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Yamaha XJR1300 2007, Service Manual

The Yamaha XJR1300 2007 Service Manual is a comprehensive user manual that provides detailed instructions for maintaining and servicing the Yamaha XJR1300 motorcycle. This manual can be downloaded for free from 88.208.23.73:8080, ensuring you have all the necessary information to keep your bike running smoothly and efficiently.

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PERIODIC CHECKS AND ADJUSTMENTS

 

PERIODIC MAINTENANCE .......................................................................... 3-1

 

INTRODUCTION ..................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ..................... 3-1

 

ENGINE ......................................................................................................... 3-4

 

ADJUSTING THE VALVE CLEARANCE ................................................ 3-4
SYNCHRONIZING THE THROTTLE BODIES........................................ 3-6
ADJUSTING THE EXHAUST GAS VOLUME ......................................... 3-8
CHECKING THE ENGINE IDLING SPEED ............................................ 3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-9
CHECKING THE SPARK PLUGS ........................................................... 3-10
CHECKING THE IGNITION TIMING ....................................................... 3-11
MEASURING THE COMPRESSION PRESSURE .................................. 3-11
CHECKING THE ENGINE OIL LEVEL.................................................... 3-12
CHANGING THE ENGINE OIL ............................................................... 3-13
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-14
ADJUSTING THE CLUTCH LEVER........................................................ 3-15
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-15
BLEEDING THE HYDRAULIC CLUTCH SYSTEM ................................. 3-16
REPLACING THE AIR FILTER ELEMENT ............................................. 3-17
CHECKING THE THROTTLE BODY JOINT ........................................... 3-17
CHECKING THE FUEL LINE .................................................................. 3-17
CHECKING THE CRANKCASE BREATHER HOSE .............................. 3-18
CHECKING THE EXHAUST SYSTEM.................................................... 3-18
ADJUSTING THE EXUP CABLES .......................................................... 3-19

 

CHASSIS ....................................................................................................... 3-20

 

ADJUSTING THE FRONT BRAKE ......................................................... 3-20
ADJUSTING THE REAR BRAKE ............................................................ 3-20
CHECKING THE BRAKE FLUID LEVEL................................................. 3-21
CHECKING THE FRONT BRAKE PAD .................................................. 3-21
CHECKING THE REAR BRAKE PADS .................................................. 3-21
CHECKING THE FRONT BRAKE HOSES ............................................. 3-22
CHECKING THE REAR BRAKE HOSE .................................................. 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-22
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-23
ADJUSTING THE SHIFT PEDAL ............................................................ 3-24
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-24
LUBRICATING THE DRIVE CHAIN ........................................................ 3-25
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-25
CHECKING THE FRONT FORK ............................................................. 3-26
ADJUSTING THE FRONT FORKS ......................................................... 3-27
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................. 3-28
CHECKING THE TIRES .......................................................................... 3-30
CHECKING THE WHEELS ..................................................................... 3-32
CHECKING AND LUBRICATING THE CABLES .................................... 3-32
LUBRICATING THE LEVERS ................................................................. 3-32
LUBRICATING THE PEDAL ................................................................... 3-32
LUBRICATING THE SIDESTAND........................................................... 3-32
LUBRICATING THE CENTER STAND ................................................... 3-32

Summary of Contents for XJR1300 2007

Page 1: ...SERVICE MANUAL XJR1300 W 5WM 28197 E0 2007 ...

Page 2: ......

Page 3: ...00 W 2007 SERVICE MANUAL 2007 by Yamaha Motor Co Ltd First edition February 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...s 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 NOTE Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety ...

Page 5: ...into the spacer and then re move the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to inspection of all friction plates 1 Check Friction plate Damage wear Replace 2 Measure friction plate thickness Out of specification Replace NOTE Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to ...

Page 6: ... 2 3 4 5 6 7 8 BF 12 S 16 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicon grease 17 Apply locking agent LOCTITE 18 Replace the part ...

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

Page 8: ......

Page 9: ...THE FI SYSTEM 1 2 FI SYSTEM 1 3 IMMOBILIZER SYSTEM 1 4 INSTRUMENT FUNCTION 1 5 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 10: ...20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 ...

Page 11: ...gine 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 FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by ...

Page 12: ... position sensor intake air pressure sensor intake temperature sensor O2 sensor and engine temperature 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 fuel that is required by the engine can be supplied at all times in accordance with the driving conditions 1 13 12 B 11 10...

Page 13: ...lizer unit The immobilizer unit and ECU computation results are checked with the 2 codes and if the key is recognized as legal the ECU releases ignition control cutoff and the engine can start With a copy key with only identical key grooves code verification does not proceed correctly the ECU fails to release ignition control and the engine cannot start NOTE While the code is being verified after ...

Page 14: ... 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO When approximately 4 5 L 1 19 US gal 0 99 Imp gal of fuel remains in the fuel tank the dis play will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the dis play between the various trip meter and odome ter modes in the f...

Page 15: ...trouble warning light will come on and then the odometer tripmeter display will indicate a two digit error code If the multi function display indicates such an fault code note the code number and check the vehicle Refer to FUEL INJECTION SYSTEM on page 7 25 This model is also equipped with a self diagno sis device for the immobilizer system If any of the immobilizer system circuits are de fective ...

Page 16: ...FEATURES 1 7 CAUTION ECA5UXB016 If the multi function display indicates an er ror code the vehicle should be checked as soon as possible in order to avoid engine damage ...

Page 17: ...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 EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts ...

Page 18: ...ng surfac es EAS20240 CIRCLIPS Before 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 Bearings a Shaft 1 1 1 2 3 a ...

Page 19: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at ...

Page 20: ...o avoid any mistakes NOTE 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 Illustration Reference pages Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 26 4 52 Frok seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 47 Fork seal driver attachment ø43 90890 01374 Replacement 43 mm YM A5142 3 4 47 D...

Page 21: ...3141 3 11 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 6 8 6 10 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 19 Valve spring compressor 90890 04019 YM 04019 5 17 5 23 Pressure gauge 90890 03153 3 15 6 7 Oil pressure adapter B 90890 03124 3 15 Fuel pressure adapter 90890 03176 YM 03176 6 7 Tool name Tool No Illustration ...

Page 22: ...7 Valve lapper 90890 04101 Valve lapping tool YM A8998 5 20 Tappet adjusting tool 90890 04110 Valve adjustment tool YM 33966 3 5 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 92 Yamaha bond No 1215 Three Bond No 1215 90890 85505 5 63 Digital tachometer 90890 06760 YU 39951 B 3 7 3 9 3 11 Tool name Tool No Illustration Reference pages ...

Page 23: ...ATIONS 2 2 CHASSIS SPECIFICATIONS 2 9 ELECTRICAL SPECIFICATIONS 2 12 TIGHTENING TORQUE 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE 2 15 CHASSIS 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION DIAGRAMS 2 25 CABLE ROUTING 2 31 ...

Page 24: ...mensions Overall length 2175 mm 85 6 in Overall width 765 mm 30 1 in Overall height 1115 mm 43 9 in Seat height 795 mm 31 3 in Wheelbase 1500 mm 59 1 in Ground clearance 125 mm 4 92 in Minimum turning radius 2800 mm 110 2 in Weight With oil and fuel 245 0 kg 540 lb Maximum load 205 kg 452 lb ...

Page 25: ...ity Total amount 4 20 L 4 44 US qt 3 70 Imp qt Without oil filter element replacement 2 80 L 2 96 US qt 2 46 Imp qt With oil filter element replacement 3 15 L 3 33 US qt 2 77 Imp qt Oil cooler capacity including all routes 0 2 L 0 21 US qt 0 18 Imp qt Oil pressure hot 80 0 kPa 1000 r min 11 6 psi 1000 r min 0 80 kgf cm2 1000 r min Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor t...

Page 26: ...n Limit 27 910 mm 1 0988 in Exhaust A 35 950 36 050 mm 1 4154 1 4193 in Limit 35 850 mm 1 4114 in Exhaust B 28 045 28 145 mm 1 1041 1 1081 in Limit 27 945 mm 1 1002 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links 79RH2015 156 Tensioning system Automatic Valve valve seat valve guide Valve clearance cold Intake 0 11 0 15 mm 0 0043 0 0059 in Exhaust 0 16 0 20 mm 0 0063 ...

Page 27: ...0 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve spring Inner spring Free...

Page 28: ...rce intake 130 40 154 00 N 29 31 34 62 lbf 13 30 15 70 kgf Installed compression spring force exhaust 130 40 154 00 N 29 31 34 62 lbf 13 30 15 70 kgf Spring tilt intake 2 5 1 8 mm 2 5 0 071 in Spring tilt exhaust 2 5 1 8 mm 2 5 0 071 in Winding direction intake Counter clockwise Winding direction exhaust Counter clockwise Valve lifter Valve lifter outside diameter intake 27 978 28 002 mm 1 1015 1 ...

Page 29: ...iston pin bore inside diameter 18 004 18 015 mm 0 7088 0 7093 in Limit 18 045 mm 0 7104 in Piston pin outside diameter 17 991 18 000 mm 0 7083 0 7087 in Limit 17 971 mm 0 7075 in Piston ring Top ring Ring type Barrel Dimensions B T 1 00 3 05 mm 0 04 0 12 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 045 0 080 mm 0 0018 0 0032 in Limit 0 100 mm 0 0...

Page 30: ... 2 514 in Width B 382 00 383 20 mm 15 04 15 09 in Runout limit C 0 020 mm 0 0008 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Limit 0 50 mm 0 0197 in Big end radial clearance E 0 023 0 047 mm 0 0009 0 0019 in Journal oil clearance using plastigauge 0 020 0 044 mm 0 0008 0 0017 in Limit 0 09 mm 0 0035 in Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push ...

Page 31: ...ft mechanism type Guide bar Shift fork guide bar bending limit 0 100 mm 0 0039 in Shift fork thickness 6 26 6 39 mm 0 2465 0 2516 in Air filter Air filter element Oil coated paper element Fuel injector Model quantity 1150 4 Manufacturer DENSO Throttle body Type quantity ACW34 2 Manufacturer MIKUNI ID mark 5UXB 00 Throttle valve size 50 Throttle position sensor Resistance 4 0 6 0 kΩL B Output volta...

Page 32: ...in Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D252F L Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model DUNLOP D252 L Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm2 2 50 bar Rear 250 kPa 36 psi 2 50 kgf cm2 2 50 bar Loading c...

Page 33: ...m 0 22 in Limit 0 5 mm 0 02 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 42 85 mm 1 69 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 37 0 Center to lock angle right 37 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring fr...

Page 34: ...losed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm2 Spring preload adjusting positions Minimum 0 mm 0 in Standard 17 mm 0 67 in Maximum 28 mm 1 10 in Rebound damping adjusting positions Minimum 36 Standard 10 Maximum 1 Compression damping adjusting positions Minimum 20 Standard 16 Maximum 1 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm...

Page 35: ...ndard output 13 5 V 28 0 A 5000 r min Field coil resistance 2 75 3 04 Ω Armature coil resistance 0 19 0 21 Ω Brush overall length 13 7 mm 0 54 in Limit 4 7 mm 0 19 in Brush spring pressure 5 10 5 69 N 18 36 20 48 oz 520 580 gf Rectifier regulator Regulator type Semi conductor field control Model manufacturer B3GB DENSO No load regulated voltage 14 2 14 8 V Battery Model YTZ14S Voltage capacity 12 ...

Page 36: ...tarter relay Model manufacturer MS5E 691 JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 2 pcs Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω Performance 105 113 dB 2m Turn signal hazard relay Relay type Full transistor Model manufacturer FE246BS DENSO Built in self canceling device No Turn signal blinking frequency 75 0 95 0 cyc...

Page 37: ...ELECTRICAL SPECIFICATIONS 2 14 Fuel injection system fuse 15 0 A Backup fuse 7 5 A Spare fuse 15 0 A Spare fuse 7 5 A ...

Page 38: ...15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Camshaft cap bolt M6 18 12 Nm 1 2 m kg 8 7 ft lb Timing chain insertion stud bolt chamber front M6 2 5 Nm 0 5 m kg 3 6 ft lb Timing chain insertion stud bolt chamber rear M6 2 5 Nm 0 5 m kg 3 6 ft lb Exhaust pipe stud bolt M8 8 15 Nm 1 5 m kg 11 ft lb ...

