housing Oil pump driver sprocket 1 2 1 1 1 1 1 1 Disassemble the parts in the order listed For asse...

Page 277: ...G THE OIL PUMP 1 Check Soil pump driven gear 1 Soil pump rotor housing 2 Soil pump cover Cracks damage wear Replace the de fective part s 2 Measure Sinner rotor to outer rotor tip clearance a Souter r...

Page 278: ...HE OIL DELIVERY PIPE AND OIL PIPE 1 Check Soil delivery pipe 1 Soil pipe 2 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check Soil strainer 1...

Page 279: ...Install Soil pump housing 1 Soil pump shaft 2 Swasher 3 Spin 4 Sinner rotor 5 Souter rotor 6 Sdowel pins 7 Soil pump cover 8 When installing the inner rotor align the pin 4 in the oil pump shaft with...

Page 280: ...r housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine EAS00380 INSTALLING THE OIL PAN 1 Install Soil...

Page 281: ...ain Oil pump drive chain Oil pump drive chain guide Lower crankcase Dowel pin 1 1 1 1 3 Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to STARTER CLUTCH AND GENERATO...

Page 282: ...5 63 Order Job Part Q ty Remarks 6 7 8 Thrust plate Washer Plate 1 1 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CRANKCASE ENG...

Page 283: ...15 mm 4 5 in bolts 8 9 M8 65 mm 2 6 in bolts 11 12 M6 65 mm 2 6 in bolts 13 14 M6 55 mm 2 2 in bolts 15 22 X 26 M6 45 mm 1 8 in bolts 16 19 20 M6 65 mm 2 6 in bolts 17 27 M6 75 mm 3 0 in bolt 18 M6 10...

Page 284: ...then rotate the inner race with your finger Rough movement Replace 2 Check Soil seals Damage wear Replace CHECKING THE TIMING CHAIN 1 Check Stiming chain 2 Damage stiffness Replace the timing chain a...

Page 285: ...lts SLubricate the bolt threads with engine oil SInstall a washer on bolts 1 X 10 SSeal bolt 18 STighten the bolts in the tightening sequence cast on the crankcase M8 85 mm 3 3 in bolts 1 X 7 10 M8 11...

Page 286: ...g Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring 4 4 4 8 4 4 4 4 4 4 Remove the parts in the order listed Refer to CRANKCASE For installation reverse...

Page 287: ...on pin 2 Spiston 3 Do not use a hammer to drive the piston pin out SFor reference during installation put identifica tion marks on the piston crown SBefore removing the piston pin deburr the pis ton p...

Page 288: ...bearing so that it can be reinstalled in its original place EAS00261 CHECKING THE CYLINDER AND PISTON 1 Check Spiston wall Scylinder wall Vertical scratches Replace the cylinder and the piston and pi...

Page 289: ...size P 65 475 X 65 490 mm 2 5778 X 2 5783 in d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cy...

Page 290: ...Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top r...

Page 291: ...ore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 16 002 X 16 013 mm 0 6300 X 0 6304 in Limit 16 043 mm 0 6316 in 4 Calculate Spiston pin to piston clearanc...

Page 292: ...ean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod...

Page 293: ...urther to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the nut and then retighten it Replace the bolt and nut with a new one and perform the pr...

Page 294: ...ds are used to determine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbe...

Page 295: ...n the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod ca...

Page 296: ...necting rod and connecting rod cap once using a single unit of the connecting rod i Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touchin...

Page 297: ...her to reach the specified angle 120_ p After the installation check that the section show a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more tha...

Page 298: ...big end bearings 2 Select Sbig end bearings P1 X P4 SThe numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes...

Page 299: ...the manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y...

Page 300: ...big end bearings with the notches in the connecting rods and connecting rod caps SBe sure to reinstall each big end bearing in its original place SWhile compressing the piston rings with one hand ins...

Page 301: ...the nut further to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the nuts and then retighten it Replace the bolt and nut with a new one and per...

Page 302: ...manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y mark...

Page 303: ...end bearings Sconnecting rod big end inner surface with the recommended lubricant Recommended lubricant Engine oil 6 Install Sbig end bearings Sconnecting rod cap onto the connecting rod SAlign the pr...

Page 304: ...h with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the...

Page 305: ...ed angle 120_ e After the installation check that the section shown a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more than the specified angle d...

Page 306: ...ing rod caps Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS Fo...

