Yamaha FZS10VC Service manual

FZS10V
FZS10VC
SERVICE MANUAL
LIT-11616-19-79
3C3-28197-10
EAS20050
FZS10V/FZS10VC
SERVICE MANUAL
©2006 by Yamaha Motor
Corporation, U.S.A.
First edition, January 2006
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-19-79
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• 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 Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title is shown at the top of each page “1”.
• Sub-section titles appear in smaller print than the section title “2”.
• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”.
• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
• Jobs requiring more information (such as special tools and technical data) are described sequentially “7”.
EAS20100
16.Replace the part
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
2
3
4
5
6
7
8
T.
1
R.
9
10
E
12
11
13
B
15
M
G
14
M
LS
16
LT
New
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.Wheel-bearing grease
13.Lithium-soap-based grease
14.Molybdenum-disulfide grease
15.Apply locking agent (LOCTITE®)
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
COOLING SYSTEM
6
FUEL SYSTEM
7
ELECTRICAL SYSTEM
8
TROUBLESHOOTING
9
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION.......................................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER................................................... 1-1
MODEL LABEL....................................................................................... 1-1
FEATURES ................................................................................................... 1-2
FI SYSTEM ................................................................................................... 1-3
INSTRUMENT FUNCTIONS......................................................................... 1-4
IMPORTANT INFORMATION ....................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY.......................... 1-7
REPLACEMENT PARTS ........................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS.................................................. 1-7
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-7
BEARINGS AND OIL SEALS ................................................................. 1-8
CIRCLIPS ............................................................................................... 1-8
CHECKING THE CONNECTIONS ............................................................... 1-9
SPECIAL TOOLS ....................................................................................... 1-10
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
ENGINE SPECIFICATIONS.......................................................................... 2-1
CHASSIS SPECIFICATIONS ....................................................................... 2-7
ELECTRICAL SPECIFICATIONS................................................................. 2-9
TIGHTENING TORQUES............................................................................2-11
GENERAL TIGHTENING TORQUE SPECIFICATIONS....................... 2-11
ENGINE TIGHTENING TORQUES ...................................................... 2-12
CHASSIS TIGHTENING TORQUES .................................................... 2-16
LUBRICATION POINTS AND LUBRICANT TYPES ..................................2-19
ENGINE ................................................................................................ 2-19
CHASSIS .............................................................................................. 2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS ................................. 2-23
ENGINE OIL LUBRICATION CHART ................................................... 2-23
LUBRICATION DIAGRAMS .................................................................. 2-25
COOLING SYSTEM DIAGRAMS ............................................................... 2-35
CABLE ROUTING ...................................................................................... 2-39
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENT
PERIODIC MAINTENANCE ......................................................................... 3-1
INTRODUCTION .................................................................................... 3-1
ENGINE......................................................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE ................................................ 3-4
SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-6
ADJUSTING THE ENGINE IDLING SPEED .......................................... 3-8
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-8
CHECKING THE SPARK PLUGS........................................................... 3-9
MEASURING THE COMPRESSION PRESSURE ................................. 3-9
CHECKING THE ENGINE OIL LEVEL................................................. 3-10
CHANGING THE ENGINE OIL............................................................. 3-11
MEASURING THE ENGINE OIL PRESSURE ..................................... 3-12
ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-13
REPLACING THE AIR FILTER ELEMENT ........................................... 3-14
CHECKING THE THROTTLE BODY JOINTS ...................................... 3-15
CHECKING THE FUEL LINE ............................................................... 3-15
CHECKING THE CRANKCASE BREATHER HOSE ............................ 3-15
CHECKING THE EXHAUST SYSTEM ................................................. 3-16
ADJUSTING THE EXUP CABLES .......................................................3-16
CHECKING THE EXUP SERVO MOTOR ............................................ 3-17
CHECKING THE COOLANT LEVEL .................................................... 3-17
CHECKING THE COOLING SYSTEM ................................................. 3-18
CHANGING THE COOLANT................................................................ 3-18
CHASSIS .................................................................................................... 3-21
ADJUSTING THE FRONT DISC BRAKE ............................................. 3-21
ADJUSTING THE REAR DISC BRAKE ............................................... 3-21
CHECKING THE BRAKE FLUID LEVEL.............................................. 3-22
CHECKING THE FRONT BRAKE PADS.............................................. 3-22
CHECKING THE REAR BRAKE PADS ................................................ 3-22
CHECKING THE FRONT BRAKE HOSES........................................... 3-23
CHECKING THE REAR BRAKE HOSE ............................................... 3-23
ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM................................. 3-24
ADJUSTING THE SHIFT PEDAL ......................................................... 3-25
ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-25
LUBRICATING THE DRIVE CHAIN...................................................... 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-26
CHECKING THE FRONT FORK .......................................................... 3-27
ADJUSTING THE FRONT FORK LEGS .............................................. 3-28
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-30
CHECKING THE TIRES ....................................................................... 3-31
CHECKING THE WHEELS .................................................................. 3-33
CHECKING AND LUBRICATING THE CABLES ..................................3-33
LUBRICATING THE LEVERS............................................................... 3-33
LUBRICATING THE PEDAL ................................................................. 3-33
LUBRICATING THE SIDESTAND......................................................... 3-33
LUBRICATING THE CENTERSTAND .................................................. 3-33
LUBRICATING THE REAR SUSPENSION .......................................... 3-33
ELECTRICAL SYSTEM.............................................................................. 3-34
CHECKING AND CHARGING THE BATTERY..................................... 3-34
CHECKING THE FUSES...................................................................... 3-34
REPLACING THE HEADLIGHT BULBS............................................... 3-34
ADJUSTING THE HEADLIGHT BEAM ................................................ 3-34
CHAPTER 4
CHASSIS
GENERAL CHASSIS.................................................................................... 4-1
REMOVING THE COVER....................................................................... 4-5
INSTALLING THE COVER ..................................................................... 4-5
FRONT WHEEL ............................................................................................ 4-6
REMOVING THE FRONT WHEEL .........................................................4-8
CHECKING THE FRONT WHEEL.......................................................... 4-8
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-9
INSTALLING THE FRONT WHEEL (DISC) .......................................... 4-10
REAR WHEEL ............................................................................................ 4-12
REMOVING THE REAR WHEEL (DISC) ............................................. 4-15
CHECKING THE REAR WHEEL.......................................................... 4-15
CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-15
CHECKING AND REPLACING THE REAR WHEEL SPROCKET....... 4-16
ADJUSTING THE REAR WHEEL STATIC BALANCE.......................... 4-16
INSTALLING THE REAR WHEEL (DISC) ............................................ 4-16
FRONT BRAKE .......................................................................................... 4-18
INTRODUCTION .................................................................................. 4-23
CHECKING THE FRONT BRAKE DISCS ............................................ 4-23
REPLACING THE FRONT BRAKE PADS ............................................ 4-24
REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-25
DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-25
CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-26
ASSEMBLING THE FRONT BRAKE CALIPERS ................................. 4-26
INSTALLING THE FRONT BRAKE CALIPERS.................................... 4-26
REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-27
CHECKING THE FRONT BRAKE MASTER CYLINDER ..................... 4-28
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................. 4-28
INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-28
REAR BRAKE ............................................................................................ 4-30
INTRODUCTION .................................................................................. 4-35
CHECKING THE REAR BRAKE DISC................................................. 4-35
REPLACING THE REAR BRAKE PADS .............................................. 4-35
REMOVING THE REAR BRAKE CALIPER.......................................... 4-36
DISASSEMBLING THE REAR BRAKE CALIPER................................ 4-36
CHECKING THE REAR BRAKE CALIPER .......................................... 4-37
ASSEMBLING THE REAR BRAKE CALIPER...................................... 4-37
INSTALLING THE REAR BRAKE CALIPER ........................................ 4-38
REMOVING THE REAR BRAKE MASTER CYLINDER....................... 4-39
CHECKING THE REAR BRAKE MASTER CYLINDER ....................... 4-39
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ................... 4-39
INSTALLING THE REAR BRAKE MASTER CYLINDER...................... 4-39
HANDLEBAR.............................................................................................. 4-41
REMOVING THE HANDLEBAR ........................................................... 4-43
CHECKING THE HANDLEBAR............................................................ 4-43
INSTALLING THE HANDLEBAR .......................................................... 4-43
FRONT FORK............................................................................................. 4-46
REMOVING THE FRONT FORK LEGS ............................................... 4-48
DISASSEMBLING THE FRONT FORK LEGS ..................................... 4-48
CHECKING THE FRONT FORK LEGS................................................ 4-49
ASSEMBLING THE FRONT FORK LEGS ........................................... 4-50
INSTALLING THE FRONT FORK LEGS .............................................. 4-54
STEERING HEAD....................................................................................... 4-55
REMOVING THE LOWER BRACKET .................................................. 4-57
CHECKING THE STEERING HEAD .................................................... 4-57
INSTALLING THE STEERING HEAD................................................... 4-58
REAR SHOCK ABSORBER ASSEMBLY .................................................. 4-59
HANDLING THE REAR SHOCK ABSORBER ..................................... 4-61
DISPOSING OF A REAR SHOCK ABSORBER................................... 4-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-61
CHECKING THE CONNECTING ARM AND RELAY ARM .................. 4-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ............... 4-62
SWINGARM ................................................................................................ 4-63
REMOVING THE SWINGARM ............................................................. 4-65
CHECKING THE SWINGARM ............................................................. 4-65
INSTALLING THE SWINGARM ............................................................ 4-66
CHAIN DRIVE ............................................................................................. 4-67
REMOVING THE DRIVE CHAIN .......................................................... 4-68
CHECKING THE DRIVE CHAIN .......................................................... 4-68
CHECKING THE DRIVE SPROCKET .................................................. 4-69
CHECKING THE REAR WHEEL SPROCKET ..................................... 4-69
CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-69
INSTALLING THE DRIVE CHAIN ......................................................... 4-69
CHAPTER 5
ENGINE
ENGINE REMOVAL ...................................................................................... 5-1
INSTALLING THE ENGINE .................................................................... 5-7
CAMSHAFTS................................................................................................ 5-9
REMOVING THE CAMSHAFTS ........................................................... 5-11
CHECKING THE CAMSHAFTS ........................................................... 5-12
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET....... 5-13
CHECKING THE TIMING CHAIN GUIDES .......................................... 5-13
CHECKING THE TIMING CHAIN TENSIONER ................................... 5-13
INSTALLING THE CAMSHAFTS .......................................................... 5-15
CYLINDER HEAD....................................................................................... 5-18
REMOVING THE CYLINDER HEAD .................................................... 5-19
CHECKING THE CYLINDER HEAD .................................................... 5-19
INSTALLING THE CYLINDER HEAD ................................................... 5-19
VALVES AND VALVE SPRINGS ................................................................ 5-21
REMOVING THE VALVES .................................................................... 5-23
CHECKING THE VALVES AND VALVE GUIDES ................................. 5-24
CHECKING THE VALVE SEATS .......................................................... 5-25
CHECKING THE VALVE SPRINGS...................................................... 5-27
CHECKING THE VALVE LIFTERS .......................................................5-28
INSTALLING THE VALVES................................................................... 5-28
GENERATOR.............................................................................................. 5-30
REMOVING THE GENERATOR ........................................................... 5-32
INSTALLING THE GENERATOR.......................................................... 5-32
STARTER CLUTCH .................................................................................... 5-34
REMOVING THE STARTER CLUTCH ................................................. 5-35
CHECKING THE DAMPER .................................................................. 5-35
CHECKING THE STARTER CLUTCH.................................................. 5-35
INSTALLING THE STARTER CLUTCH ................................................ 5-36
CRANKSHAFT POSITION SENSOR ......................................................... 5-37
REMOVING THE CRANKSHAFT POSITION SENSOR ...................... 5-38
INSTALLING THE CRANKSHAFT POSITION SENSOR ..................... 5-38
ELECTRIC STARTER................................................................................. 5-39