Page 39: ...il pipe stay nut M6 2 10 Nm 1 0 m kg 7 2 ft lb Throttle body joint 1 2 bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Air filter case bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Throttle body joint clamp screw M4 8 3 Nm 0 3 m kg 2 2 ft lb Air filter case joint clamp screw M4 4 3 Nm 0 3 m kg 2 2 ft lb Engine temperature sensor M14 1 17 Nm 1 7 m kg 12 ft lb Exhaust pipe nut M8 8 25 Nm 2 5 m kg 18 ft lb Muffler bolt M10 2...

Page 40: ...Clutch boss nut M20 1 70 Nm 7 0 m kg 51 ft lb Lock washer use Pressure plate bolt M6 6 8 Nm 0 8 m kg 5 8 ft lb Push lever complete bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Bleed screw M8 1 6 Nm 0 6 m kg 4 3 ft lb Drive sprocket nut M22 1 85 Nm 8 5 m kg 62 ft lb Lock washer use Stopper screw M8 1 22 Nm 2 2 m kg 16 ft lb Stopper plate 1 bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Stopper plate bolt M6 1 10 Nm 1 0 ...

Page 41: ...ft lb Headlight stay lower bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Handlebar and grip end M16 2 26 Nm 2 6 m kg 19 ft lb Front flasher nut M12 2 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Headlight stay upper cover bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Clutch hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Throttle cable and throttle body bolt M6 2 4 Nm 0 4 m kg 2 9 ft lb Temperatu...

Page 42: ...0 7 m kg 5 1 ft lb Rear flasher and fender M12 2 4 Nm 0 4 m kg 2 9 ft lb Side cover hook screw M6 2 7 Nm 0 7 m kg 5 1 ft lb Helmet hanger bolt M6 2 13 Nm 1 3 m kg 9 4 ft lb Taillight bracket and frame M8 4 30 Nm 3 0 m kg 22 ft lb Taillight bracket and stay M5 2 8 Nm 0 8 m kg 5 8 ft lb Taillight cover and stay M5 2 2 Nm 0 2 m kg 1 4 ft lb EXUP bracket and frame M6 2 10 Nm 1 0 m kg 7 2 ft lb Lean an...

Page 43: ... lb Tension bar bolt and nut M8 2 2 23 Nm 2 3 m kg 17 ft lb Rear sprocket nut M8 6 69 Nm 6 9 m kg 50 ft lb Chain puller lock nut M8 2 16 Nm 1 6 m kg 12 ft lb Rear caliper and caliper bracket M10 2 40 Nm 4 0 m kg 29 ft lb Rear wheel axle nut M24 1 150 Nm 15 0 m kg 109 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear caliper bleed screw M8 2 6 Nm 0 6 m kg 4 3 ft lb Rear brake disc...

Page 44: ...e stem ends intake and exhaust Valve lifter surfaces Camshaft lobes and camshaft journals Oil pump rotors inner and outer and oil pump shaft Idle gear 1 inner surface Starter clutch assembly Starter gear internal diameter Oil pump drive gear Primary driven gear Ball for clutch Transmission gears wheel and pinion and coller Shift cam bearing Shift fork bar Shift shaft assembly Ball left right Shift...

Page 45: ...and cover 2 Yamaha bond No 1215 Three Bond No 1215 Hexagonal socket head bolt clamp Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant Steering bearings and oil seal lip Front wheel oil seal lip left right Rear wheel oil seal lip left right Clutch hub and mating section Rear brake pedal shaft Shift pedal boss inner Rear footrest bolt shaft and ball Center stand sidestand and bracke...

Page 46: ...N POINTS AND LUBRICANT TYPES 2 23 Swingarm head pipe bearing Swingarm head pipe left right thrust cover oil seal lip Engine bracket bearing Crankcase rear end left side bearing Lubrication point Lubricant M M M M ...

Page 47: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 48: ...LUBRICATION DIAGRAMS 2 25 EAS28860 LUBRICATION DIAGRAMS ...

Page 49: ...LUBRICATION DIAGRAMS 2 26 1 Relief valve 2 Bypass valve 3 Oil filter element 4 Oil pump 5 Camshaft intake 6 Camshaft exhaust 7 Oil strainer housing 8 Oil strainer ...

Page 50: ...LUBRICATION DIAGRAMS 2 27 ...

Page 51: ...LUBRICATION DIAGRAMS 2 28 1 Drive axle 2 Push rod 3 Main axle 4 Camshaft 5 Crankshaft ...

Page 52: ...LUBRICATION DIAGRAMS 2 29 ...

Page 53: ...LUBRICATION DIAGRAMS 2 30 1 Nozzle 2 Bypass valve 3 Oil filter element 4 Relief valve ...

Page 54: ...CABLE ROUTING 2 31 EAS20430 CABLE ROUTING ...

Page 55: ...asten the seat lock cable to the seat rail with a band Face the band clasp downwards and the band end along the top of the fender side M Fasten the O2 sensor lead EXUP sensor lead and throttle body lead together with the leads from the fuse box Ends should face inwards following the rear fender side surface N Flatten the EXUP lead and O2 sensor lead against the engine bracket front side with the l...

Page 56: ...CABLE ROUTING 2 33 ...

Page 57: ...ew The band end should be cut facing towards the front of the vehicle D Fasten the throttle cable to the tension pipe with a band on the tank fitting The band end should face downwards E Pass a clamp through the hole at the top of the gusset and fasten the 2 cables The band end should face inside the vehicle F Clamp high tension cord 3 and high tension cord 4 with a clamp Clamp position is over th...

Page 58: ...CABLE ROUTING 2 35 ...

Page 59: ...bracket Fasten forward of the EXUP lead and O2 sensor lead branch point Band end should face downward to the inside of the back stay K Fit the wire harness plug clamp to the T stud L High tension cords in the order 1 4 from the left M Fasten the wire harness and starter cable on the harness positioning tape to the tank rail with a band The band end should face downwards The wire harness should not...

Page 60: ...CABLE ROUTING 2 37 ...

Page 61: ...ed facing the rear and securely fastened E Insert the left front flasher lead main switch lead immobilizer unit lead and wire harness into the left hole in the bottom of the headlight F Insert the right front flasher lead in the right hole at the bottom of the headlight G Clamp the right handlebar switch lead and brake hose 2 with a band to the side of the cable guide H The band end should clamped...

Page 62: ...CABLE ROUTING 2 39 ...

Page 63: ...tarter motor lead 13 Crankshaft position sensor lead 14 Generator lead A The sub wire harness to 3 should the routed under the vacuum hose B Fit the white mark to 3 C Fit the white mark to 1 D The sub wire harness should be routed under the suction pressure sensor E The sub wire harness should be routed over the fuel hose F Leads and hoses should be routed so as not to get entangled G Should be ro...

Page 64: ...CABLE ROUTING 2 41 ...

Page 65: ...filter case 19 Clip 20 ISC hose 21 ISC motor 22 Throttle bodies 23 Intake manifold A Vacuum hose 1 should be routed under the connector B Fuel hose 1 should be routed over fuel hose 2 C Should be routed over right fuel rail collar D Install vacuum hose 1 in this position E To suction pressure sensor F Install hose 1 2 and 3 clamps from the left side of the vehicle G Install 4 hose clamp from the r...

Page 66: ...CABLE ROUTING 2 43 ...

Page 67: ...Pressure regulator 7 Breather hose 2 8 Vacuum hose 9 Air induction system hose A Direct the claw of the clip upwards on the left of the vehicle B Fit the vacuum hose to the suction pressure sensor C Fit with the white paint facing upwards D Direct the claw of the clip towards the rear of the vehicle ...

Page 68: ...CABLE ROUTING 2 45 ...

Page 69: ...Route pipe 3 to the left side together with pipe 5 to the wire guide J Insert pipe 3 to the end K The bolt should be inserted until the clamp touches the nut L Pipe 5 should be routed between clamp and frame M The tab of the clip faces the rear of the vehicle N When installing the pump align the cut end on the damper with the projection on the pump O The tab of the clip faces the rear of the vehic...

Page 70: ...CABLE ROUTING 2 47 ...

Page 71: ...7 CHECKING THE FUEL LINE 3 17 CHECKING THE CRANKCASE BREATHER HOSE 3 18 CHECKING THE EXHAUST SYSTEM 3 18 ADJUSTING THE EXUP CABLES 3 19 CHASSIS 3 20 ADJUSTING THE FRONT BRAKE 3 20 ADJUSTING THE REAR BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PAD 3 21 CHECKING THE REAR BRAKE PADS 3 21 CHECKING THE FRONT BRAKE HOSES 3 22 CHECKING THE REAR BRAKE HOSE 3 22 ADJUSTING THE RE...

Page 72: ...LUBRICATING THE REAR SUSPENSION 3 32 ELECTRICAL SYSTEM 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULB 3 33 ADJUSTING THE HEADLIGHT BEAM 3 33 ...

Page 73: ...amaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUA L CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 20000 km 4 Air filter element Replace 5 Clutch Check operation fluid level and vehicle for fluid ...

Page 74: ...ration 20 Front fork Check operation and for oil leakage 21 Shock absorber assemblies Check operation and shock absorbers for oil leakage 22 Fuel injection sys tem Adjust synchronization 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter ele ment Replace 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Throttle grip hous in...

Page 75: ...laced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch service Regularly check and if necessary correct the brake fluid and clutch fluid levels Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every ...

Page 76: ...er to AIR INDUCTION SYSTEM on page 6 13 Spark plug 3 Cylinder head cover 4 Timing plate cover 5 Refer to CAMSHAFTS on page 5 5 2 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When the piston is at TDC on the compres sion stroke align the mark a on the pickup coil rotor with the mark b on the crankcase cover TDC NOTE TDC on the compression stroke can be found...

Page 77: ...fter slots with each other b Install the tappet adjusting tool 1 between the camshaft and the valve lifter 2 NOTE Make sure the tappet adjusting tool touches only the valve lifter 2 not the valve pad 3 c Slowly turn the tappet adjusting tool so that the valve pad can be removed Valve clearance measuring sequence Cylinder 1 2 4 3 A Front a Degrees that the crankshaft is turned counterclockwise b Cy...

Page 78: ...nly an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect h Install a new valve pad with the numbered surface facing downward i Remove the tappet adjusting tool j Measure the valve clearance again k If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the s...

Page 79: ...e same value NOTE After each step rev the engine two or three times each time for less than a second and check the throttle bodies When the adjusting screw has been removed turn the screw is fully and then turn it out 3 4 turn Then syncronize the throttle bodies CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body syncroni zation NOTE The pressure difference ...

Page 80: ...aneously for at least 2 seconds 5 Press the SELECT and RESET buttons to select a cylinder NOTE The selected cylinder number appears on the clock LCD To decrease the selected cylinder number press the RESET button To increase the selected cylinder number press the SELECT button 6 After selecting the cylinder simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the sele...

Page 81: ...Check Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play NOTE Pull the cable to the acceleration side to acceler ate Throttle body side a Loosen the locknut 1 on the decelerator ca ble b Turn the adjusting nut 2 in direction a or b to take up any slack on the decelerator ca ble c Loosen the locknut 3 on the accelerator ca ble d Turn the adjusting nut 4 in dire...

Page 82: ...e 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 Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap...

Page 83: ...Timing light Digital tachometer 5 Install Timing plate cover EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 2 Start the engine warm it up for several min utes and t...

Page 84: ...ug cap EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a center stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine...

Page 85: ... the engine oil level wait a few minutes until the oil has settled EAS20790 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil drain bolt 1 along with the gasket Engine oil filler cap 2 O rings 3 4 Drain Engine oil completely from the crankcase 5 If the oil filter element is also to...

Page 86: ...he minimum level mark Add the recommended engine oil to the proper level 2 Install a pocket tester with temperature probe in the oil drain bolt 1 3 Start the engine warm it up for several min utes and then turn it off CAUTION ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure ...

Page 87: ...with the arrow mark 2 on the clutch lever hold er EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the vehicle on a level surface Pressure gauge 90890 03153 Oil pressure adapter B 90890 03124 Oil pressure hot 80 0 kPa 1000 r min 11 6 psi 1000 r min 0 80 kgf cm2 1000 r min Oil temperature 85 0 95 0 C 185 00 203 00 F Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil...

Page 88: ...ed a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty NOTE Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over flow When bleeding the hydraulic clutch system make sure there is always enough clutch fluid before applying the clutch lever Ignoring this precaution could allow air to enter the hydraulic clutch ...

Page 89: ...f you are riding in unusually wet or dusty areas 3 Install Air filter element 1 Air filter case cover Side cover right Refer to GENERAL CHASSIS on page 4 1 CAUTION ECA14400 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carbure t...