Page 307: ...kshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 034 X 0 058 mm 0 0013 X 0 0023 in Do not int...

Page 308: ...case halves SAlign the projections a of the crankshaft jour nal lower bearings with the notches b in the lower crankcase SDo not move the crankshaft until the clearance measurement has been completed...

Page 309: ...nd the numbers 1 stamped into the low er crankcase are used to determine the re placement crankshaft journal bearing sizes S J1 X J5 refer to the bearings shown in the crankshaft illustration SIf J1 X...

Page 310: ...bearings 1 into the upper crankcase SAlign the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase SBe sure to install each crankshaft journal up per bea...

Page 311: ...Shift drum retainer Shift fork guide bar Spring Shift fork L Shift fork R Shift drum assembly Shift fork C 1 1 1 1 1 2 4 1 1 1 1 Remove the part in the order listed Separate Refer to CRANKCASE 12 Nm 1...

Page 312: ...emarks 12 13 14 15 16 Main axle assembly Oil pipe Oil baffle plate Thrust plate Washer 1 1 1 1 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm...

Page 313: ...pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemb...

Page 314: ...5 95 Order Job Part Q ty Remarks Bearing housing Bearing 1 1 For installation reverse the removal procedure 15 16 TRANSMISSION ENG...

Page 315: ...st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble t...

Page 316: ...Order Job Part Q ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 15 16 17...

Page 317: ...he main axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Sshift fork cam follower 1 Sshift fork paw...

Page 318: ...G THE TRANSMISSION 1 Measure Smain axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 02 mm 0 0008 in 2 Measure Sdrive axle runout...

Page 319: ...Install Soil pipe 1 Smain axle assembly 2 with the Torx wrench T30 Make sure to caulk the bolts at three positions after installing the bearing housing 2 Install Sshift fork C 3 Sshift drum assembly...

Page 320: ...drum retainer SInstall shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle SMake sure that the drive axle bearing circlip a is i...

Page 321: ...e Radiator inlet hose Oil cooler outlet hose Radiator Radiator cap 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK in chapter 3 Ref...

Page 322: ...6 2 6 RADIATOR COOL Order Job Part Q ty Remarks 9 Radiator fan 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb...

Page 323: ...ning pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 93 X 123 kPa 0 93 X 1 23 kg cm2 13 2 X 17 5 psi a Install the radiator cap tester 1 and radiator cap t...

Page 324: ...ing system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check Scooling system Leaks Repair or replace any faulty part 4 Measure Sradiator cap open...

Page 325: ...on bolt Washer Oil cooler O ring Oil cooler inlet hose Oil cooler inlet pipe Water jacket joint hose Water jacket joint 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to RADIATOR Drain R...

Page 326: ...IL COOLER COOL Order Job Part Q ty Remarks 10 11 12 O ring Water pump outlet hose Radiator outlet hose 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 63 Nm 6 3 mSkg 46 f...

Page 327: ...w Sunion bolt 3 SBefore installing the oil cooler lubricate the union bolt and O ring with a thin coat of engine oil SMake sure the O ring is positioned properly 3 Fill Scooling system with the specif...

Page 328: ...let hose Thermostat cover Thermostat 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHA...

Page 329: ...ly heat the water c Place a thermometer in the water d While stirring the water observe the thermo stat and thermometer s indicated tempera ture 1 Thermometer 2 Water 3 Thermostat 4 Container A Fully...

Page 330: ...he thermostat cover to the cyl inder head lubricate the O ring with a thin coat of lithium soap based grease 3 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANG...

Page 331: ...ove the parts in the order listed It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Drain Refer to CHANGING THE COOLANT in chapt...

Page 332: ...er O ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O ring Copper washer 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disasse...

Page 333: ...rom the outside of the water pump housing 2 Water pump housing 3 Remove Soil seal 1 with a thin flat head screwdriver Remove the oil seal from the outside of the wa ter pump housing 4 Remove Sbearing...

Page 334: ...damage wear Replace EAS00475 ASSEMBLING THE WATER PUMP 1 Install Sbearing Soil seal New 1 into the water pump housing 2 SBefore installing the oil seal apply tap water or coolant onto its out surface...

Page 335: ...3 Install Srubber damper New 1 Srubber damper holder New 2 Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Simpeller shaft tilt Out of specification Rep...