CHECKING THE STARTER MOTOR ................................................... 5-41
ASSEMBLING THE STARTER MOTOR ............................................... 5-42
INSTALLING THE STARTER MOTOR.................................................. 5-42
CLUTCH...................................................................................................... 5-43
REMOVING THE CLUTCH................................................................... 5-47
CHECKING THE FRICTION PLATES .................................................. 5-48
CHECKING THE CLUTCH PLATES..................................................... 5-48
CHECKING THE CLUTCH SPRINGS.................................................. 5-49
CHECKING THE CLUTCH HOUSING ................................................. 5-49
CHECKING THE CLUTCH BOSS ........................................................ 5-49
CHECKING THE PRESSURE PLATE .................................................. 5-49
CHECKING THE PULL LEVER SHAFT AND PULL ROD.................... 5-49
INSTALLING THE CLUTCH ................................................................. 5-50
SHIFT SHAFT ............................................................................................. 5-53
REMOVING THE SHIFT SHAFT .......................................................... 5-55
CHECKING THE SHIFT SHAFT .......................................................... 5-55
CHECKING THE STOPPER LEVER.................................................... 5-55
INSTALLING THE SHIFT SHAFT ......................................................... 5-55
OIL PUMP ................................................................................................... 5-57
REMOVING THE OIL PAN ................................................................... 5-61
CHECKING THE SPROCKET AND CHAIN ......................................... 5-61
CHECKING THE OIL PUMP ................................................................ 5-61
CHECKING THE RELIEF VALVE ......................................................... 5-62
CHECKING THE OIL DELIVERY PIPES.............................................. 5-62
CHECKING THE OIL STRAINER......................................................... 5-62
CHECKING THE OIL NOZZLES .......................................................... 5-62
ASSEMBLING THE OIL PUMP ............................................................ 5-62
INSTALLING THE OIL/WATER PUMP ASSEMBLY.............................. 5-63
INSTALLING THE OIL PAN .................................................................. 5-64
CRANKCASE ............................................................................................. 5-65
DISASSEMBLING THE CRANKCASE................................................. 5-67
CHECKING THE CRANKCASE ........................................................... 5-67
CHECKING THE BEARING AND OIL SEALS ..................................... 5-67
ASSEMBLING THE CRANKCASE.......................................................5-67
CRANKSHAFT ........................................................................................... 5-69
REMOVING THE CONNECTING RODS AND PISTONS .................... 5-71
REMOVING THE CRANKSHAFT ASSEMBLY ..................................... 5-71
CHECKING THE CYLINDER AND PISTON......................................... 5-72
CHECKING THE PISTON RINGS ........................................................ 5-72
CHECKING THE PISTON PINS ........................................................... 5-73
CHECKING THE BIG END BEARINGS ............................................... 5-74
INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-77
CHECKING THE CRANKSHAFT ......................................................... 5-80
CHECKING THE CRANKSHAFT DRIVE SPROCKET......................... 5-80
CHECKING THE CRANKSHAFT JOURNAL BEARINGS .................... 5-80
INSTALLING THE CRANKSHAFT........................................................ 5-82
TRANSMISSION......................................................................................... 5-84
REMOVING THE TRANSMISSION...................................................... 5-89
CHECKING THE SHIFT FORKS.......................................................... 5-89
CHECKING THE SHIFT DRUM ASSEMBLY........................................ 5-90
CHECKING THE TRANSMISSION ...................................................... 5-90
INSTALLING THE TRANSMISSION..................................................... 5-91
CHAPTER 6
COOLING SYSTEM
RADIATOR.................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................. 6-3
INSTALLING THE RADIATOR ................................................................ 6-3
OIL COOLER ................................................................................................ 6-4
CHECKING THE OIL COOLER.............................................................. 6-5
INSTALLING THE OIL COOLER ............................................................ 6-5
THERMOSTAT .............................................................................................. 6-6
CHECKING THE THERMOSTAT............................................................ 6-8
ASSEMBLING THE THERMOSTAT ASSEMBLY ................................... 6-8
INSTALLING THE THERMOSTAT ASSEMBLY ...................................... 6-8
WATER PUMP ............................................................................................ 6-10
DISASSEMBLING THE WATER PUMP ............................................... 6-11
CHECKING THE WATER PUMP .......................................................... 6-11
ASSEMBLING THE WATER PUMP ..................................................... 6-11
.
CHAPTER 7
FUEL SYSTEM
FUEL TANK .................................................................................................. 7-1
REMOVING THE FUEL TANK................................................................ 7-2
REMOVING THE FUEL PUMP............................................................... 7-2
CHECKING THE FUEL PUMP BODY .................................................... 7-2
CHECKING THE FUEL PUMP OPERATION ......................................... 7-2
INSTALLING THE FUEL PUMP ............................................................. 7-2
INSTALLING THE FUEL TANK............................................................... 7-3
THROTTLE BODIES..................................................................................... 7-4
CHECKING THE INJECTORS ............................................................... 7-8
CHECKING THE THROTTLE BODIES .................................................. 7-8
CHECKING THE FUEL PRESSURE...................................................... 7-8
ADJUSTING THE THROTTLE POSITION SENSOR ............................. 7-8
ADJUSTING THE SUB-THROTTLE POSITION SENSOR .................... 7-9
CHECKING THE SUB-THROTTLE SERVO MOTOR ........................... 7-10
CHECKING THE THERMO WAX ......................................................... 7-11
ADJUSTING THE THERMO WAX........................................................ 7-11
AIR INDUCTION SYSTEM ......................................................................... 7-13
CHECKING THE AIR INDUCTION SYSTEM ....................................... 7-14
INSTALLING THE AIR INDUCTION SYSTEM ..................................... 7-15
CHAPTER 8
ELECTRICAL SYSTEM
IGNITION SYSTEM....................................................................................... 8-1
CIRCUIT DIAGRAM................................................................................ 8-1
TROUBLESHOOTING............................................................................ 8-3
ELECTRIC STARTING SYSTEM.................................................................. 8-5
CIRCUIT DIAGRAM................................................................................ 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......................... 8-7
TROUBLESHOOTING............................................................................ 8-9
CHARGING SYSTEM ................................................................................. 8-11
CIRCUIT DIAGRAM.............................................................................. 8-11
TROUBLESHOOTING.......................................................................... 8-13
LIGHTING SYSTEM ................................................................................... 8-15
CIRCUIT DIAGRAM.............................................................................. 8-15
TROUBLESHOOTING.......................................................................... 8-17
SIGNALING SYSTEM................................................................................. 8-19
CIRCUIT DIAGRAM.............................................................................. 8-19
TROUBLESHOOTING.......................................................................... 8-21
COOLING SYSTEM.................................................................................... 8-25
CIRCUIT DIAGRAM.............................................................................. 8-25
TROUBLESHOOTING.......................................................................... 8-27
FUEL INJECTION SYSTEM ....................................................................... 8-29
CIRCUIT DIAGRAM.............................................................................. 8-29
TROUBLESHOOTING.......................................................................... 8-31
ECU SELF-DIAGNOSTIC FUNCTION ................................................. 8-35
SELF-DIAGNOSTIC FUNCTION TABLE.............................................. 8-36
TROUBLESHOOTING METHOD ......................................................... 8-39
DIAGNOSTIC MODE............................................................................8-40
TROUBLESHOOTING DETAILS .......................................................... 8-48
FUEL PUMP SYSTEM................................................................................ 8-73
CIRCUIT DIAGRAM.............................................................................. 8-73
TROUBLESHOOTING.......................................................................... 8-75
ELECTRICAL COMPONENTS................................................................... 8-77
CHECKING THE SWITCHES............................................................... 8-81
CHECKING THE BULBS AND BULB SOCKETS................................. 8-84
CHECKING THE FUSES...................................................................... 8-85
CHECKING AND CHARGING THE BATTERY..................................... 8-85
CHECKING THE RELAYS.................................................................... 8-88
CHECKING THE TURN SIGNAL/HAZARD RELAY ............................. 8-89
CHECKING THE RELAY UNIT (DIODE) .............................................. 8-90
CHECKING THE IGNITION COILS...................................................... 8-91
CHECKING THE CRANKSHAFT POSITION SENSOR....................... 8-92
CHECKING THE LEAN ANGLE SENSOR........................................... 8-93
CHECKING THE STARTOR MOTOR OPERATION ............................. 8-93
CHECKING THE STATOR COIL........................................................... 8-93
CHECKING THE RECTIFIER/REGULATOR........................................ 8-94
CHECKING THE HORN ....................................................................... 8-94
CHECKING THE FUEL SENDER ........................................................ 8-95
CHECKING THE SPEED SENSOR ..................................................... 8-95
CHECKING THE RADIATOR FAN MOTOR.......................................... 8-96
CHECKING THE COOLANT TEMPERATURE SENSOR .................... 8-96
CHECKING THE THROTTLE POSITION SENSOR ............................ 8-97
CHECKING THE SUB-THROTTLE POSITION SENSOR .................... 8-97
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ................... 8-98
CHECKING THE ATMOSPHERIC PRESSURE SENSOR................... 8-99
CHECKING THE CYLINDER IDENTIFICATION SENSOR .................. 8-99
CHECKING THE INTAKE AIR PRESSURE SENSOR ......................... 8-99
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ................8-100
CHAPTER 9
TROUBLESHOOTING
TROUBLESHOOTING .................................................................................. 9-1
GENERAL INFORMATION ..................................................................... 9-1
STARTING FAILURES............................................................................ 9-1
INCORRECT ENGINE IDLING SPEED ................................................. 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................ 9-2
FAULTY GEAR SHIFTING ...................................................................... 9-2
SHIFT PEDAL DOES NOT MOVE.......................................................... 9-2
JUMPS OUT OF GEAR.......................................................................... 9-2
FAULTY CLUTCH ................................................................................... 9-2
OVERHEATING ...................................................................................... 9-2
OVERCOOLING ..................................................................................... 9-3
POOR BRAKING PERFORMANCE ....................................................... 9-3
FAULTY FRONT FORK LEGS ................................................................ 9-3
UNSTABLE HANDLING.......................................................................... 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 9-4
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
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
FEATURES
EAS20170
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
14.Spark plug
15.Cylinder identification sensor
16.Battery
17.ECU
18.Atomospheric pressure sensor
19.Relay unit (fuel pump relay)
20.Engine trouble warning light
21.Lean angle sensor
22.Air cut-off valve
23.O2 sensor
1. Ignition coil
2. Air filter case
3. Intake air temperature sensor
4. Fuel delivery hose
5. Fuel tank
6. Fuel pump
7. Intake air pressure sensor
8. Throttle position sensor
9. Sub-throttle position sensor
10.Fuel injector
11.Catalytic converter
12.Crankshaft position sensor
13.Coolant temperature sensor
1-2
1
FI SYSTEM
ET2D1001
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature
sensor, coolant temperature sensor, speed sensor and O2 sensor enable the ECU to determine the
injection duration. The injection timing is determined through the signals from the crankshaft position sensor. 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.
Illustration is for reference only.
13.Throttle body
14.Air filter case
A. Fuel system
B. Air system
C. Control system
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Intake air temperature sensor
6. Throttle position sensor
7. Sub-throttle position sensor
8. O2 sensor
9. Catalytic converter
10.Coolant temperature sensor
11.Crankshaft position sensor
12.Intake air pressure sensor
1-3
INSTRUMENT FUNCTIONS
miles, press the “SELECT” button for at least
one second.
ET2D1002
INSTRUMENT FUNCTIONS
Multi-function meter unit
Tachometer
1. Coolant temperature display/air intake temperature display
2. Speedometer
3. Tachometer
4. Odometer/tripmeter/fuel reserve tripmeter
5. “SELECT” button
6. “RESET” button
7. Clock
8. Fuel meter
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachometer needle will sweep once across the r/min
range and then return to zero r/min in order to
test the electrical circuit.
EW2D1005
WARNING
EC2D1007
CAUTION:
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
Do not operate the engine in the tachometer red zone.
Red zone: 12000 r/min and above
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding
speed)
• a tachometer (which shows engine speed)
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance traveled since they were last set to zero)
• a fuel reserve tripmeter (which shows the
distance traveled since the left segment of
the fuel meter started flashing)
• a clock
• a fuel meter
• a coolant temperature display
• an air intake temperature display
• a self-diagnosis device
• an LCD and tachometer brightness control
mode
Clock mode
1. Clock
2. Speedometer
The clock is displayed when the key is turned
to “ON”. In addition, the clock can be displayed
for 10 seconds by pushing the “SELECT” button when the main switch is in the “OFF” or
“LOCK” position.
To set the clock
1. Turn the key to “ON”.
2. Push the “SELECT” button and “RESET”
button together for at least two seconds.
NOTE:
• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.
• To switch the speedometer and odometer/
tripmeter displays between kilometers and
1-4
INSTRUMENT FUNCTIONS
3. When the hour digits start flashing, push
the “RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then
release it to start the clock.