Page 90: ...e Loose connection Connect properly CAUTION ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 6 1 EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Check Exhaust pipe Muffler Cracks damage Replace Gasket Exhaust gas leaks Replace 2 Check Tightening torque 1 1 1 2 Exhaust pi...

Page 91: ...e pul ley a 4 Adjust EXUP cable free play a Turn the main switch to ON b Check the EXUP pully position c Remove right side cover d Loosen both locknuts 1 e Turn both adjusting bolts 2 to adjust free play in EXUP cable f Install the right side cover 5 Install EXUP valve pulley cover Maximum EXUP cable free play at the EXUP valve pulley Within 1 5 mm 0 06 in 1 a a Direction a Increase EXUP cable fre...

Page 92: ...AS21190 ADJUSTING THE REAR BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position check that the end of ...

Page 93: ...ing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediate...

Page 94: ...upright and apply the brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 27 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake l...

Page 95: ...agm brake master cylinder reservoir or brake fluid reservoir Brake master cylinder reservoir or brake fluid reser voir c Connect a clear plastic hose 1 tightly to the bleed screw 2 and place an oil pan under the vinyl hose end on one side d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake pedal and h...

Page 96: ...er 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 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Both wheels should be on the ground without a rider on the vehicle 2 Move the rear wheel several times...

Page 97: ... oughly lubricate it with chain lubricant that is suitable for O ring chains EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs a...

Page 98: ... h Install the lock washer 1 NOTE Make sure the lock washer 1 tabs a sit cor rectly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 50 Handlebar Refer to HANDLEBAR on page 4 38 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage ...

Page 99: ... preload a Turn the adjusting bolt 1 in direction a or b Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload Minimum soft 8 Standard 5 Maximum hard ...

Page 100: ...ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Loosen the lock screw 1 by 1 2 turn b Insert a screwdriver into the hole in the spring seat c Turn the spring seat 2 in direction a or b Direction a Compression damping is increased sus pension is harder Direction b Compression damping is decreased sus pension is softer Compression damping Maximum hard 1...

Page 101: ...ON ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping a Turn the adjusting knob 1 in direction a or b Lock screw 0 1 Nm 0 01 m kg 0 07 ft lb Direction a Rebound damping is increased suspen sion is harder Direction b Rebound damping is decreased suspen sion is softer c T R Rebound damping Minimum soft 36 click s out Standard 10 click s out Maximum hard...

Page 102: ... OVERLOAD THE VEHICLE WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check Tire surfaces Damage wear Replace the tire 1 a b Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm2 2 50 bar Rear 250 kPa 36 psi 2 50 kgf cm2 2 50 bar Loading condition 90 205 k...

Page 103: ...es should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA5UXB003 New tires have a relatively low grip on the road surface until they have been slightly worn Failure to do so could lead to an acci dent with possible injury to the rider...

Page 104: ...e cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21730 LUBRICATING T...

Page 105: ...oled down 4 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacqu...

Page 106: ...ECTRICAL SYSTEM 3 34 2 Adjust Headlight beam horizontally a Turn the adjusting screw 2 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 2 a b ...

Page 107: ...REMOVING THE FRONT BRAKE CALIPERS 4 21 DISASSEMBLING THE FRONT BRAKE CALIPER 4 21 CHECKING THE FRONT BRAKE CALIPER 4 22 ASSEMBLING THE FRONT BRAKE CALIPER 4 22 INSTALLING THE FRONT BRAKE CALIPERS 4 23 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 24 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 24 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 25 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 25 REAR BRAKE ...

Page 108: ...E STEERING HEAD 4 52 REAR SHOCK ABSORBER ASSEMBLY 4 54 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4 55 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 55 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 55 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 55 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 SWINGARM 4 57 REMOVING THE SWINGARM 4 58 CHECKING THE SWINGARM 4 58 INSTALLING THE SWINGAR...

Page 109: ...SIS Removing the passenger seat and side cover Order Job Parts to remove Q ty Remarks 1 Seat 1 2 Side cover left right 1 1 3 Grab bar 1 4 Rear fender cover 1 For installation reverse the removal proce dure 2 1 3 4 2 T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 110: ... pinch bolt 1 Loosen 2 Brake hose holder left right 1 1 3 Front brake caliper left right 1 1 4 Wheel axle 1 5 Front wheel assembly 1 6 Spacer 1 7 Collar 1 8 Brake disc left right 1 1 For installation reverse the removal proce dure 2 3 4 1 7 6 6 8 5 8 6 2 3 T R 72 Nm 7 2 m kg 52 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib ...

Page 111: ...RONT WHEEL 4 3 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Bearing 1 For assembly reverse the disassembly pro cedure 5 4 1 2 3 ...

Page 112: ...3 EAS21910 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle ...

Page 113: ... oil seal EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1...

Page 114: ...nce a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS5UXB010 INSTALLING THE FRONT WHEEL DISC 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Front wheel axle 1 NOTE Align the tire rotation mark a wit...

Page 115: ...all Right brake caliper Left brake caliper WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 31 Brake caliper bolt 40 Nm 4 0 m kg 29 ft lb a 1 2 3 T R ...

Page 116: ...to remove Q ty Remarks 1 Chain adjuster 1 2 Nut 2 3 Washers 1 4 Left chain puller 1 5 Wheel axle 1 6 Right chain puller 1 7 Rear wheel assembly 1 8 Spacer left 1 9 Spacer right 1 For installation reverse the removal proce dure 1 2 3 4 1 5 6 7 9 8 T R 150 Nm 15 0 m kg 109 ft Ib ...

Page 117: ...s to remove Q ty Remarks 1 Brake disc 1 2 Rear wheel sprocket 1 3 Rear wheel drive hub 1 4 Rear wheel drive hub damper 5 5 Oil seal 1 6 Bearing 1 7 Collars 1 For installation reverse the removal proce dure 1 6 3 7 2 4 6 6 5 T R 23 Nm 2 3 m kg 17 ft Ib T R 69 Nm 6 9 m kg 50 ft Ib ...

Page 118: ...REAR WHEEL 4 10 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Bearing 1 3 Spacer 1 4 Bearing 1 For assembly reverse the disassembly pro cedure 2 3 4 1 ...

Page 119: ...ove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 4 EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 4 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHECKING THE WHEELS on page 3 32 3 Measure Radial wheel runout Lateral wheel runout Refer to CHEC...

Page 120: ...earing at an angle NOTE Knock in the bearing so that dimension a is 7 mm as in the illustration EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL ...

Page 121: ...REAR WHEEL 4 13 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 Wheel axle nut 150 Nm 15 0 m kg 109 ft lb Drive chain slack 20 0 30 0 mm 0 79 1 18 in T R ...

Page 122: ...14 EAS22210 FRONT BRAKE Removing the front brake pads Order Job Parts to remove Q ty Remarks 1 Clip 2 2 Pad pin 1 3 Pad support 1 4 Brake pad Brake pad shim 2 2 For installation reverse the removal proce dure 4 3 1 2 ...

Page 123: ...C BRAKE SYSTEM on page 3 23 1 Brake lever 1 2 Front brake switch lead 2 Disconnect 3 Front brake switch 1 4 Brake hose union bolt 1 5 Copper washer front brake hose 3 2 6 Brake master cylinder holder 1 7 Brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 5 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib S ...

Page 124: ...16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder boots 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 For assembly reverse the disassembly pro cedure 1 2 3 4 ...

Page 125: ...Remarks Drain the brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Front brake caliper 1 For installation reverse the removal proce dure 1 2 3 4 T R 40 Nm 4 0 m kg 29 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 126: ...ty Remarks 1 Clip 2 2 Pad pin 1 3 Pad support 1 4 Brake pad Brake pad shim 2 2 5 Brake caliper piston 4 6 Brake caliper dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure 7 1 2 4 3 7 5 5 6 7 6 T R 6 Nm 0 6 m kg 4 3 ft Ib S S BF BF ...

Page 127: ... water for 15 minutes and get im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISC The following procedure applies to both brake disc 1 Remove Front wheel Refer to FRONT WHEEL on page 4 2 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so...

Page 128: ...h brake pad NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Remove Clip 1 Turn the pad pin with pliers to change to a po sition for easy removal of the clip Pad pin 2 Pad support 3 2 Remove Brake pads 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pad shims onto the brake...

Page 129: ... 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake caliper NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose NOTE Put the end of t...

Page 130: ...out with compressed air WARNING EWA13600 Whenever a brake caliper is disassembled replace the dust seals and piston seals 2 Check Brake caliper brackets Cracks damage Replace EAS22410 ASSEMBLING THE FRONT BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents a...

Page 131: ...e 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 flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly...

Page 132: ...rake hoses 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit 1 Damage scratches wear R...

Page 133: ... NOTE While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Add the recommended brake fluid to the proper level Brake master cylinder reservoir WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deterio...

Page 134: ...d Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 a ...

Page 135: ... Job Parts to remove Q ty Remarks 1 Rear brake caliper 1 2 Clip 4 3 Pad pin 2 4 Pad support 1 5 Brake pad 2 6 Brake caliper shim 2 7 Bleed screw 2 For installation reverse the removal proce dure 2 3 4 5 2 3 6 6 7 7 1 T R 40 Nm 4 0 m kg 29 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 136: ...t 2 2 Right footrest assembly 1 3 Rear brake switch hook 1 4 Brake hose union bolt 1 5 Copper washer 2 6 Clip hose 2 1 7 Clip washer 1 1 8 Pin 1 9 Rear brake master cylinder 1 10 Rear brake fluid reservoir brake fluid reservoir diaphragm brake fluid reservoir cap 1 1 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 2...

Page 137: ...ssembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder boots 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Spring 1 For assembly reverse the disassembly pro cedure 1 2 3 4 S ...

Page 138: ...emarks Drain the brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Front brake caliper 1 For installation reverse the removal proce dure 1 2 3 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib ...

Page 139: ...Remarks 1 Clip 4 2 Pad pin 2 3 Pad support 1 4 Brake pad Brake pad shim 2 2 5 Brake caliper piston 2 6 Brake caliper dust seal 2 7 Brake caliper piston seal 2 8 Bleed screw 2 For assembly reverse the disassembly pro cedure 8 8 6 5 6 3 4 2 1 1 2 7 7 T R 6 Nm 0 6 m kg 4 3 ft Ib S S BF BF ...

Page 140: ...e disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 19 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 DISC on page 4 19 5 Adjust Brake disc deflection...

Page 141: ...ake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake ho...

Page 142: ... Whenever a brake caliper is disassembled replace the brake caliper piston dust seals EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disass...

Page 143: ...When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 5 Check Brake...

Page 144: ...iaphragm 2 Cracks damage Replace 4 Check Brake hoses 1 Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Install Master cylinder kit 1 Circlip 2 Dust boot 3 EAS22750 INSTALLING THE REAR BRAK...

Page 145: ... a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer t...

Page 146: ...cable 2 7 Grip end 1 8 Throttle grip 1 9 Master cylinder holder 1 10 Clutch master cylinder 1 11 Left handlebar switch 1 12 Grip end 1 13 Handlebar grip 1 14 Collars 1 15 Handlebar upper holder 2 16 Handlebar 1 For installation reverse the removal proce dure 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m ...

Page 147: ...Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22930 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar 1 Handlebar upper holder 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear sid...

Page 148: ... NOTE Align the projections a on the handlebar switches with the holes b in the handlebar 5 Install Right handlebar switch 1 NOTE Align the projection on the handlebar switch with the hole a on the handlebar 6 Install Left handlebar switch 1 NOTE Align the projection on the left handlebar switch with the hole a on the handlebar 7 Install Brake master cylinder Refer to INSTALLING THE FRONT BRAKE MA...

Page 149: ...EEL on page 4 2 1 Bracket 2 2 Front fender 1 3 Upper bracket pinch bolt 2 Loosen 4 Cap bolt 2 Loosen 5 Lower bracket pinch bolt 4 Loosen 6 Fork leg left right 1 1 For installation reverse the removal proce dure 1 2 5 3 4 6 T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 150: ...6 Spacer 1 7 Spring 1 8 Dust seal 1 9 Stopper ring 1 10 Bolt 1 11 Gasket 1 12 Oil seal 1 13 Oil seal washer 1 14 Slide metal 1 15 Inner tube 1 16 Piston metal 1 17 Tapered spindle 1 18 Spring 1 19 Damper rod assembly 1 20 Outer tube 1 9 12 13 14 15 16 18 17 20 11 10 1 2 3 4 6 7 5 19 8 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib ...