Page 336: ...utlet hose 2 SInstall the radiator outlet hose with white a mark positioned outside SInstall the hose clamp with its screw head pointed to the inner side 3 Fill Scooling system with the specified amou...

Page 337: ...Intake air pressure sensor 8 Throttle position sensor 9 Fuel injector 10 Catalytic converter 11 Crankshaft position sensor 12 Coolant temperature sensor 13 Spark plug 14 Pressure regulator 15 Battery...

Page 338: ...ntake air pressure sensor 16 Lean angle cut off switch 17 Crankshaft position sensor 18 Intake air temperature sensor 19 Coolant temperature sensor 20 ECU 21 Cylinder 1 injector 22 Cylinder 2 injector...

Page 339: ...ing an engine trouble warning light SAfter the engine has been stopped the lowest fault code number appears on the LCD meter Once a fault code has been displayed it remains stored in the memory of the...

Page 340: ...mperature sensor Intake temperature sensor open or short circuit detected S Fixes the intake temperature to 20_C Able Able 33 Faulty ignition Open circuit detected in the primary lead of the ignition...

Page 341: ...ble Er 2 ECU internal malfunction output signal error No signals are received from the ECU within the specified duration Unable Unable Er 3 ECU internal malfunction output signal error Data from the E...

Page 342: ...OFF turn the mainswitch back to ON and then check if the fault code num ber is still displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF...

Page 343: ...the clock and tripmeter displays S dIAG appears on the LCD meter 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press...

Page 344: ...s on the trip LCD SActuator operation Set the engine stop switch to ON to operate the actuator If the engine stop switch is set to ON set it to OFF and then set it to ON again 8 Turn the main switch t...

Page 345: ...led sensor 06 22 Intake air temperature sensor open or short circuit detected S Open or short circuit in wiring harness S Defective intake temperature sensor S Malfunction in ECU S Improperly installe...

Page 346: ...m the ECU S Open or short circuit in wiring sub lead S Malfunction in meter S Malfunction in ECU Er 2 No signals are received from the ECU within the specified duration S Improper connection in wiring...

Page 347: ...ltage Displays the fuel system voltage battery voltage Engine stop switch is on 0 X 18 7 V Normally approximately 12 0 V 20 Sidestand switch Displays that the switch is ON or OFF When the gear is in a...

Page 348: ...t that time the fan motor rotates 52 Headlight relay 1 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON it actuates the headlight relay five times every 5...

Page 349: ...mal signals are received from the crankshaft position sensor Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Install...

Page 350: ...out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Intake air pressure sensor coupler Main wiring harness ECU coupler Sub wire harness coupler R...

Page 351: ...01 throttle position sensor Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of throttle position sensor Check the instal...

Page 352: ...e is a malfunction repair it and connect it securely If the transmis sion is in gear it is reinstated by retracting the sidestand If the transmis sion is in neu tral it is rein 2 Open or short circuit...

Page 353: ...r pinching Reinstated by turning the 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction r...

Page 354: ...the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Lean angle cut off switch coupler Main wiring h...

Page 355: ...have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Ignition coil primary side coupler gray black Main wiring harness ECU coupler Sub...

Page 356: ...to 30 km h A3 Gear for detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 A4 Defective speed sensor Execute the diagnostic mode code No 07 Replace if defective...

Page 357: ...r it and connect it securely Starting circuit cut off relay coupler fuel injection system relay Fuel pump coupler Injector coupler ECU coupler Reinstated by starting the engine and operating it at idl...

Page 358: ...countermeasure Reinstatement method 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction r...

Page 359: ...ave pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the...

Page 360: ...e pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the m...

Page 361: ...ottle body joint clamp screw Throttle bodies Throttle cable Throttle body joint Heat protector 2 1 1 4 1 2 4 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chap...

Page 362: ...7 26 Order Job Part Q ty Remarks 9 Plunger control unit hose 1 Disconnect For installation reverse the removal procedure THROTTLE BODIES FI...

Page 363: ...r Cylinder 2 injector coupler Cylinder 3 injector coupler Cylinder 4 injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Throttle position sen...

Page 364: ...CHECKING THE THROTTLE BODIES 1 Check Sthrottle bodies Cracks damage Replace the throttle bo dies as a set 2 Check Sfuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based sol...