Odometer and tripmeter modes
1. Fuel meter
The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear towards “E” (Empty) as the
fuel level decreases. When only one segment
is left near “E”, refuel as soon as possible.
NOTE:
This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective,
the following cycle will be repeated until the
malfunction is corrected: “E” (Empty), “F” (Full)
and symbol “ ” will flash eight times, then go
off for approximately 3 seconds. If this occurs,
have a Yamaha dealer check the electrical circuit.
1. Odometer/tripmeter/fuel reserve tripmeter
Push the “SELECT” button to switch the display between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
TRIP A → TRIP B → ODO → TRIP A
When the fuel amount in the fuel tank
decreases to 3.4 L (0.90 US gal) (0.75
Imp.gal), the left segment of the fuel meter will
start flashing, and the odometer display will
automatically change to the fuel reserve tripmeter mode “FTRIP” and start counting the
distance traveled from that point. In that case,
push the “SELECT” button to switch the display between the various tripmeter and odometer modes in the following order:
F-TRIP → TRIP A → TRIP B → ODO → FTRIP
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).
Coolant temperature mode
1. Coolant temperature display
The coolant temperature display indicates the
temperature of the coolant.
Push the “RESET” button to switch the coolant
temperature display to the air intake temperature display.
NOTE:
Fuel meter
When the coolant temperature display is
selected, “C” is displayed for one second, and
then the coolant temperature is displayed.
1-5
INSTRUMENT FUNCTIONS
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
display will indicate a two-digit error code (e.g.,
11, 12, 13).
EC2D1011
CAUTION:
Do not operate the engine if it is overheated.
LCD and tachometer brightness control
mode
Air intake temperature mode
1. Air intake temperature display
1.
2.
3.
4.
The air intake temperature display indicates
the temperature of the air drawn into the air filter case. Push the “RESET” button to switch
the coolant temperature display to the air
intake temperature display.
Tachometer panel
Tachometer needle
LCD
Brightness level
This function allows you to adjust the brightness of the LCD and the tachometer panel and
needle to suit the outside lighting conditions.
To set the brightness
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the
“SELECT” button after five seconds.
4. Push the “RESET” button to select the
desired brightness level.
5. Push the “SELECT” button to confirm the
selected brightness level. The display will
return to the odometer or tripmeter mode.
NOTE:
• Even if the air intake temperature is set to be
displayed, the coolant temperature warning
light comes on when the engine overheats.
• When the key is turned to “ON”, the coolant
temperature is automatically displayed, even
if the air intake temperature was displayed
prior to turning the key to “OFF”.
• When the air intake temperature display is
selected, “A” is displayed for one second,
and then the air intake temperature is displayed.
Self-diagnosis device
1. Error code display
This model is equipped with a self-diagnosis
device for various electrical circuits.
1-6
IMPORTANT INFORMATION
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil
seal lips with grease.
2. Use only the proper tools and cleaning
equipment.
Refer to "SPECIAL TOOLS" on page 1-10.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced
as an assembly.
1.
2.
3.
4.
Oil
Lip
Spring
Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-7
IMPORTANT INFORMATION
EAS20230
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
CAUTION:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always 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.
1-8
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS
Pocket tester
90890-03112
Analog Pocket tester
YU-03112-C
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
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 most part stores.
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)
1-9
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to 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
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
Reference
pages
5-71
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
6-3
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
6-3
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
3-26, 4-57
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
4-57
Damper rod holder
90890-01423
Damping rod holder
YM-01423
4-49, 4-50
1-10
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Oil filter wrench
90890-01426
YU-38411
Reference
pages
3-11
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
4-48, 4-53
Rod puller
90890-01437
Universal damping rod bleeding tool set
YM-A8703
4-52
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding tool set
YM-A8703
4-52
Fork spring compressor
90890-01441
YM-01441
4-48, 4-53
Fork seal driver
90890-01442
Adjust table fork seal driver (36-46 mm)
YM-01442
4-51
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
3-7
1-11
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Compression gauge
90890-03081
Engine compression tester
YU-33223
Reference
pages
3-10
Valve spring compressor
90890-04019
YM-04019
5-23, 5-29
Valve spring compressor attachment
90890-04108
Valve spring compressor adapter (22 mm)
YM-04108
5-23, 5-29
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter
YM-04114
5-23, 5-29
Middle driven shaft bearing driver
90890-04058
Bearing driver (40 mm)
YM-04058
6-12
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
6-12
Universal clutch holder
90890-04086
YM-91042
5-47
1-12
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Valve guide remover (E)
90890-04111
Valve guide remover (4.0 mm)
YM-04111
Reference
pages
5-25
Valve guide remover (E.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116
5-25
Valve guide installer (E)
90890-04112
Valve guide installer (4.0 mm)
YM-04112
5-25
Valve guide installer (E.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
5-25
Valve guide reamer (E)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113
5-25
Valve guide reamer (E.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
5-25
Ignition checker
90890-06754
Opama pet-4000 spark checker
YU-34487
8-92
1-13
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Yamaha bond No.1215
(Three Bond No.1215®)
90890-85505
Reference
pages
2-19, 5-67, 6-12
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
7-9, 7-10
Pivot shaft wrench
90890-01471
Frame spanner socket
YM-01471
5-7
Pivot shaft wrench adapter
90890-01476
5-7
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-9, 5-41, 8-83,
8-84, 8-85, 888, 8-89, 8-90,
8-91, 8-92, 893, 8-94, 8-95,
8-96, 8-97, 898, 8-99, 8-100
3-13, 7-8
Oil pressure gauge
90890-03153
Pressure gauge
YU-03153
Oil pressure gauge adapter
90890-03139
3-13
1-14
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Vacuum/pressure pump gauge set
90890-06756
Reference
pages
7-8
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
3-5
Fuel pressure adapter
90890-03176
YM-03176
7-8
Pressure gauge
90890-03153
YU-03153
3-13, 7-8
Camshaft wrench
90890-04143
YM-04143
5-11, 5-16
1-15
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model
3C34 (U.S.A.)
3C35 (California)
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
2140 mm (84.3 in)
770 mm (30.3 in)
1205 mm (47.4 in)
815 mm (32.1 in)
1460 mm (57.5 in)
135 mm (5.31 in)
3000 mm (118.1 in)
Weight
With oil and fuel
220.0 kg (485 lb) (U.S.A.)
221.0 kg (487 lb) (California)
190 kg (419 lb) (U.S.A.)
189.0 kg (417 lb) (California)
Maximum load
EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Liquid cooled 4-stroke, DOHC
998.0 cm³ (60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0 × 53.6 mm (3.03 × 2.11 in)
11.50 : 1
1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8
kgf/cm²/350 r/min)
Electric starter
Starting system
Fuel
Recommended fuel
Fuel tank capacity
Fuel reserve amount
Unleaded gasoline only
18.0 L (4.76 US gal) (3.96 Imp.gal)
3.4 L (0.90 US gal) (0.75 Imp.gal)
Engine oil
Lubrication system
Type
Recommended engine oil grade
Engine oil quantity
Total amount
Without oil filter cartridge replacement
With oil filter cartridge replacement
Wet sump
YAMALUBE 4 , SAE10W30 or SAE20W40
API service SE, SF, SG type or higher
3.80 L (4.02 US qt) (3.34 Imp.qt)
2.90 L (3.07 US qt) (2.55 Imp.qt)
3.10 L (3.28 US qt) (2.73 Imp.qt)
Oil filter
Oil filter type
Paper
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Trochoid
0.010–0.100 mm (0.0004–0.0039 in)
0.18 mm (0.0071 in)
0.090–0.150 mm (0.0035–0.0059 in)
0.22 mm (0.0087 in)
0.06–0.13 mm (0.0024–0.0051 in)
2-1
ENGINE SPECIFICATIONS
Limit
Bypass valve opening pressure
0.20 mm (0.0079 in)
80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20
kgf/cm²)
600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80
kgf/cm²)
Relief valve operating pressure
Cooling system
Radiator capacity (including all routes)
Coolant reservoir capacity (up to the maximum
level mark)
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Water pump
Water pump type
Reduction ratio
Max impeller shaft tilt limit
2.25 L (2.38 US qt) (1.98 Imp.qt)
0.25 L (0.26 US qt) (0.22 Imp.qt)
93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23
kgf/cm²)
222.6 mm (8.76 in)
360.0 mm (14.17 in)
22.0 mm (0.87 in)
Single suction centrifugal pump
65/43 × 25/32 (1.181)
0.15 mm (0.0059 in)
Spark plug (s)
Manufacturer/model
Spark plug gap
NGK/CR9EK
0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Volume
Warpage limit*
12.20–13.00 cm³ (0.74–0.79 cu.in)
0.10 mm (0.0039 in)
Camshaft
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap clearance
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
Chain drive (right)
22.500–22.521 mm (0.8858–0.8867 in)
22.459–22.472 mm (0.8842–0.8847 in)
0.028–0.062 mm (0.0011–0.0024 in)
32.500–32.600 mm (1.2795–1.2835 in)
32.400 mm (1.2756 in)
24.950–25.050 mm (0.9823–0.9862 in)
24.850 mm (0.9783 in)
30.699–30.799 mm (1.2086–1.2126 in)
30.599 mm (1.2047 in)
22.950–23.050 mm (0.9035–0.9075 in)
22.850 mm (0.8996 in)
Camshaft runout limit
0.030 mm (0.0012 in)
2-2
2
ENGINE SPECIFICATIONS
Timing chain
Model/number of links
Tensioning system
RH2020/122
Automatic
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A (intake)
Valve head diameter A (exhaust)
0.11–0.20 mm (0.0043–0.0079 in)
0.21–0.25 mm (0.0083–0.0098 in)
23.40–23.60 mm (0.9213–0.9291 in)
24.90–25.10 mm (0.9803–0.9882 in)
Valve face width B (intake)
Valve face width B (exhaust)
1.760–2.900 mm (0.0693–0.1142 in)
1.760–2.900 mm (0.0693–0.1142 in)
Valve seat width C (intake)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake)
Valve margin thickness D (exhaust)
0.50–0.90 mm (0.0197–0.0354 in)
0.50–0.90 mm (0.0197–0.0354 in)
Valve stem diameter (intake)
Limit
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
Valve guide inside diameter (exhaust)
Limit
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide clearance (exhaust)
Limit
Valve stem runout
2-3
3.975–3.990 mm (0.1565–0.1571 in)
3.945 mm (0.1553 in)
4.460–4.475 mm (0.1756–0.1762 in)
4.425 mm (0.1742 in)
4.000–4.012 mm (0.1575–0.1580 in)
4.050 mm (0.1594 in)
4.500–4.512 mm (0.1772–0.1776 in)
4.550 mm (0.1791 in)
0.010–0.037 mm (0.0004–0.0015 in)
0.080 mm (0.0032 in)
0.025–0.052 mm (0.0010–0.0020 in)
0.100 mm (0.0039 in)
0.010 mm (0.0004 in)
ENGINE SPECIFICATIONS
Cylinder head valve seat width (intake)
Cylinder head valve seat width (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
0.90–1.10 mm (0.0354–0.0433 in)
Valve spring
Inner spring
Free length (intake)
Free length (exhaust)
Installed length (intake)
Installed length (exhaust)
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Installed compression spring force (intake)
Spring tilt (intake)*
Spring tilt (exhaust)*
40.47 mm (1.59 in)
40.53 mm (1.60 in)
32.66 mm (1.29 in)
33.88 mm (1.33 in)
17.53 N/mm (100.10 lb/in) (1.79 kgf/mm)
22.86 N/mm (130.53 lb/in) (2.33 kgf/mm)
21.52 N/mm (122.88 lb/in) (2.19 kgf/mm)
27.99 N/mm (159.82 lb/in) (2.85 kgf/mm)
127.40–144.60 N (28.64–32.51 lb) (12.99–
14.74 kgf)
133.00–153.00 N (29.90–34.39 lb) (13.56–
15.60 kgf)
2.5 °/1.8 mm
2.5 °/1.8 mm
Winding direction (intake)
Winding direction (exhaust)
Clockwise
Clockwise
Installed compression spring force (exhaust)
Cylinder
Bore
Taper limit
Out of round limit
77.000–77.010 mm (3.0315–3.0319 in)
0.050 mm (0.0020 in)
0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance
Limit
Diameter D
Height H
0.010–0.035 mm (0.0004–0.0014 in)
0.12 mm (0.0047 in)
76.975–76.990 mm (3.0305–3.0311 in)
5.0 mm (0.20 in)
Offset
Offset direction
0.50 mm (0.0197 in)
Intake side
2-4
ENGINE SPECIFICATIONS
Piston pin bore inside diameter
Piston pin outside diameter
17.002–17.013 mm (0.6694–0.6698 in)
16.991–17.000 mm (0.6689–0.6693 in)
Piston ring
Top ring
Ring type
Dimensions (B × T)
Barrel
0.90 × 2.75 mm (0.04 × 0.11 in)
End gap (installed)
Ring side clearance
2nd ring
Ring type
Dimensions (B × T)
0.15–0.25 mm (0.0059–0.0098 in)
0.030–0.065 mm (0.0012–0.0026 in)
Taper
0.80 × 2.75 mm (0.03 × 0.11 in)
End gap (installed)
Ring side clearance
Oil ring
Dimensions (B × T)
0.30–0.45 mm (0.0118–0.0177 in)
0.020–0.055 mm (0.0008–0.0022 in)
1.50 × 2.25 mm (0.06 × 0.09 in)
End gap (installed)
0.10–0.40 mm (0.0039–0.0157 in)
Connecting rod
Oil clearance (using plastigauge®)
Bearing color code
0.034–0.058 mm (0.0013–0.0023 in)
1.Blue 2.Black 3.Brown 4.Green
Crankshaft
Width A
Width B
Runout limit C
Big end side clearance D
55.20–56.60 mm (2.173–2.228 in)
298.75–300.65 mm (11.76–11.84 in)
0.030 mm (0.0012 in)
0.160–0.262 mm (0.0063–0.0103 in)
Journal oil clearance (using plastigauge®)
Bearing color code
0.014–0.037 mm (0.0006–0.0015 in)
0.White 1.Blue 2.Black 3.Brown 4.Green
Clutch
Clutch type
Clutch release method
Clutch lever free play
Friction plate thickness
Wear limit
Plate quantity
Wet, multiple-disc
Outer pull, rack and pinion pull
10.0–15.0 mm (0.39–0.59 in)
2.90–3.10 mm (0.114–0.122 in)
2.80 mm (0.1102 in)
9 pcs
2-5
ENGINE SPECIFICATIONS
Clutch plate thickness
Plate quantity
Warpage limit
Clutch spring free length
Spring quantity
1.90–2.10 mm (0.075–0.083 in)
8 pcs
0.10 mm (0.0039 in)
52.50 mm (2.07 in)
6 pcs
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratio
1st
2nd
3rd
4th
5th
6th
Main axle runout limit
Drive axle runout limit
Constant mesh 6-speed
Spur gear
65/43 (1.512)
Chain drive
45/17 (2.647)
Left foot operation
38/15 (2.533)
33/16 (2.063)
37/21 (1.762)
35/23 (1.522)
27/20 (1.350)
29/24 (1.208)
0.08 mm (0.0032 in)
0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type
Shift fork guide bar bending limit
Shift fork thickness
Guide bar
0.100 mm (0.0039 in)
5.80–5.88 mm (0.2283–0.2315 in)
Air filter
Air filter element
Oil-coated paper element
Fuel pump
Pump type
Model/manufacturer
Maximum consumption amperage
Output pressure
Electrical
2D1/DENSO
4.3 A
324.0 kPa (47.0 psi) (3.24 kgf/cm²)
Fuel injection
Model/quantity
Manufacturer
297500-0300/4
DENSO
Throttle body
Type/quantity
SE 45EIDW-B10/1 (U.S.A.)