Page 151: ...e the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 9 12 13 14 15 16 18 17 20 11 10 1 2 3 4 6 7 5 19 8 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib ...

Page 152: ...A13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 3 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from inner tube Loosen 2 and remove 2 Remove Nut 1 Spring guide 2 Push rod 3 Spacer 4 Front fork spring 3 Drain Fork oil 4 Remove Dust seal 1 with a flat head...

Page 153: ...the outer tube during the above procedure as the oil flow stopper will be damaged 8 Remove Inner tube 1 Piston metal 2 Tapered spindle 3 Spring 4 Damper rod assembly 5 EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube Bends damage scratches Replace Damper rod assembly 2 Damage wear Replace Obstruction Blow out all o...

Page 154: ...ust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Spring 2 Tapered spindle 3 Piston metal 4 Inner tube 5 CAUTION ECA5UXB009 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Ins...

Page 155: ... a plastic bag to protect the oil seal during installation 5 Install Stopper ring Dust seal 1 with the fork seal driver 2 and attachment 3 NOTE Fit the stopper ring into the outer tube 6 Check Inner tube operation Not operating smoothly Disassemble and check again 7 Fully compress the front fork leg Frok seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachment ø43 9...

Page 156: ...stroke the inner tube over 150 mm 8 12 in as this will cause air to enter 11 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed CAUTION ECA5UXB007 Be sure to fill to the top of the inner tube with fork oil and remove air If the inner tube is not filled to the top the fork oil will not circulate outside the tube resulting in incorrect s...

Page 157: ...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 NOTE Check that the top end of the inner tube is level with the upper bracket s top end 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload R...

Page 158: ...ight body internal connections Disconnect 3 Nut Collar 2 2 4 Headlight body 1 5 Brake hose holder 2 6 Meter assemblies 1 7 Damper 4 8 Headlight bracket 1 9 Temperature sensor lead coupler 1 Disconnect For installation reverse the removal proce dure 2 1 3 3 6 7 8 5 5 2 9 4 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 159: ... ring nut 1 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 8 Dust seal 1 9 Ball race cover 1 10 Bearing set upper 1 11 Bearing set lower 1 12 Dust seal 1 13 Handlebar lower holder 2 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 11 12 13 T R 110 Nm 11 0 m kg 80 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 52 Nm 5 2 m kg 38 ft Ib 18 Nm 1 8 m kg 13 ft Ib Return fully T R 1st 2nd ...

Page 160: ...the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is d...

Page 161: ... to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 25 3 Install Upper bracket Steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 41 NOTE Temporarily tighten the upper and lower bracket pinch bolts Recommended lubricant Lithium soap based grease Steering stem nut 110 Nm 11 0 m kg 80 ft lb 1 2 3 4 T R ...

Page 162: ...EMBLY Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks 1 Right left rear shock absorber assembly 1 1 For installation reverse the removal proce dure 1 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib ...

Page 163: ...st be released before dis posing of a rear shock absorber and gas cyl inder To release the gas pressure drill a 2 3 mm hole through the rear shock absorber at a point 15 20mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23220 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Secu...

Page 164: ...SEMBLY 1 Install Rear shock absorber assembly NOTE With the rear shock absorber assembly tighten in the order left right lower bolts then upper bolts Rear shock absorber assembly lower bolt 30 Nm 3 0 m kg 22 ft lb Rear shock absorber assembly upper bolt 23 Nm 2 3 m kg 17 ft lb T R ...

Page 165: ... 4 54 1 Chain case 1 2 Brake hose clamp 2 3 Brake torque rod brake caliper bracket 1 1 4 Pivot shaft 1 5 Swingarm 1 6 Seal guard 1 7 Thrust cover oil seal 2 2 8 Bushing 1 9 Bearing 2 For installation reverse the removal proce dure 1 M 3 2 2 6 4 M M 7 9 9 7 8 5 3 T R 125 Nm 12 5 m kg 90 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 ft...

Page 166: ...ica tion check the spacers and bearings d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers and bearings EAS23370 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Bends damage Replace 3 Check Thrust cover 1 Oil seals 2 Bearings 3 Spacer 4 Damage wear Re...

Page 167: ...haft 3 Install Rear shock absorber assembly Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 54 and REAR WHEEL on page 4 8 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 Drive chain slack 20 0 30 0 mm 0 79 1 18 in New ...

Page 168: ...ENGINE REMOVAL on page 5 1 Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 54 Rear wheel Refer to REAR WHEEL on page 4 8 Swingarm Refer to SWINGARM on page 4 57 1 Drive sprocket nut 1 2 Lock washer 1 3 Drive sprocket 1 4 Drive chain 1 For installation reverse the removal proce dure 1 3 2 4 T R 85 Nm 8 5 m kg 62 ft Ib ...

Page 169: ...RM on page 4 57 EAS23440 CHECKING THE DRIVE CHAIN 1 Measure 15 link length of the drive chain Out of specification Replace the drive chain a Measure the 15 link section inside length a and pin outer length b b Measure the drive chain s 15 link length c using the following formula 15 link section a of the drive chain Pin inside length a pin outer length b 2 NOTE While measuring the 15 link section ...

Page 170: ...ain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket Refer to CHECKING THE REAR WHEEL SPROCKET on page 4 11 EAS23470 CHECKING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket Refer to CHECKING THE REAR WHEEL SPROCKET on page 4 11 EAS23480 CHECKING...

Page 171: ... AND VALVE GUIDES 5 18 CHECKING THE VALVE SEATS 5 19 CHECKING THE VALVE SPRINGS 5 21 CHECKING THE VALVE LIFTERS 5 22 INSTALLING THE VALVES 5 22 CYLINDER AND PISTON 5 24 REMOVING THE PISTON 5 25 CHECKING THE CYLINDER AND PISTON 5 25 CHECKING THE PISTON RINGS 5 26 CHECKING THE PISTON PIN 5 27 INSTALLING THE PISTON AND CYLINDER 5 27 GENERATOR 5 30 CHECKING THE GENERATOR 5 31 TIMING PLATE 5 33 ELECTRI...

Page 172: ...THE OIL PUMP 5 56 SHIFT SHAFT 5 57 CHECKING THE SHIFT SHAFT 5 58 CHECKING THE STOPPER LEVER 5 58 INSTALLING THE SHIFT SHAFT 5 58 OIL PAN 5 59 REMOVING THE OIL PAN 5 60 CHECKING THE RELIEF VALVE 5 60 CHECKING THE OIL STRAINER 5 60 INSTALLING THE OIL STRAINER 5 60 INSTALLING THE OIL PAN 5 60 CRANKCASE 5 61 DISASSEMBLING THE CRANKCASE 5 62 CHECKING THE CRANKCASE 5 62 ASSEMBLING THE CRANKCASE 5 62 STA...

Page 173: ...G THE CRANKSHAFT 5 76 TRANSMISSION 5 77 CHECKING THE SHIFT FORKS 5 81 CHECKING THE SHIFT FORKS 5 81 CHECKING THE TRANSMISSION 5 81 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 5 82 INSTALLING THE TRANSMISSION 5 82 ...

Page 174: ...EXUP cover 1 4 EXUP cable 2 5 O2 sensor 1 6 Exhaust pipe exhaust gasket 1 4 7 Exhaust pipe bracket 1 8 Oil cooler 1 9 O ring 2 10 Air scoop left right 1 1 11 Crankcase breather hose 1 12 Ground lead 1 Disconnect For installation reverse the removal proce dure 2 4 3 9 8 10 6 11 12 6 7 5 1 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 10 Nm 1 0 m kg 7 2 ft ...

Page 175: ... Shift arm 1 6 Generator 1 7 Clutch push lever Comp 1 8 Cover stay 1 1 9 Speed sensor 1 10 Drive sprocket cover 1 11 Starter motor lead 1 12 Starter motor 1 13 Dowel pin 2 14 Drive sprocket nut 1 15 Lock washer 1 16 Drive sprocket Drive chain 1 1 For installation reverse the removal proce dure 11 12 1 5 4 7 6 8 9 10 16 13 14 15 16 2 3 LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T ...

Page 176: ... Engine bracket rear lower 1 7 Engine 1 For installation reverse the removal proce dure 5 1 2 4 7 3 3 5 6 T R 48 Nm 4 8 m kg 35 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib T R 30 Nm 3 0 ...

Page 177: ...gine mounting nut front Engine mounting nut rear lower 3 Install Shift arm 1 NOTE Align the punch mark a in the shift shaft with the punch mark b in the shift arm 4 Adjust Shift pedal position Refer to ADJUSTING THE SHIFT PEDAL on page 3 24 Engine bracket bolt rear upper 88 Nm 8 8 m kg 64 ft lb Engine bracket bolt rear upper 48 Nm 4 8 m kg 35 ft lb Engine mounting nut rear upper 55 Nm 5 5 m kg 40 ...

Page 178: ...ty Remarks Air induction system Refer to AIR INDUCTION SYSTEM on page 6 13 1 Oil cooler bolt 2 2 Air scoop left right 1 1 3 Plug cap 4 Disconnect 4 Cylinder head cover 1 5 Gasket 1 For installation reverse the removal proce dure 4 5 3 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 179: ... chain tensioner assembly 1 5 Chain guide 1 6 Camshaft cap 8 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Camshaft sprockets 2 For installation reverse the removal proce dure 6 9 5 2 4 1 7 8 3 M M T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 180: ...ing chain guide top side 1 Camshaft sprockets 2 Camshaft caps 3 Timing chain guide exhaust side NOTE For reference during installation put identifica tion marks on each camshaft cap CAUTION ECA13720 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 6 Remove Intake camshaft 1 Exhaust cam...

Page 181: ...inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 Camshaft lobe dimension limit Intake A 35 849 35 949 mm 1 4114 1 4153 in Limit 35 749 mm 1 4074 in Intake B 28 010 28 110 mm 1 1023 1 1067 in Limit 27 910 mm 1 0988 in Exhaust A 35 950 36 050 mm 1 4154...

Page 182: ...Damage wear Replace EAS23960 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner housing 3 Check Cap bolt Spring One way cam Timing chain tensioner rod Damage wear Replace EAS24000 INSTALLING THE CAMSHAFTS 1 Install Intake camshaft sprocket Exhaust camshaft sprocket with the camshaf...

Page 183: ...n the crankshaft when installing the camshaft s to avoid damage or improp er valve timing d Install the camshaft caps 3 NOTE Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows I Intake E Exhaust Make sure the arrow mark on each camshaft points towards the right side of the engine Do not tighten the camshaft cap bolts yet CAUTION ECA13730 The...

Page 184: ...l turns counterclockwise 6 Check T mark a T mark should be aligned with the stationary pointer b Camshaft punch mark c Make sure the punch mark on the camshaft is aligned with the camshaft cap hole d When out of alignment re install Refer to the installation steps above 7 Tighten Camshaft sprocket bolts CAUTION ECA13750 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoi...

Page 185: ...CAMSHAFTS 5 12 Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 10 Install Timing plate cover ...

Page 186: ... assembly2 1 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Gasket 2 5 Dowel pin 4 6 Left right protector bracket 1 1 7 Intake manifold O ring 2 4 8 Engine temperature sensor gasket 1 1 For installation reverse the removal proce dure 1 2 4 5 5 6 7 7 8 7 7 5 5 3 4 T R 35 Nm 3 5 m kg 25 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E ...

Page 187: ...der head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d 400 Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding ...

Page 188: ...ad nuts NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 4 Install Exhaust camshaft Intake camshaft Refer to CAMSHAFTS on page 5 5 Cylinder head nuts 35 Nm 3 5 m kg 25 ft lb T R 12 8 4 2 6 10 9 5 3 7 11 1 15 14 13 16 ...

Page 189: ... Cylinder head Refer to CYLINDER HEAD on page 5 13 1 Valve pad 16 2 Valve lifter 16 3 Valve cotter 32 4 Valve spring retainer 16 5 Valve spring inner 16 6 Valve spring outer 16 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Valve spring seat 16 For installation reverse the removal proce dure 1 2 3 4 5 6 9 10 1 2 3 4 6 5 10 9 7 8 ...

Page 190: ... Check Valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 19 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve sp...

Page 191: ...and to maintain the correct fit heat the cylinder head to 100 C in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037...

Page 192: ...ve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the oil seal EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Clean Eliminate Carbon deposits from the valve face and valve seat Valve guide remover installer set ø5 5 90890 ...