Page 365: ...nk Refer to SEAT AND FUEL TANK in chapter 3 b Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe Pressure gauge 90890 03153 YU 03153 Adapter 90890 03176 YM 03176 c Install the fue...

Page 366: ...om the throttle body c Connect the pocket tester 1k to the throttle position sensor Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 d Measure the maximum throttle pos...

Page 367: ...ings from closed to wide open throttle may dif fer slightly from those specified Throttle position sensor resistance 0 X 5 1 5 k at 20_C 68_F yellow black blue 2 Adjust Sthrottle position sensor angle...

Page 368: ...ed exhaust gases is approximately 600 to 700_C 1112 to 1292_F EAS0097 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Or...

Page 369: ...7 33 AIR INDUCTION SYSTEM FI A To cylinder 1 and 2 B To cylinder 3 and 4 1 Air cut off valve 2 Reed valve 3 To air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS...

Page 370: ...amage Replace Spipes Cracks damage Replace 2 Check S reed valve 1 S reed valve stopper Sreed valve seat Cracks damage Replace the reed valve 3 Measure S reed valve bending limit a Out of specification...

Page 371: ...ler from the wire harness b Connect the pocket tester 1 to the AI system solenoid terminal as shown Tester positive probe brown red 1 Tester negative probe red white 2 c Measure the AI system solenoid...

Page 372: ...switch 10 Radiator fan motor 11 Horn 12 Ignition coil 1 Main switch 2 Front brake light switch 3 Starter relay 4 Battery 5 Fuse box 6 Rear brake light switch 7 Neutral switch 8 Sidestand switch EAS00...

Page 373: ...ctifier regulator 12 Throttle position sensor 1 Coolant temperature sensor 2 Intake air temperature sensor 3 Intake air pressure sensor 4 Fuel pump 5 ECU 6 Lean angle cut off switch 7 Starting circuit...

Page 374: ...to 0 and to the 1 range SWhen checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown...

Page 375: ...nd switch 8 Engine stop switch 9 Front brake light switch 10 Start switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for...

Page 376: ...and usually use a bulb holder that must be detached before removing the bulb The ma jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise SBulbs C...

Page 377: ...quer thinner 2 Check Sbulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 YU 3112 Before checking for continuity set the pocket tester to 0 and to the 1 range a...

Page 378: ...ies to all of the LEDs 1 Check SLED for proper operation Improper operation Replace a Disconnect the meter assembly coupler me ter assembly side b Connect two jumper leads 1 from the bat tery terminal...

Page 379: ...estand switch 12 Neutral switch 16 Lean angle cut off switch 17 Crankshaft position sensor 20 ECU 27 Ignition coil 1 and 4 28 ignition coil 2 and 3 29 Spark plug 40 Engine stop switch 47 Fuse ignition...

Page 380: ...TION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse...

Page 381: ...following procedure applies to all of the spark plug caps SRemove the spark plug cap from the spark plug lead SConnect the pocket tester 1k to the spark plug cap as shown SMeasure the spark plug cap r...

Page 382: ...ure the crankshaft position sensor re sistance EAS00748 Crankshaft position sensor resis tance 248 X 372 at 20_C 68_F between gray and black SIs the crankshaft position sensor OK YES NO Replace the cr...

Page 383: ...SCheck the starting circuit cut off relay for continuity Positive tester probe black red Negative tester probe sky blue 1 2 EAS00753 Positive tester probe black red Negative tester probe blue green C...

Page 384: ...54 15 Wiring SCheck the entire ignition system s wiring Refer to CIRCUIT DIAGRAM SIs the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition...

Page 385: ...Starter motor 9 Battery 10 Starting circuit cut off relay 11 Sidestand switch 12 Neutral switch 40 Engine stop switch 41 Start switch 47 Fuse ignition 54 Clutch switch ELECTRIC STARTING SYSTEM ELEC E...

Page 386: ...relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so cur rent cannot reach the starter motor Whe...

Page 387: ...lean the battery terminals SRecharge or re place the battery EAS00739 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CH...

Page 388: ...cket tester 1 and battery 12 V to the starter relay coupler as shown YES NO Replace the starter relay Positive battery terminal red white Negative battery terminal blue white Positive tester probe red...

Page 389: ...e start switch for continuity Refer to CHECKING THE SWITCHES SIs the start switch OK YES NO Replace the right handlebar switch EAS00764 10 Clutch switch SCheck the clutch switch for continuity Refer t...