SE 45EIDW-B13/1 (California)
MIKUNI
2D11 00 (U.S.A.)
3C35 00 (California)
#100
Manufacturer
ID mark
Throttle valve size
Throttle position sensor
Resistance
Output voltage (at idle)
4.9–5.1 kΩ
0.63–0.73 V
Idling condition
Engine idling speed
Intake vacuum
Water temperature
Oil temperature
Throttle cable free play
1100–1300 r/min
30.0 kPa (8.9 inHg) (225 mmHg)
95.0–105.0 °C (203.00–221.00 °F)
80.0–90.0 °C (176.00–194.00 °F)
3.0–5.0 mm (0.12–0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS20300
CHASSIS SPECIFICATIONS
Chassis
Frame type
Caster angle
Trail
Diamond
25.00 °
109.0 mm (4.29 in)
Front wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Cast wheel
17M/C x MT3.50
Aluminum
130.0 mm (5.12 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
Rear wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Cast wheel
17M/C x MT6.00
Aluminum
130.0 mm (5.12 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
Front tire
Size
Manufacturer/model
Manufacturer/model
Wear limit (front)
120/70 ZR17M/C (58W)
MICHELIN/Pilot Road S
DUNLOP/D221FA
0.8 mm (0.03 in)
Rear tire
Size
Manufacturer/model
Manufacturer/model
Wear limit (rear)
190/50 ZR17M/C (73W)
MICHELIN/Pilot Road D
DUNLOP/D221G
0.8 mm (0.03 in)
Tire air pressure (measured on cold tires)
Loading condition
Front
Rear
Loading condition
0–90 kg (0–198 lb)
250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
90–190 kg (198–419 lb) (U.S.A.)
90-189 kg (198-417 lb) (California)
250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
Front
Rear
High-speed riding
Front
Rear
250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
Front brake
Type
Operation
Front brake lever free play
Front disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Dual disc brake
Right hand operation
2.3–11.5 mm (0.09–0.45 in)
320.0 × 4.5 mm (12.60 × 0.18 in)
4.0 mm (0.16 in)
0.10 mm (0.0039 in)
4.5 mm (0.18 in)
0.5 mm (0.02 in)
4.5 mm (0.18 in)
0.5 mm (0.02 in)
2-7
CHASSIS SPECIFICATIONS
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
16.00 mm (0.63 in)
30.20 mm (1.19 in)
27.00 mm (1.06 in)
DOT 4
Rear brake
Type
Operation
Brake pedal free play
Rear disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Single disc brake
Right foot operation
4.3–9.3 mm (0.17–0.37 in)
245.0 × 5.0 mm (9.65 × 0.20 in)
4.5 mm (0.18 in)
0.15 mm (0.0059 in)
6.0 mm (0.24 in)
1.0 mm (0.04 in)
6.0 mm (0.24 in)
1.0 mm (0.04 in)
12.7 mm (0.50 in)
38.20 mm (1.50 in)
DOT 4
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Angular bearing
33.0 °
33.0 °
Front suspension
Type
Spring/shock absorber type
Front fork travel
Fork spring free length
Collar length
Installed length
Spring rate K1
Spring stroke K1
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Recommended oil
Quantity
Level
Telescopic fork
Coil spring/oil damper
130.0 mm (5.12 in)
243.5 mm (9.59 in)
100.0 mm (3.94 in)
239.0 mm (9.41 in)
9.32 N/mm (53.22 lb/in) (0.95 kgf/mm)
0.0–130.0 mm (0.00–5.12 in)
43.0 mm (1.69 in)
0.2 mm (0.01 in)
No
Suspension oil 01
545.0 cm³ (18.43 US oz) (19.22 Imp.oz)
91.0 mm (3.58 in)
Rear suspension
Type
Spring/shock absorber type
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate K1
Spring stroke K1
Optional spring available
Enclosed gas/air pressure (STD)
Swingarm (link suspension)
Coil spring/gas-oil damper
60.0 mm (2.36 in)
191.3 mm (7.53 in)
181.8 mm (7.16 in)
120.00 N/mm (685.20 lb/in) (12.24 kgf/mm)
0.0–60.0 mm (0.00–2.36 in)
No
1000 kPa (142.2 psi) (10.0 kgf/cm²)
Drive chain
Type/manufacturer
Link quantity
Drive chain slack
15-link length limit
50VA8/DAIDO
122
25.0–35.0 mm (0.98–1.38 in)
239.3 mm (9.42 in)
2-8
ELECTRICAL SPECIFICATIONS
EAS20310
ELECTRICAL SPECIFICATIONS
Voltage
System voltage
12 V
Ignition system
Ignition system
Ignition timing (B.T.D.C.)
Transistorized coil ignition (digital)
5.0 °/1200 r/min
Engine control unit
Model/manufacturer
TBDF29/DENSO
Transistorized coil ignition
Crankshaft position sensor resistance
336–504 Ω at 20°C (68°F)
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
F6T558/MITSUBISHI
6.0 mm (0.24 in)
1.19–1.61 Ω at 20°C (68°F)
8.5–11.5 kΩ at 20°C (68°F)
AC magneto
Model/manufacturer
Standard output
Startor coil resistance
STATOR:F074T85073/MITSUBISHI
14.0 V40.0 A6500 r/min
0.14–0.18 Ω at 20°C (68°F)
Voltage regulator
Rectifier/regulator
Regulator type
Model/manufacturer
Regulated voltage (DC)
Rectifier capacity
Withstand voltage
Semi conductor-short circuit
FH012AA/SHINDENGEN
14.2–14.8 V
50.0 A
40.0 V
Battery
Model
Voltage, capacity
Specific gravity
Manufacturer
Ten hour rate amperage
YTZ14S
12 V, 11.2 Ah
1.310
GYM
1.12 A
Headlight
Bulb type
Halogen bulb
Bulb voltage, wattage × quantity
Headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
License plate light
Meter lighting
12 V, 60 W/55.0 W × 2
12 V, 5.0 W/21.0 W × 1
12 V, 21 W/5.0 W × 2
12 V, 21 W × 2
12 V, 5.0 W × 1
LED
Indicator light
Neutral indicator light
Turn signal indicator light
Oil level warning light
High beam indicator light
Coolant temperature warning light
Engine trouble warning light
LED
LED
LED
LED
LED
LED
2-9
ELECTRICAL SPECIFICATIONS
Electric starting system
System type
Constant mesh
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Commutator diameter
Limit
Mica undercut (depth)
SM13/MITSUBA
0.80 kW
0.0250–0.0350 Ω
12.5 mm (0.49 in)
5.00 mm (0.20 in)
7.65–10.01 N (27.54–36.03 oz) (780–1021 gf)
28.0 mm (1.10 in)
27.0 mm (1.06 in)
0.70 mm (0.03 in)
Starter relay
Model/manufacturer
Amperage
Coil resistance
2768109-A/JIDECO
180.0 A
4.18–4.62 Ω at 20°C (68°F)
Horn
Horn type
Quantity
Model/manufacturer
Maximum amperage
Coil resistance
Performance
Plane
1 pcs
YF-12/NIKKO
3.0 A
1.15–1.25 Ω at 20°C (68°F)
105–113 dB/2m
Turn signal/hazard relay
Relay type
Model/manufacturer
Built-in, self-canceling device
Turn signal blinking frequency
Wattage
Full transistor
FE246BH/DENSO
No
75.0–95.0 cycles/min
21 W × 2.0 +3.4 W
Oil level gauge
Model/manufacturer
5VY/SOMIC ISHIKAWA
Servo motor
Model/manufacturer
2D1/YAMAHA
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Fuel injection system fuse
Backup fuse
Reserve fuse
Reserve fuse
Reserve fuse
50.0 A
20.0 A
10.0 A
15.0 A
10.0 A × 2
15.0 A
10.0 A
20.0 A
15.0 A
10.0 A
2-10
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
m·kg
ft·lb
6
0.6
4.3
15
1.5
11
30
3.0
22
55
5.5
40
85
8.5
61
130
13.0
94
2-11
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES
Item
Spark plug
Cylinder head nut
Thread
Q’ty
size
M10
4
M10
10
Tightening torque
13 Nm (1.3 m·kg, 9.4 ft·lb)
See NOTE
Cylinder head bolt
Camshaft caps bolt
M6
M6
2
28
12 Nm (1.2 m·kg, 8.7 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head cover bolt
Cylinder head stud bolt (exhaust
pipe)
Air indication system cap bolt
M6
M8
6
8
12 Nm (1.2 m·kg, 8.7 ft·lb)
15 Nm (1.5 m·kg, 11 ft·lb)
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft sprocket bolt
Cylinder head and throttle body
clamp
Connecting rod cap bolt (1st)
M7
M5
4
4
24 Nm (2.4 m·kg, 17 ft·lb)
3 Nm (0.3 m·kg, 2.2 ft·lb)
M8
8
20 Nm (2.0 m·kg, 14 ft·lb)
Connecting rod cap bolt (final)
M8
8
Specified angle 150°
Generator rotor bolt
Timing chain tensioner bolt
Water pump outlet pipe bolt
M10
M6
M6
1
2
1
60 Nm (6.0 m·kg, 43 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump inlet pipe bolt (water
pump side)
Water pump inlet pipe bolt (front
side)
Oil/water pump drive sprocket
bolt
Water pump bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
M6
1
15 Nm (1.5 m·kg, 11 ft·lb)
M6
5
12 Nm (1.2 m·kg, 8.7 ft·lb)
Thermostat cover nut
Thermostat inlet pipe bolt
Oil cooler bolt
M6
M6
M20
2
1
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
63 Nm (6.3 m·kg, 46 ft·lb)
Engine oil drain bolt
Oil pipe bolt
M14
M6
1
2
43 Nm (4.3 m·kg, 31 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil strainer bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil delivery pipe bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil filter union bolt
Oil filter
M20
M20
1
1
70 Nm (7.0 m·kg, 51 ft·lb)
17 Nm (1.7 m·kg, 12 ft·lb)
Oil pan bolt
Oil pan bolt
M6
M6
14
1
12 Nm (1.2 m·kg, 8.7 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
Air filter case cover screw
Throttle body and throttle body
joint clamp
Throttle body and funnel bolt
Throttle cable adjusting bolt
M5
M5
11
4
1.2 Nm (0.12 m·kg, 0.9 ft·lb)
3 Nm (0.3 m·kg, 2.2 ft·lb)
M5
M6
6
1
4.2 Nm (0.42 m·kg, 3.0 ft·lb)
4.5 Nm (0.45 m·kg, 3.3 ft·lb)
2-12
Remarks
TIGHTENING TORQUES
Item
Cylinder head and exhaust pipe
nut
Exhaust pipe and muffler bolt
EXUP pulley and shaft arm nut
EXUP valve pulley cover bolt
EXUP cable nut
Exhaust pipe and exhaust pipe
bracket bolt
EXUP servo motor cover bolt
EXUP servo motor nut
Crankcase stud bolt