Page 193: ...acing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve f...

Page 194: ...p the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring b c Valve spring free length Inner Free length intake 39 65 mm 1 56 in Free length exhaust 39 65 mm 1 56 in Outer Fr...

Page 195: ...l of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 3 with the recommended lubricant 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head b Installed length Spring tilt limit Inner Spring tilt intake 2 5 1 7 mm 2 5 0 067 in Spring tilt exhaust 2 5 1 7 mm 2 5 0 067 in O...

Page 196: ...tters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad 1 Valve lifter 2 with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original ...

Page 197: ...er Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 13 1 Cylinder 1 2 Dowel pin 3 3 Cylinder gasket 1 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Piston ring set 4 For installation reverse the removal proce dure 3 4 7 5 6 4 1 2 E T R 20 Nm 2 0 m kg 15 ft Ib ...

Page 198: ...HE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the measurements b If out ...

Page 199: ... cylinder NOTE Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification Replace the piston ring NOTE 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 b 5 mm 0 20 in from the bottom edge of the piston Piston diameter D 78 970 78 985 mm 3 1090 3 1096 in Piston to c...

Page 200: ...oil ring rail 3 Upper oil ring rail 4 Oil ring expander 5 NOTE Be sure to install the piston rings so that the manufacturer s marks face up piston ring end gap Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 75 mm 0 0295 in Oil ring End gap installed 0 20 0 50 mm 0 0079 0 0197 in Piston pin outside di...

Page 201: ...wards the exhaust side of the engine Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank case Reinstall each piston into its original cylinder In order from left 1 4 3 Install Cylinder gasket 1 Dowel pins 2 5 3 1 2 4 a New A Exhaust side B Intake side 2 1 3 1 a A B New 1 2 2 ...

Page 202: ...bricate Piston Piston rings Cylinder Apply recommended lubricant 5 Offset Piston ring end gap 6 Install Cylinder Recommended lubricant Engine oil a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Forward d c b A a ...

Page 203: ...5 1 1 End cover 1 2 Brush holder 1 3 Regulator 1 4 Rectifier cover 1 5 Rectifier 1 6 Rear cover 1 7 Rotor assembly 1 8 Bearing cover plate 1 9 Bearing drive side 1 10 Bearing slip ring side 1 11 Stator assembly 1 For installation reverse the removal proce dure 9 8 7 10 1 2 3 4 5 11 6 T R 25 Nm 2 5 m kg 18 ft Ib T R 7 Nm 0 7 m kg 5 ft Ib ...

Page 204: ...force 4 Measure Field coil rotor resistance Out of specification Replace the rotor coil a Connect the pocket tester Ω 1 to the stator coil terminals as shown Stator coil resistance 0 19 0 21 Ω at 20 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Tester positive probe White 1 Negative tester probe Black 2 Tester positive probe White 1 Negative tester probe Black 3 1 2 3 Brush use limit...

Page 205: ...GENERATOR 5 32 b Measure the stator coil resistances 1 2 ...

Page 206: ... Fuel tank Refer to FUEL TANK on page 6 1 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Timing plate cover 1 3 Gasket 1 4 Crankshaft position sensor 1 5 Timing plate 1 6 Dowel pin 1 7 Pickup base 1 For installation reverse the removal proce dure LT T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 45 Nm 4 5 m kg 33 ft Ib LT 1 2 3 4 5 6 7 ...

Page 207: ... Order Job Parts to remove Q ty Remarks Starter motor Refer to ENGINE REMOVAL on page 5 1 1 Front bracket 1 2 Washer kit 1 3 Rear bracket 1 4 Washer kit 1 5 Brush holder Brush1 1 1 6 Armature coil 1 7 Stator assembly 1 For assembly reverse the disassembly pro cedure 1 2 7 6 5 4 3 ...

Page 208: ...ances commutator and insulation Out of specification Replace the starter motor a Measure the resistance 1 and mica 2 re sistance with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Commutator diamet...

Page 209: ...ar cover 2 Install Starter motor yoke 1 Front bracket 2 Rear bracket 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and rear brackets EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor Starter motor bolts 2 Connect Starter motor lead Brush spring force 7 65 10 01 N 27 54 36 03 oz 780 1021 gf 1 b a Starter motor 10 Nm 1 0 m kg 7 2 ft lb b b a...

Page 210: ...e cover Order Job Parts to remove Q ty Remarks Drain the engine oil Refer to ENGINE on page 3 4 1 Crankcase cover right 1 2 Crankcase cover gasket right 1 3 Dowel pin 2 For installation reverse the removal proce dure 1 3 2 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 211: ...h push rod 1 8 O ring 1 9 Friction plate 1 narrow 1 10 Clutch plate 6 11 Friction plate 2 3 12 Friction plate 3 3 13 Clutch boss nut 1 14 Lock washer 1 15 Clutch boss 1 16 Wire circlip 1 17 Clutch plate 1 18 Spring 1 19 Spring seat plate 1 20 Friction plate 1 narrow 1 New New LS E E 13 14 15 24 21 22 23 20 19 18 17 16 11 10 9 1 2 3 4 5 8 6 7 12 T R 70 Nm 7 0 m kg 51 ft Ib T R 8 Nm 0 8 m kg 5 8 ft ...

Page 212: ...rimary driven gear 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks New New LS E E 13 14 15 24 21 22 23 20 19 18 17 16 11 10 9 1 2 3 4 5 8 6 7 12 T R 70 Nm 7 0 m kg 51 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib ...

Page 213: ...uid Refer to ENGINE on page 3 4 1 Clutch lever 1 2 Clutch switch lead 1 3 Clutch switch 1 4 Union bolt 1 5 Copper washer Clutch hose 2 1 6 Master cylinder bracket 1 7 Master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib S S ...

Page 214: ...41 Disassembling the clutch master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 For assembly reverse the disassembly pro cedure 3 2 4 1 ...

Page 215: ... fluid Refer to ENGINE on page 3 4 1 Clutch release cylinder bolt long short 2 1 2 Clutch hose union bolt 1 3 Copper washer 3 4 Spacers 1 5 Clutch hose 1 6 Clutch release cylinder 1 For installation reverse the removal proce dure 1 1 1 6 3 4 3 2 3 5 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 216: ...e clutch release cylinder Order Job Parts to remove Q ty Remarks 1 Clutch release cylinder 1 2 Piston seals 1 3 Clutch release cylinder piston 1 4 Piston seals 1 5 Spring 1 For assembly reverse the disassembly pro cedure 5 3 4 2 1 ...

Page 217: ...tch chattering 3 Remove Spacer 1 Bearing NOTE Insert M6 bolts 2 into the spacer and then re move the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to inspection of all friction plates 1 Check Friction plate Damage wear Replace the friction plate as a set 2 Measure Friction plate thickness Out of specification Replace the friction plate as a se...

Page 218: ...ce 2 Check Clutch spring seat Damage Replace 3 Measure Clutch spring free height Out of specification Replace the clutch spring plate EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bea...

Page 219: ...tch push rod 2 Long clutch push rod 3 Ball 4 Bearing 5 Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out of specification Replace EAS25250 INSTALLING THE CLUTCH 1 Install Clutch housing 1 NOTE Make sure the oil pump drive gear and primary driven gear are installed with the two projections meshed into the two slots respectively 2 Install Bearing 1 Spa...

Page 220: ...e clutch boss first 7 Lubricate Friction plates1 2 3 Clutch plates with the recommended lubricant 8 Install Friction plates 3 1 Friction plates 2 2 Friction plates 1 3 Clutch plates 4 NOTE First install a friction plate and then alternate be tween a clutch plate and a friction plate 9 Install Pressure plate 1 Clutch plate spring 2 Clutch springs 3 Clutch spring bolts 4 NOTE Tighten the clutch spri...

Page 221: ...dy Obstruction Blow out with compressed air WARNING EWA13330 Whenever a clutch master cylinder is disas sembled replace the piston seals 2 Check Clutch master cylinder 1 Clutch master cylinder kit 2 Rust scratches wear Replace the clutch master cylinder and clutch master cylinder kit as a set Clutch hose 3 Cracks damage wear Replace EAS25300 ASSEMBLING THE CLUTCH MASTER CYLINDER WARNING EWA13340 B...

Page 222: ...olt 2 Install Copper washers Clutch hose 1 Union bolt 2 WARNING EWA13360 Proper clutch hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING on page 2 31 NOTE While holding the clutch hose tighten the union bolt 3 Install Clutch lever 1 NOTE Lubricate the clutch lever pivot bolt with silicon grease 4 Fill Fill with the specified amount of recommend ed clutch fluid C...

Page 223: ... clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 16 EAS25320 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1 Remove Oil seal 1 Clutch release cylinder piston 2 Spring 3 Piston seal 4 a Blow compressed air into the bleed screw of the clutch hose joint opening to force out the piston from the clutch release cylinder WARNING EWA13380 Cover the clutch release cylinder with a rag Be c...

Page 224: ...utch fluid Clutch master cylinder reservoir WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be carefu...

Page 225: ...eck Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 15 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 16 a ...

Page 226: ...age 5 37 1 Oil pump drive gear 1 2 Collar 1 3 Washer 1 4 Oil buffer plate 1 5 Circlip 1 6 Oil pump driven gear 1 7 Plate washer 1 8 Oil pump assembly 1 9 Dowel pin 1 10 Collar 1 11 O ring 3 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 11 11 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib ...

Page 227: ...emarks 1 Rotor housing 1 2 Inner rotor 1 3 Outer rotor 1 4 Dowel pin 1 5 Dowel pin 1 6 Housing 1 7 Inner rotor 1 8 Outer rotor 1 9 Dowel pin 1 10 Pump shaft 1 11 Pump cover 1 For installation reverse the removal proce dure 2 3 4 6 9 7 8 11 5 10 1 T R 7 Nm 0 7 m kg 5 2 ft Ib ...

Page 228: ... and out er rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Replace the defective part s EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 4 3 1 2 4 3 1 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 120 mm or less 0 0047 in or less Lim...

Page 229: ... 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 55 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly NOTE Align the arrow mark a on the oil pump with the arrow mark b on the crankcase Recommended lubricant Engine oil Oil pump cover screw 7 Nm 0 7 m kg 5 1 ft lb Oil pump bolt 10 Nm 1 0 m kg ...

Page 230: ...ks Oil pump Refer to OIL PUMP on page 5 53 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 1 1 Circlip 1 2 Plate washer 1 3 Shift shaft 1 4 Plate washer 1 5 Torsion spring 1 6 Bolt 1 7 Stopper lever 1 8 Torsion spring 1 For installation reverse the removal proce dure 1 2 3 5 4 7 6 8 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 231: ...place Roller turns roughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 Shift shaft lever 3 NOTE Hook the ends 4 of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly 2 Install Washer 1 Shift shaft 2 Circlip 3 NOTE Lubricate the oil seal lips with lithi...

Page 232: ...age 5 1 1 Oil level switch O ring 1 1 2 Oil pan 1 3 Dowel pin 2 4 Oil pan gasket 1 5 Relief valve Large O ring 1 1 6 Relief valve Small O ring 1 1 7 Oil strainer 1 8 Oil strainer housing 1 9 Gasket 1 For installation reverse the removal proce dure LT 4 6 3 3 2 5 9 8 7 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 233: ... STRAINER 1 Install Oil strainer housing 1 NOTE Install with the oil strainer housing arrow mark a facing forward 2 Install Oil strainer 1 Relief valve large 2 NOTE Install with the oil strainer arrow mark a facing forward EAS5UXB007 INSTALLING THE OIL PAN 1 Install Dowel pins Gasket Oil pan Oil level switch Engine oil drain bolt NOTE Tighten the oil pump mounting bolts in two stag es and in a cri...

Page 234: ... on page 5 53 Shift shaft Refer to SHIFT SHAFT on page 5 57 Timing plate crankshaft position sensor Refer to TIMING PLATE on page 5 33 Oil pan Refer to OIL PAN on page 5 59 1 Spring Rod 1 1 2 Timing chain guide intake side 1 3 Cover 1 4 Bearing cover plate 1 5 Lower crankcase 1 6 Dowel pin 1 For installation reverse the removal proce dure LT LT 3 4 2 1 5 6 E T R 35 Nm 3 5 m kg 25 ft Ib T R 24 Nm 2...