Page 390: ...Throttle bodies Starter motor lead Starter motor 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to THROTTLE B...

Page 391: ...seal Bearing Washer set Rear cover Washer set O ring Brush holder Armature assembly Starter motor yoke O ring 1 1 1 1 1 1 1 1 2 1 1 1 2 Disassembly the parts in the order listed For assembly reverse...

Page 392: ...been grounded to fit the commuta tor Mica undercut 0 7 mm 0 03 in The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances comm...

Page 393: ...Replace the brush springs as a set Brush spring force 7 16 X 9 52 N 730 X 971 gf 25 77 X 34 27 oz 7 Check Sgear teeth Damage wear Replace the gear 8 Check Sbearing Soil seal Damage wear Replace the de...

Page 394: ...Nm 0 34 mSkg 2 5 ftSlb NOTE 3 Install Sstarter motor yoke 1 SO ring 2 New Sfront cover 3 Srear cover 4 Sbolts 5 Align the match marks a on the starter motor yoke with the match marks b on the front an...

Page 395: ...8 24 2 A C magneto 3 Rectifier regulator 6 Fuse main 9 Battery CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM...

Page 396: ...arged NOTE Minimum open circuit voltage 12 8 V or more at 20_C 68_F SIs the battery OK CHARGING SYSTEM ELEC NOTE YES NO 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in c...

Page 397: ...the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly con nected and without defects Properly connect or repair the charging system s...

Page 398: ...8 27 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM...

Page 399: ...h beam indicator light 46 Fuse headlight 47 Fuse ignition 48 Fuse tail 51 License plate light 52 Tail brake light 55 Dimmer switch 60 Dimmer relay 61 Headlight high beam 62 Headlight low beam 65 Front...

Page 400: ...tail ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main tail ignition and headlight fuses OK Replace the fuse s 2 Battery SCheck the condition of the b...

Page 401: ...r 1 and bat tery 12 V to the dimmer relay as shown Positive battery lead red yellow Negative battery lead yellow black EAS00787 YES NO 6 Wiring SCheck the entire lighting system s wiring Refer to CIRC...

Page 402: ...the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Low beam Headlight Positive tester probe black Negative tester probe black green 1 2 Meter assembly cou...

Page 403: ...cense plate light fails to come on YES NO 2 Voltage SConnect the pocket tester DC 20 V to the license plate light coupler wire harness light side as shown The wiring circuit from the main switch to th...

Page 404: ...light fails to come on YES NO 1 Turn signal position light and socket SCheck the turn signal position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the turn s...

Page 405: ...8 34 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM...

Page 406: ...nction meter 36 Turn signal indicator light 37 Oil level switch 39 Front brake light switch 45 Fuse signal 47 Fuse ignition 48 Fuse tail 49 Turn signal relay 50 Rear brake light switch 52 Tail brake l...

Page 407: ...HTING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Backup main ignition signal and tail fuses SCheck the backup main ignition signal and tail fuses for continuity Refer to CHECKING THE FUSES in chap ter...

Page 408: ...ain switch to ON SPull in the brake lever or push down on the brake pedal SMeasure the voltage DC 12 V of yellow on the tail brake light coupler wire harness side SIs the voltage within specification...

Page 409: ...Positive tester probe brown green 1 STurn the main switch to ON SMeasure the voltage DC 12 V on brown green at the turn signal relay coupler wire harness side SIs the voltage within specification 1 Y...

Page 410: ...r continu ity Refer to CHECKING THE LEDs SAre the neutral indicator light OK EAS00801 4 The neutral indicator light fails to come on YES NO Replace the meter assembly YES NO 2 Neutral switch SCheck th...

Page 411: ...e the tester readings correct YES NO 1 Oil level warning light LEDs SCheck the oil level warning light for continu ity When the main switch is turn to ON the oil level warning light is come on SAre th...

Page 412: ...K EAS00803 6 The fuel level warning light fails to come on 1 Fuel sender SDrain the fuel from the fuel tank and remove the fuel pump from the fuel tank SDisconnect the fuel sender coupler from the wir...

Page 413: ...ng circuit from the main switch to the meter assem bly coupler is faulty and must be re paired Positive tester probe green white Negative tester probe black white 1 2 STurn the main switch to ON SMeas...