Thread
Q’ty
size
M8
8
Tightening torque
20 Nm (2.0 m·kg, 14 ft·lb)
M8
M6
M6
M6
M8
1
1
2
2
2
20 Nm (2.0 m·kg, 14 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
14 Nm (1.4 m·kg, 10 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
20 Nm (2.0 m·kg, 14 ft·lb)
M5
M6
M10
2
1
10
2 Nm (0.2 m·kg, 1.4 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
8 Nm (0.8 m·kg, 5.8 ft·lb)
Crankcase bolt (main journal)
M9
10
See NOTE
Crankcase bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt
M6
8
10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt
M8
1
24 Nm (2.4 m·kg, 17 ft·lb)
Crankcase bolt
M8
5
24 Nm (2.4 m·kg, 17 ft·lb)
Generator rotor cover bolt
Generator rotor cover bolt
Drive sprocket cover bolt
Crankcase cover screw
Clutch cover bolt
Clutch cover bolt
M6
M8
M6
M6
M6
M6
4
3
3
3
7
1
12 Nm (1.2 m·kg, 8.7 ft·lb)
22 Nm (2.2 m·kg, 16 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
Pickup rotor cover bolt
Breather cover bolt
Breather plate bolt
M6
M6
M6
6
4
3
12 Nm (1.2 m·kg, 8.7 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Plate bolt
M6
2
12 Nm (1.2 m·kg, 8.7 ft·lb)
Pickup rotor cover blind bolt
Generator rotor cover plug
Main gallery plug (oil return)
Main gallery plug
Oil return pipe bolt
M8
M20
M16
M20
M6
1
1
3
1
2
15 Nm (1.5 m·kg, 11 ft·lb)
8 Nm (0.8 m·kg, 5.8 ft·lb)
8 Nm (0.8 m·kg, 5.8 ft·lb)
8 Nm (0.8 m·kg, 5.8 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil return plug
M12
2
24 Nm (2.4 m·kg, 17 ft·lb)
AC magneto lead bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Startor coil screw
M6
3
14 Nm (1.4 m·kg, 10 ft·lb)
Generator rotor cover screw
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Thermostat assembly stay bolt
Starter clutch idler gear bolt
M6
M6
2
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch boss nut
M20
1
95 Nm (9.5 m·kg, 69 ft·lb)
2-13
Remarks
Stake
TIGHTENING TORQUES
Item
Clutch spring bolt
Thread
Q’ty
size
M6
6
Tightening torque
Remarks
10 Nm (1.0 m·kg, 7.2 ft·lb)
Use a lock
washer
Drive sprocket nut
Bearing plate bolt
Shift fork stopper plate bolt
M22
M6
M6
1
3
2
85 Nm (8.5 m·kg, 61 ft·lb)
12 Nm (1.2 m·kg, 8.7 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Stopper screw
M8
1
22 Nm (2.2 m·kg, 16 ft·lb)
Shift rod locknut (front)
Shift rod locknut (rear)
M6
M6
1
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
Shift rod joint bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Shift arm bolt
Neutral switch
Sub-throttle servo motor cover
bolt
Coolant temperature sensor
Cylinder identification sensor bolt
M6
M10
M4
1
1
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
20 Nm (2.0 m·kg, 14 ft·lb)
2 Nm (0.2 m·kg, 1.4 ft·lb)
M12
M6
1
1
18 Nm (1.8 m·kg, 13 ft·lb)
8 Nm (0.8 m·kg, 5.8 ft·lb)
Atmospheric pressure sensor bolt
Crankshaft position sensor bolt
M5
M6
2
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil level switch bolt
Starter motor bolt
M6
M6
2
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Left
thread
NOTE:
• Cylinder head nut
1 First, tighten the bolts to approximately 19 Nm (1.9 m•kg, 14 ft•lb) with a torque wrench following
the tightening order.
2 Retighten the bolts 67 Nm (6.7 m•kg, 48 ft•lb) with a torque wrench.
• Connecting rod cap bolt
1 Tighten the connecting rod bolts to 20 Nm (2.0 m•kg, 14 ft•lb) and then tighten them further to
reach the specified angle 150°.
• Crankcase bolt (main journal)
1 First, tighten the bolts to approximately 20 Nm (2.0 m•kg, 14 ft•lb) with a torque wrench following
the tightening order.
2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm (2.7
m•kg, 14 ft•lb) again.
3 Retighten the bolts further to reach the specified angle (60°)
2-14
TIGHTENING TORQUES
2-15
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES
Item
Upper bracket pinch bolt
Steering stem nut
Upper handlebar holder bolt
Lower handlebar holder nut
Lower bracket pinch bolt
Lower ring nut
Cap bolt
Damper rod assembly bolt
Brake master cylinder bracket bolt
Brake master cylinder reservoir
cap screw
Front brake hose union bolt
Front brake hose holder bolt
Cowling stay bolt
Cowling bracket bolt
Front fender bolt
Clutch lever holder pinch bolt
Right front engine mounting bolt 1
Right front engine mounting bolt 2
Left front engine mounting bolt
Upper self-locking nut
Lower self-locking nut
Engine mounting adjust bolt
(upper)
Engine mounting adjust bolt
(lower)
Pivot shaft nut
Connecting arm nut (connecting
arm and frame)
Relay arm nut (relay arm and
swingarm)
Relay arm nut (relay arm and
connecting arm)
Main frame and rear frame nut
Clutch cable locknut
Throttle cable locknut
Rear shock absorber assembly
upper nut
Rear shock absorber assembly
lower nut
Drive chain guard bolt
Drive chain guide bolt
Rear fender screw
Thread
Q’ty
size
M8
2
M28
1
M8
4
M10
2
M8
4
M30
1
M46
2
M10
1
Tightening torque
26 Nm (2.6 m·kg, 19 ft·lb)
113 Nm (11.3 m·kg, 82 ft·lb)
24 Nm (2.4 m·kg, 17 ft·lb)
32 Nm (3.2 m·kg, 23 ft·lb)
23 Nm (2.3 m·kg, 17 ft·lb)
SEE NOTE
23 Nm (2.3 m·kg, 17 ft·lb)
23 Nm (2.3 m·kg, 17 ft·lb)
M6
M4
2
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
2 Nm (0.2 m·kg, 1.4 ft·lb)
M10
M6
M8
M6
M6
M6
M10
M10
M10
M10
M10
M11
3
2
2
2
4
1
1
1
1
1
1
1
30 Nm (3.0 m·kg, 22 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
33 Nm (3.3 m·kg, 24 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
6 Nm (0.6 m·kg, 4.3 ft·lb)
11 Nm (1.1 m·kg, 8.0 ft·lb)
45 Nm (4.5 m·kg, 33 ft·lb)
50 Nm (5.0 m·kg, 36 ft·lb)
45 Nm (4.5 m·kg, 33 ft·lb)
51 Nm (5.1 m·kg, 37 ft·lb)
51 Nm (5.1 m·kg, 37 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
M11
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
M18
1
105 Nm (11 m·kg, 76 ft·lb)
M10
1
44 Nm (4.4 m·kg, 32 ft·lb)
1
44 Nm (4.4 m·kg, 32 ft·lb)
M10
1
44 Nm (4.4 m·kg, 32 ft·lb)
M10
4
41 Nm (4.1 m·kg, 30 ft·lb)
M8
M6
M10
1
2
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
5 Nm (0.5 m·kg, 3.6 ft·lb)
44 Nm (4.4 m·kg, 32 ft·lb)
M10
1
44 Nm (4.4 m·kg, 32 ft·lb)
M6
M6
M6
3
2
3
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
M10
2-16
Remarks
TIGHTENING TORQUES
Item
Rear brake hose holder screw
Fuel tank bolt (front)
Fuel tank bolt (rear)
Fuel tank bracket screw
Fuel tank cap bolt
Fuel pump bolt
Seat lock assembly nut
Mud guard assembly bolt
License plate light screw
Rear reflector nut
Mud guard assembly bracket
screw
Tail/brake light bracket bolt
Rear fender bracket bolt
Seat bracket bolt
Exhaust pipe assembly bracket
bolt
Side cover screw
Lean angle sensor bolt
Coolant reserver tank bolt
Front wheel axle shaft
Front wheel axle pinch bolt
Front brake caliper bolt
Front brake disc screw
Thread
Q’ty
size
M6
2
M6
3
M6
1
M6
4
M5
5
M5
6
M6
2
M8
4
M5
2
M5
2
M5
6
Tightening torque
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
6 Nm (0.6 m·kg, 4.3 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
16 Nm (1.6 m·kg, 12 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
2 Nm (0.2 m·kg, 1.4 ft·lb)
M8
M6
M6
M8
3
2
4
2
16 Nm (1.6 m·kg, 12 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
20 Nm (2.0 m·kg, 14 ft·lb)
M6
M4
M6
M18
M8
M10
M6
2
2
1
1
1
4
10
4 Nm (0.4 m·kg, 2.9 ft·lb)
2 Nm (0.2 m·kg, 1.4 ft·lb)
5 Nm (0.5 m·kg, 3.6 ft·lb)
72 Nm (7.2 m·kg, 52 ft·lb)
23 Nm (2.3 m·kg, 17 ft·lb)
40 Nm (4.0 m·kg, 29 ft·lb)
18 Nm (1.8 m·kg, 13 ft·lb)
Brake caliper bleed screw
Rear wheel axle nut
Rear brake disc screw
M8
M24
M8
3
1
5
5 Nm (0.5 m·kg, 3.6 ft·lb)
150 Nm (15.0 m·kg, 108 ft·lb)
30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake caliper bolt (front)
Rear brake caliper bolt (rear)
Rear wheel sprocket nut
Drive chain adjusting locknut
Rear brake hose union bolt
Sidestand nut
Sidestand bracket bolt
Sidestand switch bolt
Footrest bracket bolt
Rear brake fluid reserver tank bolt
Rear brake master cylinder bolt
Centerstand nut
Centerstand bracket nut
Centerstand bracket adapter bolt
Footrest bolt
Throttle cable adjust nut
Clutch cable adjust nut
M12
M8
M10
M8
M10
M10
M10
M5
M8
M5
M8
M10
M10
M10
M10
M6
M8
1
1
6
2
2
1
2
2
4
1
2
2
4
2
4
2
1
27 Nm (2.7 m·kg, 20 ft·lb)
22 Nm (2.2 m·kg, 16 ft·lb)
100 Nm (10.0 m·kg, 72 ft·lb)
16 Nm (1.6 m·kg, 12 ft·lb)
30 Nm (3.0 m·kg, 22 ft·lb)
48 Nm (4.8 m·kg, 35 ft·lb)
63 Nm (6.3 m·kg, 46 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
30 Nm (3.0 m·kg, 22 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
23 Nm (2.3 m·kg, 17 ft·lb)
56 Nm (5.6 m·kg, 41 ft·lb)
55 Nm (5.5 m·kg, 40 ft·lb)
73 Nm (7.3 m·kg, 53 ft·lb)
55 Nm (5.5 m·kg, 40 ft·lb)
4 Nm (0.4 m·kg, 2.9 ft·lb)
7 Nm (0.7 m·kg, 5.1 ft·lb)
2-17
Remarks
TIGHTENING TORQUES
NOTE:
1 First, tighten the ring nut to approximately 52 Nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then
loosen the lower ring nut completely.