Page 235: ... 10 M8 45mm bolt 11 15 M10 50mm bolt 16 17 M6 110mm bolt 18 M6 95mm bolt 19 21 M6 40mm bolt 20 23 M6 50mm bolt 22 26 M6 65mm bolt 25 37 M6 30mm bolt 27 M8 55mm bolt 28 30 M6 125mm bolt 24 M6 70mm bolt 31 M10 60mm bolt 32 34 M6 55mm bolt 35 36 4 Remove Dowel pins EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and c...

Page 236: ...ears shift correctly when the shift drum assembly is turned by hand NOTE Carefully position the shift forks so that they are installed correctly into the transmission gears Refer to TRANSMISSION on page 5 77 6 Install Crankcase bolts NOTE Tighten the bolts in the tightening sequence cast on the crankcase 35 and 36 tighten with clamp 1 3 5 7 and 10 have washers 37 is tightened with negative lead an...

Page 237: ...lt 20 23 M6 50mm bolt 22 26 M6 65mm bolt 25 37 M6 30mm bolt 27 M8 55mm bolt 28 30 M6 125mm bolt 24 M6 70mm bolt 31 M10 60mm bolt 32 34 M6 55mm bolt 35 36 A Upper crankcase B Lower crankcase 5 7 10 4 2 18 16 141211 13 15 17 1 9 8 6 21 20 19 3 22 23 27 283032 33 3435 36 26 25 29 31 37 ...

Page 238: ...1 2 O ring 1 3 Oil seal 1 4 Nozzle 1 5 Shaft 2 1 6 Bearing 1 7 Starter clutch drive gear 1 8 Starter clutch gear 1 9 Collar 1 10 Circlip 1 11 Starter clutch roller 1 12 Stopper plate 1 13 Shaft 1 1 14 Starter clutch idle gear 1 15 Bearing 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 239: ...gear clock wise A the starter clutch and the starter clutch gear should engage Otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely Otherwise the starter clutch is faulty and must be replaced EAS24580 CHECKING THE STARTER CLUTCH SHAFT 1 Check Starter clutch shaft 1 Starter clutch shaft spline 2 Damage wear Repl...

Page 240: ...STARTER CLUTCH 5 67 1 3 2 New ...

Page 241: ...y Order Job Parts to remove Q ty Remarks Starter clutch Refer to STARTER CLUTCH on page 5 65 1 Crankshaft assembly 1 2 Oil seal left 1 3 Cover 1 4 Timing chain 1 5 HY VO chain 1 6 Crankshaft plane bearing 10 7 Upper guide 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 B ...

Page 242: ...e connecting rod Order Job Parts to remove Q ty Remarks 1 Nut 8 2 Connecting bolt 8 3 Connecting rod 4 4 Connecting rod cap 4 5 Connecting rod bearing 8 For installation reverse the removal proce dure 1 2 3 4 5 T R 36 Nm 3 6 m kg 26 ft Ib ...

Page 243: ...es Scratches wear Replace the crankshaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crank shaft journal to crankshaft journal bearing clearance and prevent engine damage the crankshaft journal bearings must be in stalled i...

Page 244: ...nd tighten bolts to the specified torque NOTE Tighten the bolts in the tightening sequence cast on the crankcase 35 and 36 tighten with clamp 1 3 5 7 and 10 have copper washers 37 is tightened with negative lead and 2 4 and 6 have no washers M8 100mm bolt 1 10 M8 45mm bolt 11 15 M10 50mm bolt 16 17 M6 110mm bolt 18 M6 95mm bolt 19 21 M6 40mm bolt 20 23 M6 50mm bolt 22 26 M6 65mm bolt 25 37 M6 30mm...

Page 245: ... the numbers 1 on the crankcase are used to determine the replacement big end bearing sizes J1 J5 refer to the bearings shown in the crank shaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is as follows J1 bearing size A Upper crankcase B Lower cran...

Page 246: ...eads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned e Tighten the connecting rod nuts CAUTION ECA5UXB017 When tightening the connecting rod nuts be sure to use an F type torque wrench Without pausing tighten the connec...

Page 247: ...ng size EAS26110 CHECKING THE HY VO CHAIN 1 Check HY VO chain 1 Damage stiffness Replace the HY VO chain and sprockets as a set 2 Check HY VO chain guide Damage wear Replace EAS26140 INSTALLING THE CONNECTING RODS 1 Lubricate Bolt threads Nut seats with the recommended lubricant 2 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant 3 Install Big e...

Page 248: ... Tighten Connecting rod nuts CAUTION ECA5UXB017 When tightening the connecting rod nuts be sure to use an F type torque wrench Without pausing tighten the connecting rod nuts to the specified torque Tighten to a torque of 30 Nm 3 0 m kg When the gauge reading reaches 30 Nm 3 0 m kg tighten in one to specification If tightening is interrupted tighten again from the begin ning EAS25630 INSTALLING TH...

Page 249: ...ngs with the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 2 Install HY VO chain 1 onto the crankshaft sprocket Timing chain 2 onto the crankshaft sprocket Crankshaft assembly 3 NOTE Pass the timing chain through the timing chain cavity To prevent the timing chain from falling into the crankcase fasten it with a wire a b a b 1 2 3 ...

Page 250: ... Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 61 1 Main axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Drive axle assembly 1 5 Collar 1 6 O ring 1 7 Oil seal 1 8 Circlip 1 9 Bearing 1 For installation reverse the removal proce dure 8 9 4 6 7 5 2 3 1 ...

Page 251: ...shift drum assembly Order Job Parts to remove Q ty Remarks 1 Shift fork guide bar 1 2 Shift fork 1 L 1 3 Shift fork 2 C 1 4 Shift fork 3 R 1 5 Stopper plate 1 6 Shift cam 1 For installation reverse the removal proce dure 1 6 5 2 3 4 ...

Page 252: ...rclip 1 6 Plate washer 1 7 3rd wheel gear Collar 1 1 8 Plate washer 1 9 5th wheel gear 1 10 Circlip 1 11 Plate washer 1 12 2nd wheel gear Collar 1 1 13 Drive axle 1 14 2nd Pinion gear 1 15 5th Pinion gear Collar 1 1 16 Plate washer 1 17 3rd Pinion gear 1 18 Circlip 1 19 Plate washer 1 20 4th Pinion gear 1 21 Main axle 1 8 9 10 11 13 12 14 15 16 17 18 19 20 1 2 3 4 5 6 7 21 ...

Page 253: ...TRANSMISSION 5 80 For installation reverse the removal proce dure Disassembling the transmission Order Job Parts to remove Q ty Remarks 8 9 10 11 13 12 14 15 16 17 18 19 20 1 2 3 4 5 6 7 21 ...

Page 254: ...bar as a set EAS26270 CHECKING THE SHIFT FORKS 1 Check Shift drum groove Scratches wear Replace the shift drum as sembly Shift drum segment 1 Scratches wear Replace the shift drum as sembly Shift drum bearing 2 Scratches wear Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main ...

Page 255: ... guide bars 2 Shift fork R 3 Shift fork C 4 Shift fork L 5 NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C and L EAS26350 INSTALLING THE TRANSMISSION 1 Install Main axle assembly 1 Drive axle assembly 2 NOTE Check that the drive axle bearing circlip 3 is aligned with the slot in the 4 upper crankcase Check that the dr...

Page 256: ...TRANSMISSION 5 83 2 Check Transmission gear movement Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly 6 ...

Page 257: ...HE INJECTORS 6 7 CHECKING THE THROTTLE BODIES 6 7 CHECKING THE PRESSURE REGULATOR 6 7 CHECKING THE PRESSURE REGULATOR OPERATION 6 7 ADJUSTING THE THROTTLE POSITION SENSOR 6 8 CHECKING AND ADJUSTING THE SUB THROTTLE POSITION SENSOR 6 8 CHECKING THE SUB THROTTLE SERVO MOTOR 6 10 FUEL SUPPLY SYSTEM AIR BLEEDING 6 11 AIR INDUCTION SYSTEM 6 13 CHECKING THE AIR INDUCTION SYSTEM 6 16 INSTALLING THE AIR I...

Page 258: ... CHASSIS on page 4 1 1 Fuel tank 1 2 Fuel pump coupler fuel sender coupler 1 1 3 Fuel return hose clip 1 1 4 Fuel hoses 1 5 Fuel drain hose clip 1 1 6 Fuel breather hose clip 1 1 7 Stopper ring 1 8 Fuel pump assembly 1 For installation reverse the removal proce dure 1 2 2 3 4 5 6 7 8 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 19 Nm 1 9 m kg 14 ft Ib ...

Page 259: ...l pump or subject it to a strong shock EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Contaminants Clean the fuel pump pas sage Rust scratches wear Replace the fuel pump assembly EAS26710 INSTALLING THE FUEL PUMP 1 Install Fuel pump Fuel hose holders NOTE When assembling the fuel pump take care not to damage the assembly surface with the fuel tank Always use a new fuel pump gasket Fac...

Page 260: ...FUEL TANK 6 3 fuel hose end in the direction of the arrow 1 ...

Page 261: ...position sensor coupler 1 1 1 1 Disconnect 6 Throttle body side cover left right 1 1 7 ISC hose 1 8 Throttle body joint clamp screw 4 Loosen 9 Throttle body joint clamp screw 8 Loosen 10 Throttle body assembly 1 11 Throttle body joint 4 12 Breather hose breather assembly 2 1 13 Intake air pressure sensor 1 coupler intake air pressure sensor 2 coupler 1 1 Disconnect 14 Intake air pressure sensor 1 ...

Page 262: ... position sensor 1 For installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks 1 2 3 4 4 5 6 6 7 8 9 10 11 12 12 13 14 14 19 18 17 16 15 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib ...

Page 263: ...e 1 2 Fuel hose 1 fuel hose 2 1 1 3 Injector coupler 4 Disconnect 4 Left fuel rail 1 5 Pressure regulator 1 6 Right fuel rail 1 7 Injector 4 8 Vacuum hose For installation reverse the removal proce dure 1 2 3 3 4 5 6 7 7 7 7 7 8 8 8 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib ...

Page 264: ...fer to FUEL TANK on page 6 1 b Disconnect the negative pressure hose 1 from the pressure regulator at the hose joint c Connect the vacuum pressure pump gauge set 2 to the negative pressure hose of the pressure regulator d Connect the pressure gauge 3 and adapter 4 to the fuel injection pipe e Install the fuel tank Refer to FUEL TANK on page 6 1 f Start the engine g Measure the fuel pressure h Use ...

Page 265: ...r adjusting the throttle position sensor an gle tighten the throttle position sensor bolt EAS5UXB009 CHECKING AND ADJUSTING THE SUB THROTTLE POSITION SENSOR 1 Check Sub throttle position sensor a Remove the sub throttle position sensor cou pler b Remove the sub throttle position sensor from the sub throttle servo motor c Connect the pocket tester Ω 1k to the sub throttle position sensor as shown V...

Page 266: ...resistance changes gradually while turning the sub throttle 2 Adjust Sub throttle position sensor during full open a Remove the worm shaft cover 1 b Turn the sub throttle worm shaft nut 2 until the full open stopper is contacted c Measure the throttle body dimensions a d Turn the adjusting screw 3 within specifica tion 3 Adjust Initial value a Turn the sub throttle worm shaft nut fully clockwise b...

Page 267: ...le position sensor output volt age is 0 4 V or more turn the worm shaft nut towards fully open until it stops and check whether the sub throttle position sensor output voltage is 4 5 V or more EAS5UXB013 CHECKING THE SUB THROTTLE SERVO MOTOR 1 Check Sub throttle servo motor operation Incorrect Replace a Check whether the sub throttle valve is locked or not 1 Turn the worm shaft nut of the sub thro...

Page 268: ...ace the finger between the valve when the sub throttle valve operates and do not crowd EAS5UXB019 FUEL SUPPLY SYSTEM AIR BLEEDING After disassemble the fuel injectors fuel rail and fuel hose according to the following method and bleed the system of air 1 Check the injectors fuel rail and fuel hose have been correctly installed 2 Turn the main switch ON OFF repeatedly several times for several seco...

Page 269: ...THROTTLE BODIES 6 12 ...

Page 270: ...AIR INDUCTION SYSTEM 6 13 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 4 5 4 4 3 2 1 1 2 4 3 ...

Page 271: ...AIR INDUCTION SYSTEM 6 14 1 Air filter case 2 Air induction system hose Air filter case Air cut off valve 3 Air cut off valve 4 Air induction system hose Air cut off valve Cyl inder head 5 Exhaust port ...