Page 414: ...ch 6 Fuse main 9 Battery 19 Coolant temperature sensor 20 ECU 42 Fuse radiator fan motor 43 Radiator fan motor relay 44 Radiator fan motor 47 Fuse ignition COOLING SYSTEM ELEC EAS00807 COOLING SYSTEM...

Page 415: ...adiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main ignition and radiator fan motor fuses OK Replace the fuse s EAS00808 TROUBLESHOOTING SThe radiator fan mo...

Page 416: ...tor relay SDisconnect the radiator fan motor relay form the wire harness SConnect the pocket tester 1 and bat tery 12 V to the radiator fan motor terminal as shown SCheck the radiator fan motor for co...

Page 417: ...Coolant temperature sensor resistance 0_C 32_F 5 21 X 6 37 k 80_C 176_F 0 29 X 0 35 k WARNING SHandle the coolant temperature sensor with special care SNever subject the coolant temperature sensor to...

Page 418: ...n switch 5 Fuse fuel injection 6 Fuse main 9 Battery 10 Starting circuit cut off relay 13 Fuel pump 20 ECU 40 Engine stop switch 47 Fuse ignition FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUI...

Page 419: ...Fuse main 3 Main switch 4 Fuse ignition 5 Engine stop switch 6 ECU 7 Fuse fuel injection 8 Starting circuit cut off relay fuel injection system relay 9 Fuel pump EAS00815 FUEL PUMP SYSTEM The ECU incl...

Page 420: ...ndlebar switch SIs the engine stop switch OK NOTE YES NO 1 Main ignition and fuel injection system fuses SCheck the main ignition and fuel system fuses for continuity Refer to CHECKING THE FUSES in ch...

Page 421: ...starting circuit cut off relay have continuity between red and red blue YES NO 6 Fuel pump resistance SDisconnect the fuel pump coupler from the wire harness SConnect the pocket tester 1 to the fuel...

Page 422: ...o accidentally spill gasoline wipe it up immediately with dry rags SIf gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming...

Page 423: ...he warning light when the main switch is turned ON irrespective of whether the engine is running or not Circuit Defect s System response Condition code Fuel pump thermistor SOpen circuit SShort circui...

Page 424: ...n SIs the fuel pump thermistor OK YES Replace the fuel pump Replace the multi function meter NOTE 13 Fuel pump 34 Multi function meter TROUBLESHOOTING The warning light starts to indicate the self dia...

Page 425: ...oil level warning light fails to come on SIs the oil level switch OK YES Repair or replace the wire harness NO 1 Wire harness SCheck the wire harness for continuity Refer to CIRCUIT DIAGRAM SIs the w...

Page 426: ...trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING FAILURES ENGINE Cylind...

Page 427: ...nsor Switches and wiring SFaulty main switch SFaulty engine stop switch SBroken or shorted wiring SFaulty neutral switch SFaulty start switch SFaulty sidestand switch SFaulty clutch switch SImproperly...

Page 428: ...rect oil viscosity high SDeteriorated oil EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft SImproperly adjusted shift rod SBent shift sha...

Page 429: ...il viscosity SInferior oil quality COOLING SYSTEM Coolant SLow coolant level Radiator SDamaged or leaking radiator SFaulty radiator cap SBent or damaged radiator fin Water pump SDamaged or faulty wate...

Page 430: ...h SLoose damper rod assembly bolt SDamaged damper rod assembly bolt copper washer SCracked or damaged cap bolt O ring MALFUNCTION SBent or damaged inner tube SBent or damaged outer tube SDamaged fork...

Page 431: ...horn SFaulty main switch SFaulty horn switch SFaulty battery SBlown damaged or incorrect fuse SFaulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON SWrong headl...

Page 432: ...B B Y Br R Y G Y B R Y Br B L G Y R W Dg Y L B Br W Ch B R G B B Y Br B L W Y W Y B B Br Y Br G Y R R L W L W R B B L B L B B Y B Y B B L G B B R B R R L W L R B L W L W R Lg B Y Sb B R L G R W L Y L...

Page 433: ...FZ6 SS FZ6 SSC WIRING DIAGRAM...

Page 434: ...Coolant temperature sensor 20 ECU 21 Cylinder 1 injector 22 Cylinder 2 injector 23 Cylinder 3 injector 24 Cylinder 4 injector 25 Air cut off valve 26 Speed sensor 27 Ignition coil 1 and 4 28 Ignition...

Page 435: ......