2 Retighten the lower ring nut 18 Nm (1.8 m•kg, 13 ft•lb).
2-18
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20370
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil/water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surface
Crankcase mating surface
Clutch cover (crankcase mating surface)
Generator rotor cover (crankcase mating surface)
2-19
Yamaha bond No.
1215
Yamaha bond No.
1215
Yamaha bond No.
1215
Yamaha bond No.
1215
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Pickup rotor cover
2-20
Lubricant
Yamaha bond No.
1215
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20380
CHASSIS
Lubrication point
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Engine mount bolts (front left and right)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting point and metal-to-metal moving parts
Sidestand switch contact point
Sidestand hook and spring contact point
Shift shaft joint rod moving parts
Shift pedal pivoting parts
Rear footrest ball and metal-to-metal moving parts
Centerstand metal-to-metal moving parts
Front wheel oil seal (left and right)
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
2-21
Lubricant
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20400
ENGINE OIL LUBRICATION CHART
2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil strainer
2. Oil pump
3. Relief valve
4. Oil cooler
5. Oil filter
6. Main gallery
7. AC magneto drive gear shower
8. Shift fork (upper)
9. Main axle
10.Mission shower
11.Drive axle
12.AC magneto axle
13.Piston cooler
14.Chain tensioner
15.Intake camshaft
16.Exhaust camshaft
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20410
LUBRICATION DIAGRAMS
2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
Intake camshaft
Exhaust camshaft
Oil filter cartridge
Oil level switch
2-26
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
6.
7.
8.
Intake camshaft
Exhaust camshaft
Crankshaft
Oil cooler
Relief valve
Oil pipe
Oil strainer
Oil pump
2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
6.
Oil filter cartridge
Oil level switch
Oil pump
Oil strainer
Oil pipe
Oil cooler
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Main axle
2. Oil delivery pipe
3. Drive axle
2-32
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-33
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Cylinder head
2. Crankshaft
2-34
COOLING SYSTEM DIAGRAMS
EAS20420
COOLING SYSTEM DIAGRAMS
2-35
COOLING SYSTEM DIAGRAMS
1. Water pump
2. Radiator
3. Radiator fan
2-36
COOLING SYSTEM DIAGRAMS
2-37
COOLING SYSTEM DIAGRAMS
1.
2.
3.
4.
Radiator cap
Radiator
Oil cooler
Thermostat
2-38
CABLE ROUTING
EAS20430
CABLE ROUTING
2-39
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
A.
B.
C.
D.
E.
F.
Clutch cable
Left handlebar switch lead
Main switch lead
Horn lead
Throttle cable (pull side)
Throttle cable (return side)
Brake hose
Throttle cables
Right handlebar switch lead
Secure the brake hose to the front fork.
Secure the horn lead to the front fork. Cut
the tip of the clamp head leaving 2 to 4mm
(0.08 to 0.16in) toward the outside of the
vehicle.
The center position of the clamp shall be
within this numeric range.
The outside of the vehicle.
The inside of the vehicle.
Pass the brake hose in the space by the
right side of the vehicle from this wire and
pass the throttle cables and right handlebar switch lead in the left side space. Next,
route the right handlebar switch lead to the
vehicle rear side where the throttle cables
are routed.
2-40
CABLE ROUTING
2-41
CABLE ROUTING
N. Pass the coolant reservoir hose to the vehicle inner side of the radiator inlet hose and
route it to the lower outside of the vehicle of
the thermostat assembly.
O. Route in the concavity section of the radiator stay.
P. Route the wire guide of the radiator stay as
shown in the illustration. (Twisting not
allowed)
Q. The outside of the vehicle.
R. The inside of the vehicle.
S. The front side of the vehicle.
T. Point the clamp head to the outside of the
vehicle and fit it so that the band tip is positioned at the vehicle front side.
1. Wire harness
2. Right handlebar switch lead
3. Throttle cable
4. Radiator inlet hose
5. Brake fluid reservoir hose
6. Fuel tank breather hose
7. EXUP cable wire bending attachment
8. EXUP cables
9. Rear brake light switch lead
10.Radiator fan motor lead (Right)
11.Coolant reservoir tank hose
12.Clutch cable
13.Radiator stay
14.Throttle cable (return side)
15.Throttle cable (pull side)
16.Frame
17.Rear brake light switch stay
18.Footrest bracket (Right)
19.Rear brake light switch
A. Wire is connected to the meter.
B. Clamp the brake hose to the stay assembly. Clamping position should be 5 mm
(0.20 in) or more away and less than 10
mm (0.39 in) from the top end of the brake
hose protector. Cut the tip to be between 2
to 4 mm (0.08 to 0.16 in).
C. To the throttle bodies
D. Clamp the coolant reservoir hose and radiator inlet hose. Point the clamp opening to
the outside of the vehicle and the tip of the
clamp to the front upper side of the vehicle,
and pay attention so that the tip does not
protrude from the radiator cover.
E. Pass the fuel tank breather hose through
the guide wire of the centerstand bracket.
Make sure to place the white paint position
of the hose lower than the guide wire.
F. To the EXUP
G. Pass the fuel tank breather hose, and
EXUP cable through the wire guide of the
rear brake light switch stay.
H. The clamp position shall be at the center of
bending section of the brake fluid reservoir
hose as shown in the illustration.
I. Bind the two EXUP cables with the clamp.
For the clamping position, a part of the
clamp should be located within a range of
10 mm (0.39 in) from the end of wire bending attachment. Any direction of the clamp
opening can be accepted.
J. To the wire harness
K. To the coolant reservoir tank
L. Route the radiator fan motor lead (right) so
that there is no slack as much as possible
in this section.
M. Pass the radiator fan motor lead (right)
above the coolant reservoir hose and route
it to the inside of the frame.
2-42
CABLE ROUTING
2-43
CABLE ROUTING
J. Route the sidestand switch lead by the
vehicle front side where the hose assembly
1 and water pump inlet pipe are routed.
K. Pass the oil level switch lead to the vehicle
front side of the water pump breather hose
and water pipe.
L. Route the AC magneto lead by the inside
of the frame.
M. There should be no exposure of bare conductors due to the misalignment of tubes.
N. Route the AC magneto lead by the inside
of vehicle away from the water hose.
O. Clamp the clutch cable, radiator fan motor
lead (left) and water pump breather hose.
Point the clamp head to the upper side of
the vehicle and fit it so that the band tip is
positioned inside. For the band position,
install the band using the engine position
as a guide as shown in the illustration.
P. Insert the clamp to the frame and clamp
the clutch cable. For the clamping position,
place the clamp so that the caulking
attachment on the clutch cable side is positioned at the vehicle front side where the
clamp is located. Clamp opening should be
positioned at the outside of the vehicle.
Q. The inserting direction of the onion-head of
the horn lead shall be as shown in the illustration.
R. The outside of the vehicle.
S. The upper side of the vehicle.
T. The inside of the vehicle.
U. Route the clutch cable under the convexity
sections of the throttle bodies.
V. Route the radiator fan motor lead (left)
between the convexity sections of the throttle bodies.
W. Route the wire harness between the convexity sections of the throttle bodies.
X. Innermost section of the vehicle.
Y. Can be routed in any order.
Z. Route the water pump breather hose finally
in the guide after passing other hoses so
that it can be positioned on the outside of
the vehicle.
AA.Route the coolant reservoir tank drain
hose so that it is positioned at the innermost part in hoses and leads.
AB.The rear side of the vehicle.
AC.To the radiator
AD.Open to the air
AE.The coolant reservoir tank drain hose shall
cross with the speed sensor lead under the
rear arm bracket. The coolant reservoir
tank drain hose shall be positioned above
the vehicle.
AF.Route the O2 sensor lead between the
frame and canister assembly as shown in
the illustration and clamp it to the stay.
1. Clutch cable
2. Water pump breather hose
3. Oil level switch lead
4. Sidestand switch lead
5. O2 sensor lead
6. Coolant reservoir tank drain hose
7. Wire harness
8. Battery negative lead
9. Seat lock cable
10.AC magneto lead
11.Rectifier/regulator lead
12.Water pump inlet pipe
13.Radiator fan motor lead (left)
14.Radiator stay
15.Main switch lead
16.Left handlebar switch lead
17.Horn
18.Clutch cable swaging metal
19.Throttle body
20.Stay 1
21.Drive chain case cover
22.Starter motor lead
23.Fuel tank breather hose
24.EXUP cables
25.Rear brake light switch lead
26.Rear brake fluid reservoir hose
27.Speed sensor lead
28.Stay
29.Canister assembly
A. Route in the concavity section of the radiator stay.
B. To the coolant reservoir tank
C. Clamp the wire harness, AC magneto lead,
rectifier/regulator lead, starter motor lead
and battery negative lead. Point the clamp
head to the inside of the vehicle and fit it so
that the band tip is pointed downward.
D. Pass the O2 sensor lead through the vehicle inner side of the hose assembly 1 junction pipe of the water pump inlet pipe and
route it by the outer down side of the hose
assembly 1 and to the upper direction as
shown in the illustration.
E. To the exhaust
F. Route the O2 sensor lead to the vehicle
rear side where the water pump inlet pipe
is routed.
G. Physical relationship between the coolant
reservoir tank drain hose tip and sidestand
switch lead can be in random order.
H. Route the hose assembly 1 by the vehicle
front side where the water pump inlet pipe
is routed. For the hose tip position, route
the hose so that 10 mm (0.39 in) or more
can be assured as shown in the illustration.
I. More than 10 mm (0.39 in)
2-44
CABLE ROUTING
2-45
CABLE ROUTING
AG.Route and clamp the O2 sensor lead
between clamps as shown in the illustration so that there is no slack.
2-46
CABLE ROUTING
2-47
CABLE ROUTING
53.Lean angle sensor lead
54.Battery box
55.Turn signal light relay lead
56.Rear frame
57.Battery
58.Sidestand switch lead
59.Oil level switch lead
60.O2 sensor lead
61.Mad guard
62.Fender
63.Fuel hose
A. Check that it is secured with the guide of
the radiator stay.
B. To the direct ignition coil lead
C. Make sure to install the air filter after
checking that the leads are positioned outside of the vehicle from the throttle body
side cover.
D. To the engine
E. Direct ignition coil lead protector edge
F. Bind the left handle bar switch leads, main
switch leads, right handle bar switch leads,
radiator fan motor leads (right), wire harness and direct ignition leads (in random
order). Make sure to set the clamping position to be ahead of the immobilizer antisafety alarm coupler and rear brake switch
leads branch position, and to be within a
range of 0 to 30 mm (0 to 1.18 inches)
away from the protector end of the direct
ignition coil lead. Install the band pointing
its tip end downward inside the vehicle.
G. Route the pickup coil lead below the fuel
hose, throttle body hoses and air filter drain
hose.
H. Route the wire harness below the clutch
cable and route the coupler branched from
the wire harness below the clutch cable
and then connect it.
I. Insert the wire harness wrapping clamp to
the hole of the frame.
J. To the rear brake light switch
K. Open to the air
L. Insert the main fuse to the battery band.
Soapy water can be spread.
M. Route the battery positive lead under the
relays.
N. Route the fuse box lead under the radiator
fan motor relay.
O. Route the battery positive lead above the
fuse box lead.
P. Pass the license plate light lead and turn
signal light lead under the turn signal relay.