Page 272: ...cap 4 2 Air induction system solenoid coupler 1 Disconnect 3 Air induction system hose Air filter case Air cut off valve 1 4 Air induction system hose Air cut off valve Cylinder head 4 5 Air induction system pipe left right 1 6 Air cut off valve 1 For installation reverse the removal proce dure 4 2 4 6 5 4 5 1 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib ...

Page 273: ...mately 600 to 700 C Air cut off valve The air cut off valve is controlled by the signals from the ECU The air cut off valve is normally open during idling but shuts off when the vehicle starts to move to prevent reverse flow 1 Check Hoses Loose connection Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks scratches Replac...

Page 274: ...AIR INDUCTION SYSTEM 6 17 ...

Page 275: ...JECTION SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 ECU SELF DIAGNOSTIC FUNCTION 7 27 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 7 28 TROUBLESHOOTING METHOD 7 32 DIAGNOSTIC MONITORING MODE 7 32 TROUBLESHOOTING DETAILS 7 41 FUEL PUMP SYSTEM 7 65 CIRCUIT DIAGRAM 7 65 TROUBLE SHOOTING 7 67 IMMOBILIZER SYSTEM 7 69 CIRCUIT DIAGRAM 7 69 GENERAL INFORMATION 7 71 PART REPLACEMENT AND KEY CODE REG...

Page 276: ... CHECKING THE CRANKSHAFT POSITION SENSOR 7 94 CHECKING THE LEAN ANGLE SENSOR 7 94 CHECKING THE HORN 7 95 CHECKING THE ENGINE OIL LEVEL GAUGE 7 95 CHECKING THE ENGINE TEMPERATURE SENSOR 7 96 CHECKING THE SPEED SENSOR 7 96 CHECKING THE THROTTLE POSITION SENSOR 7 97 CHECKING THE FUEL SENDER 7 97 CHECKING THE AI SYSTEM SOLENOID 7 98 CHECKING INTAKE AIR PRESSURE SENSORS 1 AND 2 7 98 CHECKING THE INTAKE...

Page 277: ......

Page 278: ...IGNITION SYSTEM 7 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 279: ...witch 3 Ignition fuse 4 Main fuse 7 Battery 13 Engine stop switch 15 Relay unit 16 Neutral switch 17 Sidestand switch 19 Ignition coil 1 20 Ignition coil 2 29 Crankshaft position sensor 30 Lean angle sensor 38 ECU 65 Clutch switch ...

Page 280: ...n page 3 10 NG Re gap or replace the spark plug OK 4 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAPS on page 7 93 NG Replace the spark plug cap OK 5 Check the ignition coil Refer to CHECKING THE IGNITION COIL on page 7 93 NG Replace the ignition coil OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 7 94 NG Replace the crankshaft po...

Page 281: ...relay Refer to CHECKING THE RELAYS on page 7 90 NG Replace the relay unit starting circuit cut off relay OK 13 Check the diode Refer to CHECKING THE DIODE on page 7 91 NG Replace the relay unit diode OK 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 94 NG Replace the lean angle sensor OK 15 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page...

Page 282: ...ELECTRIC STARTING SYSTEM 7 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 283: ...STARTING SYSTEM 7 6 2 Main switch 3 Ignition fuse 4 Main fuse 7 Battery 8 Starter relay 9 Starter motor 13 Engine stop switch 14 Start switch 15 Relay unit 16 Neutral switch 17 Sidestand switch 65 Clutch switch ...

Page 284: ...ver is 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 s...

Page 285: ... SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main 3 Main switch 4 Ignition 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch coupler 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor ...

Page 286: ...lay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 90 NG Replace the relay unit starting circuit cut off relay OK 5 Check the diode Refer to CHECKING THE DIODE on page 7 91 NG Replace the relay unit diode OK 6 Replace the starter relay Refer to CHECKING THE RELAYS on page 7 90 NG Replace the starter relay OK 7 Check the main switch Refer to CHECKING THE SWITCHES on page...

Page 287: ...ce the clutch switch OK 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the right handlebar switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 7 5 NG Properly connect or repair the starting sys tem s wiring OK The starting system circuit is OK ...

Page 288: ...CHARGING SYSTEM 7 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 289: ...CHARGING SYSTEM 7 12 1 Generator 2 Main switch 4 Main fuse 7 Battery ...

Page 290: ...n page 7 87 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the generator Refer to CHECKING THE GENERA TOR on page 5 31 NG Replace the blushes and blush springs as a set Replace the stator coil assembly Replace the field coil OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the main switch OK 5 Check the entire charging system s wiring Ref...

Page 291: ...CHARGING SYSTEM 7 14 ...

Page 292: ...LIGHTING SYSTEM 7 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 293: ...e 4 Main fuse 7 Battery 38 ECU 41 Meter light 44 Multi function display 50 High beam indicator 53 Tail brake light 54 Licence light 60 Pass switch 61 Dimmer switch 68 Headlight relay 69 Headlight fuse 72 Headlight 73 Taillight fuse 74 Auxiliary light ...

Page 294: ...3 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 7 87 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the left handlebar switch OK 6 Check the pass switch Refer to CHECKING THE SWI...

Page 295: ...LIGHTING SYSTEM 7 18 ...

Page 296: ...SIGNALING SYSTEM 7 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 297: ... Oil level warning light 47 Neutral indicator light 48 Left turn signal indicator 49 Right turn signal indicator light 51 Oil level switch 52 Rear brake switch 53 Tail brake light 55 Front left turn signal light 56 Front right turn signal light 57 Rear left turn signal light 58 Rear right turn signal light 62 Horn switch 63 Turn signal switch 64 Hazard switch 66 Turn signal relay 67 Horn 70 Signal...

Page 298: ...e 7 87 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK This circuit is OK 1 Check the horn switch Refer to CHECKING THE SWITCHES on page ...

Page 299: ...flasher indicator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 85 NG Replace the flasher flasher indicator light bulb socket or both OK 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the handlebar switch OK 3 Check the hazard switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the handlebar switch OK 4 Check the turn ...

Page 300: ...NG Replace the relay unit diode OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK This circuit is OK 1 Checking the oil level warning light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 85 NG Replace the oil level warning light bulb socket or both OK 2 Check the oil level sw...

Page 301: ...ystem s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK Replace the meter assembly 1 Check the fuel level sender Refer to CHECKING THE SPEED SENSOR on page 7 96 NG Replace the fuel pump OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK Rep...

Page 302: ...FUEL INJECTION SYSTEM 7 25 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 303: ...ector 2 23 Injector 3 24 Injector 4 25 AI solenoid 26 ISC idle speed control valve 27 Sub throttle servo motor 28 EXUP servo motor 29 Crankshaft position sensor 30 Lean angle sensor 31 Speed sensor 32 O2 sensor 33 Intake air temperature sensor 34 Engine temperature sensor 35 Throttle position sensor 36 Intake air pressure sensor 1 37 Intake air pressure sensor 2 38 ECU 44 Multi function display 46...

Page 304: ...r Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1 4 seconds after...

Page 305: ...ved from the crankshaft position sensor Unable Unable 13 Intake air pres sure sensor 1 open or short circuit Intake air pressure sensor open or short circuit Able Able 14 Intake air pres sure sensor 1 pipe system Intake air pressure sensor pipe system malfunction clogged or detached hose Able Able 15 Throttle posi tion sensor open or short circuit Throttle position sensor open or short circuit det...

Page 306: ...of faulty cylin ders Able depen ding on the number of faulty cylin ders 34 Ignition coil 2 and 3 faulty ignition Malfunction detected in the primary lead of the igni tion coil 2 and 3 Able depen ding on the number of faulty cylin ders Able depen ding on the number of faulty cylin ders 37 ISC Idle speed control valve Engine speed is high when the engine is idling Able Able 39 Injector Injector open...

Page 307: ...aulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Unable Unable 70 Left idle control After 20 minutes left idling the ECU automatically stops the engine Able Able Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON When the start switch is turned ON while an error is detect...

Page 308: ...ected for the ECU or immobilizer unit you may not be able to start or drive the vehicle Er 4 ECU internal malfunction input signal error Non registered data has been received from the meter Able Able Fault code No Item Symptom Able unableto start Able unableto drive ...

Page 309: ... to Sensor operation table and Actuator oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27440 DIAGNOSTIC MONITORING MODE Setting the diagnostic monitoring mode 1 Turn the main switch to OFF and set the en gine stop switch to 2 Disconn...

Page 310: ...or 1 second or longer to automatically increase the diagnostic moni toring code numbers 8 Verify the operation of the sensor or actuator Sensor operation The data representing the operating condi tions of the sensor appears on the trip LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the engine stop switch is set to set it to and then set it to again 9 Turn the ...

Page 311: ...e position sensor Malfunction in ECU Improperly installed throttle position sen sor 01 16 Stuck throttle position sen sor Stuck throttle position sensor Malfunction in ECU 01 17 EXUP servo motor circuit open or short circuit Open circuit in wire harness Defective EXUP servo motor Malfunction in ECU 53 18 EXUP servo motor is stuck Open circuit in wire harness Stuck EXUP servo motor mechanism motor ...

Page 312: ...ction detected in the primary lead of the ignition coil 1 and 4 Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU Defective ignition circuit cut off circuit 30 34 Malfunction detected in the primary lead of the ignition coil 2 and 3 Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU Defective ignition circuit cut off circuit 31 37 Engine speed i...

Page 313: ...e position sensor Malfunction in ECU 56 48 Sub throttle servo motor stuck Open circuit in wire harness Sub throttle servo motor is stuck mechani cal Sub throttle servo motor is stuck motor 56 50 Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Malfunction in ECU The program and data are not properly written on or read from the inter...

Page 314: ...e the throttle while pressing the start switch If the display value changes the perfor mance is OK 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured intake air tempera ture with the meter display value 07 Vehicle speed pulse 0 999 Check that the number increase when the rear wheel is rotated The number is cumulative and does not reset each time the wheel...

Page 315: ... 70 Fault detection code If more than one code num ber is defective the display alternates every two sec onds to show all the detected cylinder num bers When all code num bers are shown the display repeats the same process 62 Malfunction history code erasure No history 0 History exists 0 28 Displays the total number of malfunctions including the current malfunction that have occurred since the his...

Page 316: ...31 Ignition coil 2 and 3 Actuates the ignition coil five times at one second inter vals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuates the injector five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the injector five times 37 Injector 2 Actuates the injector five...

Page 317: ... off for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and head light Check the operating sound of the headlight relay five times 53 EXUP servomotor Turn the servo motor once in the open direction and then in the close direction Illuminates the engine trou ble warning light Check the operating sound of the EXUP servo motor 54 ISC idle speed co...

Page 318: ...E on page 7 32 Fault code No 12 Symptom No normal signals are received from the crankshaft position sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of crankshaft posi tion sensor Check for looseness or pinching Cranking the engine 2 Connections Crankshaft position sensor coupler Wire harness ECU coupler Check th...

Page 319: ...er Sub wire harness coupler Check 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 Set the main switch to ON 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler Black Bl...

Page 320: ...heck the intake air pressure sensor 1 hose condition Repair or replace the sensor hose Starting the engine and operating it at idle 2 Intake air pressure sensor malfunc tion at intermediate electrical poten tial Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor 1 coupler Wire harness ECU coupler Sub wire harness coupler Check the couple...

Page 321: ...U coupler Sub wire harness coupler Check 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 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler Black Blue Black Blue Yellow ...

Page 322: ...HECKING THE THROTTLE POSITION SEN SOR on page 7 97 Fault code No 17 Symptom EXUP servo motor circuit open or short circuit Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method When error code Nos 17 and 18 are displayed simultaneously first check and repair No 17 1 Connections EXUP servo motor coupler Wire harness ECU coupler...

Page 323: ... coupler Check 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 Set the main switch to ON And then racing it 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between EXUP servo motor coupler and ECU coupler Black Red Black Red...

Page 324: ...al reconnecting the wiring 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ECU and starting cir cuit cut off relay Orange Red 3 Defective sidestand switch Execute the diagnostic mode Code No 20 Replace if defective Refer to CHECKING THE SWITCHES on page 7 81 Fault code No 20 Symptom Intake air pressure sensor 1 and intake air pressure sensor 2...

Page 325: ...ire harness ECU coupler Check 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 Set the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air tempera ture sensor coupler and ECU coupler Black Blue Black Blue Brown White...

Page 326: ...63 2 Connections O2 sensor coupler Wire harness ECU coupler Check 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 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler Black Blue Black Blue Gray Green Gray Green ...