Q. Pass the turn signal light lead (right) and
license plate light lead under the rear
fender bracket and route between the ribs
of the battery box.
1. Throttle cables
2. Right handlebar switch lead
3. Wire harness
4. Throttle cable (pull side)
5. Throttle cable (return side)
6. Radiator fan motor lead (Right)
7. Coolant reservoir tank hose
8. Radiator inlet hose
9. Air filter drain hose
10.Crankshaft position sensor lead
11.Direct ignition coil lead coupler
12.Immobilizer anti safety alarm coupler
13.Engine ground lead
14.Neutral switch lead
15.Rear brake light switch lead
16.EXUP cable
17.EXUP servo motor
18.Main fuse
19.Atmospheric pressure sensor
20.Battery positive lead
21.Radiator fan motor relay
22.Starting circuit cut-off relay
23.Fuse box
24.Lean angle sensor
25.Turn signal light lead (right)
26.License plate light lead
27.Turn signal relay
28.Turn signal light lead (left)
29.Seat lock cable
30.Tail/brake light lead
31.Tail/brake light lead coupler
32.Headlight relay
33.Turn signal light lead coupler (left)
34.Starter relay
35.Fuel tank breather hose
36.Battery negative lead
37.AC magneto lead
38.Starter motor lead
39.Coolant reservoir tank drain hose
40.Fuel hose bend R section
41.Idle adjust screw wire
42.Throttle body lead
43.Air cut-off valve hose
44.ECU (engine control unit)
45.Water pump breather hose
46.Radiator fan motor lead (left)
47.Clutch cable
48.Left handlebar switch lead
49.Main switch lead
50.Frame
51.Direct ignition coil lead
52.Speed sensor lead
2-48
CABLE ROUTING
2-49
CABLE ROUTING
AJ.Route the lean angle sensor lead at the
uppermost side of the vehicle. Also, it must
not be protruded from the battery box ribs
toward the upper side.
AK.Routing can be in random order.
AL.Push the wire harness securely in as far as
it will go.
AM.Secure the leads with a clamp. The cut
position of the tip of the clamp shall be on
the upper side of the vehicle. (Cut it leaving
2 to 4mm (0.08 to 0.16in) of the tip). Route
the leads over the frame plate and insert
them through the hole into the inside of the
vehicle. Route the wire harness at the position shown in the illustration and other
leads can be in random order. Inserting the
band can be in any direction.
AN.Route it between the battery box ribs in
the order indicated in the figure.
AO.Clamp the fuel hose and direct ignition coil
lead. Point the opening section of the
clamp to the front side of the vehicle and
install it at the position as shown in the
illustration.
R. Pass the turn signal light lead (left) and tail/
brake light lead under the rear fender
bracket and route between the ribs of the
battery box.
S. Route the tail/brake light lead by the inner
side of the rear fender bracket and the outside of the battery box ribs. When installing
the tail cover assembly, pay attention so
that it does not catch anything between
rear frame and rear fender bracket surface.
T. After wiring the coupler, make sure to
cover the connector with the squid-shaped
protective cover on the wire harness side
and then insert it to the space made by the
external side of rear frame and tail cover
assembly. At this time, the lead should be
pushed in so that the lead does not hook
on the seat loading accepter.
U. Route the tail/brake light lead in the space
made by the top surface of the rear frame
and the bottom face of the seat bracket.
When installing the seat bracket, pay attention so that the lead is not caught by the
rear frame surface.
V. Route the battery positive lead from the
inner side of the vehicle to the down side of
the wire harness. It is not allowed to route
the lead over the wire harness.
W. Route it so that the branch connection of
the main fuse lead is placed in the upper
side.
X. To the rectifier/regulator. Route the AC.
magneto lead and rectifier/regulator lead
inside the battery box.
Y. To the speed sensor
Z. Route the AC. magneto lead under the
clutch cable.
AA.To the fuel pump
AB.Fit so that the engine ground lead is positioned below and the battery negative lead
above. Fit the leads so that each projection
of lead is positioned on the upper side of
the vehicle.
AC.To the starter motor
AD.Route the leads under the throttle bodies.
AE.Route the intake air temperature sensor by
the upper side of the air filter drain hose.
AF.To the air filter case
AG.Check that the radiator fan motor lead
(left) is secured with the guide of the radiator stay.
AH.Fit the protector by aligning the positioning
tape end and protector end for the main
switch lead, and left handlebar switch lead.
The misalignment tolerance of ends is ±5
mm (0.20 in).
AI. Secure the leads with a clamp. The cut
position of the tip of the clamp shall be on
the upper side of the vehicle. (Cut it leaving
2 to 4mm (0.08 to 0.16in) of the tip). Route
the leads over the frame plate and insert
them through the hole into the inside of the
vehicle.
2-50
CABLE ROUTING
2-51
CABLE ROUTING
M. Route the crankshaft position sensor under
the fuel hose.
N. Route the fuel tank breather hose over the
fuel hose.
O. Route the air filter drain hose under the
fuel hose.
P. The oil level switch lead coupler, sidestand
switch lead coupler and radiator fan motor
lead coupler (left) can be positioned at the
front side of the vehicle.
Q. The coupler position of the O2 sensor lead
shall be at the rear side of the vehicle
behind the clamp position.
R. Clamps shall fix the leads to the stay. The
fixing position shall be at the rear side hole
of the vehicle as shown in the illustration.
The cutting position of the clamp tip shall
be inside the vehicle (cut the tip leaving 2
to 4 mm (0.08 to 0.16 inches)).
1. Clutch cable
2. Left handlebar switch lead
3. Main switch lead
4. Protector
5. Throttle cables
6. Right handlebar switch lead
7. Throttle cable (pull side)
8. Throttle cable (return side)
9. Bracket
10.Wire harness
11.Turn signal light lead
12.Seat lock cable
13.Tail/brake light lead
14.Battery box
15.Mud guard
16.Fender
17.Frame
18.Cover
19.Velcro
20.Canister assembly
21.Stay
22.Crank shaft position sensor lead
23.Fuel tank breather hose
24.Air filter drain hose
25.Fuel hose
26.O2 sensor lead
A. Positioning tape (shaded area)
B. Secure the wire harness to the bracket.
Position the clamp head on the upper side
of the vehicle and point the tip to the front
side of the vehicle.
C. Attach the clamp to the front upper cowling. Clamp the turn signal light lead (left)
and headlight lead.
D. Pass the turn signal light lead (left) and tail/
brake light lead under the rear fender
bracket.
E. Pass the turn signal light lead (left) and tail/
brake light lead. Route between the ribs of
the battery box.
F. Clamp each lead at the positioning taping
section and then insert it to the cover. (In
random order) Positioning tape is only
used for the right handlebar switch. Fit
other leads so that they are not slack.
G. Clamp each lead at the positioning taping
section and then insert it to the cover. (In
random order) Route the rear side of the
vehicle to the wire harness.
H. The inside of the vehicle.
I. 20 X 58 mm (0.79 X 2.28 in) (shaded area)
J. The upper side of the vehicle.
K. 15 X 20 mm (0.59 X 0.79 in) (shaded area)
L. Installation procedure 1. Secure the main
switch lead with Velcro strap. 2. Secure the
left handlebar switch lead with Velcro strap.
2-52
CABLE ROUTING
2-53
CABLE ROUTING
1. Fuel tank
2. Fuel tank drain hose
3. Fuel tank breather hose
4. Clip
5. Air filter bracket
6. 3 way connector
7. Hose
8. Fuel hose
9. Damper
10.Collar
11.Fuel tank bracket
12.O-ring
13.Fuel pump
A. Hook the cover pawl to the fuel tank
bracket.
B. The knob of the clip can be positioned in
any direction.
C. Assemble the two folding sections of the
collar flange as shown in the illustration.
D. Fit the knob of the clip as shown in the
illustration.
E. Fit the white paint section of the hose
pointed downward.
F. Pass the hose through the fuel tank
bracket clamp. There should be no bend of
the hose between the fuel tank nipple and
clamp.
G. Align the projection part with the pump
seat nut.
H. Fit the orange double lock side to the pump
side.
I. Fit the black double lock side to the engine
side.
J. The fuel tank bracket shall not run on the
tank flange as shown in the illustration.
K. Fit the O ring with its lip pointed upward.
L. Tightening sequence
M. Fuel piping connector attachment directions. (fuel pump side) Always perform the
connection/disconnection works by hand.
Do not use tools.
N. 1. Insert the connector until the click sound
is heard and check that the connector does
not come off. Make sure that no foreign
matter is caught in the sealing section. (It is
prohibited to wear the cotton work gloves
or equivalent coverings.)
O. This part works as a dropout stopper.
P. 2.After Step [N] as above is finished, check
that the connector is completely attached
by sliding the double lock (orange part) on
the connector as shown in the illustration
and seeing if it touches firmly or not.
2-54
CABLE ROUTING
For California
2-55
CABLE ROUTING
1. Frame
2. Stay
3. Clip
4. Pipe 3
5. Rivet
6. Clamp
7. Roll over valve assembly
8. Balance pipe
9. Pipe 4
10.Hose
11.Canister assembly
A. Point the clip grip to the lower side of the
vehicle.
B. Install the part pointing the yellow paint
mark to the front side of the vehicle.
C. Insert the hose untill reaches the R-bottom
of the pipe.
D. Install the part pointing the white paint
mark to the front side of the vehicle.
E. Point the clip grip to the upper side of the
vehicle.
F. To the throttle body
G. The knob of the clip can be positioned in
any direction.
H. Install the part pointing the white paint
mark to the left side of the vehicle.
I. Install the part pointing the yellow paint
mark to the left side of the vehicle.
J. Install the hose so that its tip of the nipple
does not protrude.
2-56
PERIODIC MAINTENANCE
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
Periodic maintenance chart for the emission control system
INITIAL
NO.
ITEM
ROUTINE
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
1 * Fuel line
• Check fuel hoses for cracks or
damage.
• Replace if necessary.
✓
✓
✓
✓
✓
2 * Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace every 8000 mi (13000
km) or 12 months.
✓
Replace.
✓
Replace.
✓
3 * Valve clearance
• Check and adjust valve clearance when engine is cold.
4 *
Crankcase
breather system
• Check breather hose for cracks
or damage.
• Replace if necessary.
5
Fuel injection
• Check and adjust engine idle
speed and synchronization.
6 * Exhaust system
Every 26600 mi (42000 km)
✓
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
Evaporative emis- • Check control system for damsion control sysage.
7 * tem (For California
• Replace if necessary.
only)
8 * Brake hoses
✓
• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts.
✓
✓
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
General maintenance and lubrication chart
INITIAL
NO.
ITEM
ROUTINE
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
1 * Air filter element
• Replace.
2 * Clutch
• Check operation.
• Adjust or replace cable.
Every 24000 mi (37000 km)
✓
✓
✓
✓
✓
✓
3 * Front brake
• Check operation, fluid level, and
for fluid leakage.
• Replace brake pads if necessary.
✓
✓
✓
✓
✓
✓
4 * Rear brake
• Check operation, fluid level, and
for fluid leakage.
• Replace brake pads if necessary.
✓
✓
✓
✓
✓
3-1
PERIODIC MAINTENANCE
INITIAL
NO.
ITEM
ROUTINE
• Check for cracks or damage.
5 * Brake hoses
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
✓
✓
• Replace.
✓
✓
✓
✓
Every 4 years
6 * Wheels
• Check runout and for damage.
• Replace if necessary.
✓
✓
✓
✓
✓
7 * Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
✓
✓
✓
✓
✓
8 * Wheel bearings
• Check bearings for smooth
operation.
• Replace if necessary.
✓
✓
✓
✓
✓
• Check bearing assemblies for
looseness.
✓
✓
✓
✓
✓
9 *
Swingarm pivot
bearings
10 * Drive chain
• Check chain slack, alignment
and condition.
Every 600 mi (1000 km) and after washing the motorcycle or riding in the
• Adjust and lubricate chain with
rain
a special O-ring chain lubricant
thoroughly.
11 * Steering bearings
• Check bearing assemblies for
looseness.
• Moderately repack with lithiumsoap-based grease every
10000 mi (16000 km) or 18
months.
12 * Chassis fasteners
✓
✓
✓
Repack.
✓
✓
• Check all chassis fitting and
fasteners.
• Correct if necessary.
✓
✓
✓
✓
✓
13 * Brake and clutch
lever pivot shafts
• Apply lithium-soap-based
grease (all-purpose grease)
lightly.