Page 327: ...sure sensor 2 coupler Wire harness ECU coupler Sub wire harness coupler Check 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 Set the main switch to ON 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between intake air press...

Page 328: ...ondition Repair or replace the sensor hose Starting the engine and operating it at idle 2 Intake air pressure sensor malfunc tion at intermediate electrical poten tial Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor 2 coupler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may have pulled out Chec...

Page 329: ...ou pler Black Black Blue Yellow Green White 3 Defective engine temperature sensor Execute the diagnostic mode Code No 11 Replace if defective Refer to CHECKING THE EN GINE TEMPERATURE SEN SOR on page 7 96 Fault code No 30 Symptom The vehicle has over turned Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle h...

Page 330: ...rimary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNI TION COIL on page 7 93 Fault code No 34 Symptom Malfunction detected in the primary lead of the ignition coil 2 and 3 Diagnostic code No 31 Ignition coil 2 and 3 Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Ignition coil 2 3 primary lead coupler gray red...

Page 331: ...simultaneously first check and repair No 15 When error code Nos 16 and 37 are displayed simultaneously first check and repair No 16 When error code Nos 22 and 37 are displayed simultaneously first check and repair No 22 When error code Nos 25 and 37 are displayed simultaneously first check and repair No 25 When error code Nos 26 and 37 are displayed simultaneously first check and repair No 26 When...

Page 332: ...LE CABLE FREE PLAY on page 3 9 5 ISC hose disconnect Abnormally intake noise Check the ISC hose Refer to THROTTLE BODIES on page 6 4 6 ISC idle speed control valve stuck fully open Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is turned OFF Touch the ISC unit with your hand and check if it is vibrating to confirm i...

Page 333: ...range Black Orange Black 3 Defective injector Execute the diagnosis mode Code No 36 37 38 39 Replace if defective Fault code No 41 Symptom Lean angle sensor open or short circuit detected Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Lean angle sensor coupler Wire harness ECU coupler Check the coupler fo...

Page 334: ...icle speed signals by oper ating the vehi cle at a low speed of 20 30 km h A 2 Connections Speed sensor coupler Wire harness ECU coupler Check 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 A 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between...

Page 335: ...ral switch coupler Wire harness ECU coupler Sub wire harness coupler Check 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 B 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler Black Ye...

Page 336: ...lay Execute the diagnostic mode Code No 09 Replace if defective Refer to CHECKING THE RE LAYS on page 7 90 If there is no malfunction with the relay unit fuel pump relay replace the ECU Fault code No 44 Symptom Error is detected while reading or writing on EEPROM CO adjustment value Diagnostic code No 60 EEPROM improper cylinder indication Order Item components and probable cause Check or maintena...

Page 337: ...function repair it and connect it securely Starting the engine and operating it at idle 2 Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 87 3 Defectve generator Replace if defective Check the output voltage of generator Refer to CHARGING SYSTEM on page 7 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circ...

Page 338: ...to ON 2 Connections Sub throttle position sensor coupler Wire harness ECU coupler Sub wire harness coupler Check 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 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between sub thr...

Page 339: ...Set the main switch to ON 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between sub throttle position sensor coupler and ECU cou pler Yellow Red Yellow Red Yellow White Yellow White 3 Defective sub throttle servo motor Execute the diagnostic mode Code No 56 When the abnormality is detected at diagnostic mode Code No 56 inspec...

Page 340: ...w Blue Yellow Blue 3 Malfunction in meter unit Replace the meter unit 4 ECU is defective Replace the ECU Fault code No Er 2 Symptom Not within the specified signal time from the ECU Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking...

Page 341: ...Yellow Blue Yellow Blue 3 Malfunction in meter unit Replace the meter unit 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check t...

Page 342: ...FUEL PUMP SYSTEM 7 65 EAS27580 FUEL PUMP SYSTEM EAS27590 CIRCUIT DIAGRAM ...

Page 343: ...FUEL PUMP SYSTEM 7 66 2 Main switch 3 Ignition fuse 4 Main fuse 5 EFI fuse 7 Battery 13 Engine stop switch 15 Relay unit 18 Fuel pump 38 ECU ...

Page 344: ...e battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the main switch OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the right handlebar switch OK 5 Check the relay unit fuel pump relay Refer to CHECKING THE SWITCHES on page 7 81 NG Replace relay unit fuel pump relay OK 6 Check fuel pressure Refer to CHECKING THE PRES ...

Page 345: ...FUEL PUMP SYSTEM 7 68 ...

Page 346: ...IMMOBILIZER SYSTEM 7 69 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 347: ...IMMOBILIZER SYSTEM 7 70 2 Main switch 3 Ignition fuse 4 Main fuse 5 Backup fuse 7 Battery 38 ECU 40 Immobilizer system warning light 44 Multi function display 71 Immobilizer unit ...

Page 348: ...y is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is high ly recommended to use either standard key for driving and to keep the code re registering key in a safe place...

Page 349: ... Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Acc...

Page 350: ...n turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the sec...

Page 351: ...tch ON b Main switch OFF c LED lights d LED goes off e Within 5 seconds f Code re registering key g Standard key 1st h Standard key 2nd i Registration mode A Standard key 2nd registration com plete B When the 2nd standard key registration is completed immobilizer light stops flashing a Main switch ON b Main switch OFF c LED lights d LED goes off e Within 5 seconds f Code re registering key g Remai...

Page 352: ...ARG ING THE BATTERY on page 7 87 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 81 NG Replace the main switch immobilizer unit OK 4 Check the entire immobilizer sys tems wiring Refer to CIRCUIT DIAGRAM on page 7 69 NG Properly connect or repair the immobilizer system s wiring OK Check the condition of the each immo...

Page 353: ...de after ten consec utive attempts Signal received from unregistered standard key Place the immobi lizer unit at least 50 mm away from the transponder of other vehicles Register the stan dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or disconnected lead cable Interference due to radio wave noise Disconnected commu nication harn...

Page 354: ...5 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Undefinition code is received Noise interference or disconnected lead cable Check the wire harness and con nector Replace the main switch immobi lizer unit Replace the ECU Fault code Part Symptom Cause Action a Remains on b Light goes of...

Page 355: ...IMMOBILIZER SYSTEM 7 78 ...

Page 356: ...ELECTRICAL COMPONENTS 7 79 EAS27970 ELECTRICAL COMPONENTS EAS5UXB011 1 3 4 5 7 8 6 10 11 12 13 14 15 15 16 17 18 2 9 ...

Page 357: ...relay 4 Starting circuit cut off relay 5 Starter relay 6 ECU 7 Negative battery lead 8 Battery 9 Turn signal relay 10 Neutral switch 11 Neutral switch lead 12 Sidestand switch 13 Rear brake switch 14 Oil level gauge 15 Spark plug cap 16 Ignition coil 17 Horn 18 Horn ...

Page 358: ...TS 7 81 EAS27980 CHECKING THE SWITCHES 8 9 10 11 12 7 1 2 3 4 5 6 13 14 P B B Y L Y Y G L B Y R Y Ch Br W Dg Ch Dg Y B G R Y P L B Br W B Y L Y Dg Ch B B L Sb Y Br Br Br B B L Br B R B R W L W G Y L B R W R B G Y Br Br W ...

Page 359: ...in switch 2 Front brake switch 3 Engine stop switch 4 Starter switch 5 Rear brake switch 6 Fuse 7 Clutch switch 8 Horn switch 9 Dimmer switch 10 Pass switch 11 Turn signal switch 12 Hazard switch 13 Sidestand switch 14 Neutral switch ...

Page 360: ... and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustra tion similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between switch terminals i e a clo...

Page 361: ...ELECTRICAL COMPONENTS 7 84 a b Br R Br R ...

Page 362: ...cedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA5UXB011 When removing the bulb hold the socket Do not pull the lead as this may result in disconnection of the lead inside the socket Never pull the lead otherwise it may be pulled out of the term...

Page 363: ...e 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the ...

Page 364: ...arging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged as ex plained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the charge state...

Page 365: ... 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 charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact a...

Page 366: ...minutes after the machine is stopped b Connect a charger and AMP meter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery This type of bat tery charger cannot charge the MF battery A variable voltage charger is recommended d Charge...

Page 367: ...ure from main switch to flasher re lay coupler Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 1 3 2 4 R L W L W L Y R W L B O R Sb R B R L B Y Sb W...

Page 368: ...d voltage EAS28050 CHECKING THE DIODE 1 Check Diode Out of specification Replace the relay unit NOTE Checking method using pocket tester analog tester Flasher relay input voltage DC 12V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Blue Red 1 Negative tester probe Ground Flasher relay output voltage DC 12V Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 369: ...lead Sky blue 1 Continuity Positive tester lead Blue Black 3 Negative tester lead Orange Red 4 No continuity Positive tester lead Orange Red 4 Negative tester lead Blue Black 3 Continuity Positive tester lead Sky blue 1 Negative tester lead Orange Red 4 No continuity Positive tester lead Orange Red 4 Negative tester lead Sky blue 1 Continuity Positive tester lead Sky blue 1 Negative tester lead Bl...

Page 370: ...NG THE IGNITION COIL The following checking procedure applies to all of the ignition coils 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil from wire har ness b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap fr...

Page 371: ...ngle sensor from the bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe High tension code 1 Positive tester probe High tension code 2 Crankshaft position s...

Page 372: ...ecified horn sound is obtained EAS28190 CHECKING THE ENGINE OIL LEVEL GAUGE 1 Drain Engine oil 2 Remove Engine oil level gauge from the oil pan 3 Check Oil level switch continuity Out of specification Replace a Connect the pocket tester Ω 1 to the en gine oil level gauge terminals as shown Coil resistance 1 15 1 25 Ω Pocket tester 90890 03132 Positive tester probe Horn terminal 1 Negative tester p...

Page 373: ...e sensor in a container filled with coolant 2 NOTE Make sure that the engine temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the engine temperature sensor re sistance 3 Install Engine temperature sensor EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of s...

Page 374: ...ttle position sensor EAS5UXB012 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Fuel sender coupler 2 Remove Fuel tank 3 Remove Fuel pump 4 Check Fuel sender resistance Out of specification Replace the fuel pump a Connect the pocket tester Ω 10 to the ter minals of the fuel sender Positive tester probe White Yellow 1 Negative tester probe Black blue 2 Pocket tester 90890 03112 Analog pocke...

Page 375: ...Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler wire har ness side as shown Solenoid resistance 20 5 23 5Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown Black 1 Negative tester probe Red White 2 B G W L R B 4 3 Intake air pressure sensor output voltage 3 75 ...

Page 376: ...nsor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the in take air temperature sensor terminal as shown b Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor A Intake air pressure sensor 1 B Intake air pressure sensor 2 Intake air temperature sensor re sistance 5 4 6 6...

Page 377: ...URES 8 1 INCORRECT ENGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 2 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 378: ...maged fuel hose 4 Throttle bodies Clogged pilot air passage Electrical system 1 Battery Discharged battery Faulty battery 2 Fuses Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Insulator damage Faulty spark plug cap 4 Ignition coil Cracked or broken ignition coil Broken or s...

Page 379: ...S28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly assembled clutch master cylinder Improperly assembled clutch release cylinder Incorrect clutch fluid lev...

Page 380: ...NG SYSTEM Headlight does not come on Fuse open circuit Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor switch contacts main switch Burnt out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail bra...

Page 381: ...eft turn signal indicator light 50 High beam indicator 51 Oil level switch 52 Rear brake switch 53 Tail brake light 54 Licence light 55 Front left turn signal light 56 Front right turn signal light 57 Rear left turn signal light 58 Rear right turn signal light 59 Left handlebar switch 60 Pass switch 61 Dimmer switch 62 Horn switch 63 Turn signal switch 64 Hazard switch 65 Clutch switch 66 Turn sig...

Page 382: ......

Page 383: ......

Page 384: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 385: ...XJR1300 W 2007 WIRING DIAGRAM XJR1300 W 2007 SCHÉMA DE CÂBLAGE XJR1300 W 2007 SCHALTPLAN SCHEMA ELETTRICO XJR1300 W 2007 DIAGRAMA ELÉCTRICO DE LA XJR1300 W 2007 ...

Page 386: ...XJR1300 W 2007 WIRING DIAGRAM XJR1300 W 2007 SCHÉMA DE CÂBLAGE XJR1300 W 2007 SCHALTPLAN SCHEMA ELETTRICO XJR1300 W 2007 DIAGRAMA ELÉCTRICO DE LA XJR1300 W 2007 ...

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