✓
✓
✓
✓
✓
Brake and shift
14 * pedal pivot shafts
• Apply lithium-soap-based
grease all-purpose grease)
lightly.
✓
✓
✓
✓
✓
15 * Centerstand and
sidestand pivots
• Check operation.
• Apply lithium-soap-based
grease (all-purpose grease)
lightly.
✓
✓
✓
✓
✓
16 * Sidestand switch
• Check operation and replace if
necessary.
✓
✓
✓
✓
✓
17 * Front fork
• Check operation and for oil
leakage.
• Replace if necessary.
✓
✓
✓
✓
✓
✓
18 *
Shock absorber
assembly
• Check operation and for oil
leakage.
• Replace if necessary.
✓
✓
✓
✓
✓
19 *
Rear suspension
link pivots
• Check operation.
• Correct if necessary.
✓
✓
✓
✓
✓
• Change (warm engine before
draining).
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
20 * Engine oil
Engine oil filter car- • Replace.
21 * tridge
22 * Cooling system
• Check hoses for cracks or damage.
• Replace if necessary.
• Change with ethylene glycol
antifreeze coolant every 24
months.
Change.
3-2
3
PERIODIC MAINTENANCE
INITIAL
NO.
ITEM
ROUTINE
23 * Front and rear
brake switches
• Check operation.
24 * Control cables
• Apply Yamaha chain and cable
lube or engine oil SAE 10W-30
thoroughly.
✓
• Check operation and free play.
• Adjust the throttle cable free
Throttle grip housplay if necessary.
25 *
ing and cable
• Lubricate the throttle grip housing and cable.
Lights, signals and • Check operation.
26 * switches
• Adjust headlight beam.
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
NOTE:
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
NOTE:
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
ENGINE
• Valve clearance
Out of specification → Adjust.
EAS20470
ENGINE
Valve clearance (cold)
Intake valve
0.11–0.20 mm (0.0043–0.0079
in)
Exhaust valve
0.21–0.25 mm (0.0083–0.0098
in)
EAS20490
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the
pickup rotor with the crankcase mating surface “b”.
1. Remove:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Air filter case
Refer to "GENERAL CHASSIS" on page 41.
• Throttle body assembly
Refer to "THROTTLE BODIES" on page 74.
• Air cut-off valve
Refer to "AIR INDUCTION SYSTEM" on
page 7-13.
• Radiator
• Radiator fan motor
Refer to "RADIATOR" on page 6-1.
2. Remove:
• Ignition coils
• Spark plugs
• Cylinder head cover
• Cylinder head cover gasket
Refer to "CAMSHAFTS" on page 5-9.
3. Remove:
• Pickup rotor cover "1"
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thickness gauge “1”.
NOTE:
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
4. Measure:
3-4
ENGINE
6. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter “1” and the valve
pad “2” with a valve lapper “3”.
Valve lapper
90890-04101
NOTE:
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve
lifter “1” and valve pad “2” so that they can be
installed in the correct place.
A. Front
d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
TDC, turn the crankshaft counterclockwise
as specified in the following table.
Cylinder #2
Cylinder #4
Cylinder #3
180°
360°
540°
b. Calculate the difference between the specified valve clearance and the measured
valve clearance.
Example:
Specified valve clearance = 0.11–0.20 mm
(0.004–0.008 in)
Measure valve clearance = 0.25 mm (0.010
in)
0.25 mm (0.010 in)–0.20 mm (0.008 in) =
0.05 mm (0.002 in)
c. Check the thickness of the current valve
pad.
A. Degrees that the crankshaft is turned
counterclockwise
B. Cylinder
C. Combustion cycle
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• Camshaft
NOTE:
NOTE:
The thickness “a” of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
• Refer to "CAMSHAFTS" on page 5-9.
• When removing the timing chain and camshafts, fasten the timing chain with a wire to
retrieve it if it falls into the crankcase.
Example:
3-5
ENGINE
If the valve pad is marked “158”, the pad
thickness is 1.58 mm (0.062in)
g. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
d. Calculate the sum of the values obtained in
steps (b) and (c) to determine the required
valve pad thickness and the valve pad
number.
Example:
1.58 mm (0.062 in) + 0.05 mm (0.002 in) =
1.63 mm (0.064 in)
The valve pad number is 163.
e. Round off the valve pad number according
to the following table, and then select the
suitable valve pad.
Last digit
0,1,2
3,4,5,6
7,8,9
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• Refer to "CAMSHAFTS" on page 5-9.
• Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
• First, install the exhaust camshaft.
• Align the camshafts marks with the camshaft
cap marks.
• Turn the crankshaft clockwise several full
turns to seat the parts.
Rounded value
0
5
10
h. Measure the valve clearance again.
i. If the valve clearance is still out of specification, repeat all of the valve clearance
adjustment steps until the specified clearance is obtained.
NOTE:
Refer to the following table for the available
valve pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Valve pad range
Valve pad thickness
Available valve pads
f.
Nos. 150–240
1.50–2.40 mm
(0.0591–0.0945 in)
25 thicknesses in
0.05 mm (0.002 in)
increments
7. Install:
• All removed parts
NOTE:
For installation, reverse the removal procedure.
EAS20570
Example:
Valve pad number = 163
Rounded value = 165
New valve pad number = 165
Install the new valve pad “1” and the valve
lifter “2”.
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition
timing should be checked.
NOTE:
1. Stand the vehicle on a level surface.
• Lubricate the valve lifter with engine oil.
• Install the valve lifter and the valve pad in the
correct place.
• The valve lifter must turn smoothly when
rotated by hand.
NOTE:
Place the vehicle on a suitable stand.
2. Remove:
• Rider and passenger seat
3-6
ENGINE
Refer to "GENERAL CHASSIS" on page 41.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
3. Remove:
• Synchronizing hoses “1”
• Throttle body synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screw “1”.
NOTE:
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If the air screw is removed, turn the screw 3/
4 turn in and be sure to synchronize the
throttle body.
EC2D1013
CAUTION:
Do not use the throttle valve adjusting
screws to adjust the throttle body synchronization.
4. Install:
• Vacuum gauge “1”
(onto the synchronizing hose)
• Digital tachometer
(near the spark plug)
Vacuum pressure at engine
idling speed
30 kPa (225 mmHg, 8.9 inHg)
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
NOTE:
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10mmHg, 0.39 inHg).
5. Install:
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
6. Start the engine and let it warm up for several minutes.
7. Check:
• Engine idling speed
Out of specification → Adjust.
Refer to "ADJUSTING THE ENGINE
IDLING SPEED" on page 3-8.
Engine idling speed
1.100–1.300 r/min
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Measure:
• Engine idling speed
Out of specification → Adjust.
8. Adjust:
3-7
ENGINE
Make sure that the vacuum pressure is
within specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:
• Throttle cable free play
Refer to "ADJUSTING THE THROTTLE
CABLE FREE PLAY" on page 3-8.
Throttle cable free play
(at the flange of the throttle
grip)
3.0–5.0 mm (0.12–0.20 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• Throttle cable free play
Refer to "ADJUSTING THE THROTTLE
CABLE FREE PLAY" on page 3-8.
12. Install:
• Synchronizing hoses
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
Throttle cable free play
(at the flange of the throttle
grip)
3.0–5.0 mm (0.12–0.20 in)
EAS20610
EAS20630
ADJUSTING THE ENGINE IDLING SPEED
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the engine idling speed, the
throttle bodies’ synchronization should be
adjusted properly, the air filter element should
be clean, and the engine should have adequate compression.
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted
properly.
1. Check:
• Throttle cable free play “a”
Out of specification → Adjust.
1. Start the engine and let it warm up for several minutes.
2. Install:
• Digital tachometer
(onto the spark plug lead of cylinder #1)
3. Check:
• Engine idling speed
Out of specification → Adjust.
Throttle cable free play
(at the flange of the throttle
grip)
3.0–5.0 mm (0.12–0.20 in)
Engine idling speed
1,100–1,300 r/min
4. Adjust:
• Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the idle adjusting screw “1” in direction
“a” or “b” until the specified engine idling
speed is obtained.
2. Adjust:
• Throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
Handlebar side
a. Loosen the locknut “1”.
3-8
ENGINE
b. Turn the adjusting nut “2” in direction “a” or
“b” until the specified throttle cable free
play is obtained.
• 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 “a”
(with a wire thickness gauge)
Out of specification → Regap.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
Spark plug gap
0.6–0.7 mm
(0.0236–0.0276 in)
c. Tighten the locknut.
EW2D1001
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
7. Install:
• Spark plugs
• Ignition coils
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20680
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
• Radiator upper bolts
• Radiator lower bolt
Refer to "RADIATOR" on page 6-1.
2. Remove:
• Ignition coils
• Spark plugs
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
8. Install:
• Radiator upper bolts
• Radiator lower bolt
Refer to "RADIATOR" on page 6-1.
ECA13320
CAUTION:
EAS20710
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to prevent it
from falling into the cylinders.
MEASURING THE COMPRESSION PRESSURE
The following procedure applies to all of the
cylinders.
3. Check:
• Spark plug type
Incorrect → Change.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
Spark plug type (manufacturer)
CR9EK (NGK)
1. Measure:
• Valve clearance
Out of specification → Adjust.
4. Check:
3-9
ENGINE
2.
3.
•
•
b. With the throttle wide open, crank the
engine until the reading on the compression gauge stabilizes.
Refer to "ADJUSTING THE VALVE
CLEARANCE" on page 3-4.
Start the engine, warm it up for several
minutes, and then turn it off.
Remove:
Ignition coils
Spark plugs
EW2D1002
WARNING
To prevent sparking, ground all speak plug
leads before cranking the engine.
ECA13340
CAUTION:
NOTE:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
The difference in compression pressure
between cylinders should not exceed 100 kPa
(1 kg/cm², 1 bar, 14.22 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
4. Install:
• Compression gauge “1”
• Extension
Compression gauge
90890-03081
Engine compression tester
YU-33223
Compression pressure (with oil applied into
the cylinder)
Reading
Diagnosis
Higher than without
Piston ring(s) wear or
oil
damage → Repair.
Same as without oil
Piston, valves, cylinder head gasket or
piston possibly defective → Repair.
5. Measure:
• Compression pressure
Out of specification → Refer to steps (c)
and (d).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Spark plug
Compression pressure (at sea
level)
Minimum
1290 kPa (12.90 kg/cm2,12.90
bar, 183.5 psi)
Standard
1480 kPa (14.80 kg/cm2,14.80
bar, 210.5 psi)
Maximum
1660 kPa (16.60 kg/cm2, 16.60
bar, 236.1 psi)
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
7. Install:
• Ignition coils
EAS20730
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Check:
• Engine oil level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
3-10
ENGINE
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 oil to the proper
level.
EAS20790
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several
minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• Engine oil filler cap “1”
• Engine oil drain bolt “2”
(along with the gasket)
Recommended oil
YAMALUBE 4, SAE10W30 or
SAE20W40
Recommended oil grade
API service SE, SF, SG type or
higher
ECA13370
CAUTION:
Do not allow foreign materials to enter the
crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Drain:
• Engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be
replaced, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge “1” with an oil
filter wrench “2”.
Oil filter wrench
90890-01426
YU-38411
4. Start the engine, warm it up for several
minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
3-11
ENGINE
Quantity
Total amount
3.8 L (3.34 lmp qt, 4.02 US qt)
Without oil filter cartridge
replacement
2.9 L (2.55 lmp qt, 3.07 US qt)
With oil filter cartridge replacement
3.1 L (2.73 lmp qt, 3.28 US qt)
9. Install:
• Engine oil filler cap
10. Start the engine, warm it up for several
minutes, and then turn it off.
11. Check:
• Engine
(for engine oil leaks)
12. Check:
• Engine oil level
Refer to "CHECKING THE ENGINE OIL
LEVEL" on page 3-10.
b. Lubricate the O-ring “3” of the new oil filter
cartridge with a thin coat of engine oil.
ECA13390
CAUTION:
Make sure the O-ring “3” is positioned correctly in the groove of the oil filter cartridge.
EAS20820
MEASURING THE ENGINE OIL PRESSURE
1. Check:
• Engine oil level
Below the minimum level mark “a” → Add
the recommended engine oil to the proper
level.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Replace:
• Engine oil drain bolt gasket
7. Install:
• Engine oil drain bolt
(along with the new gasket)
2. Start the engine, warm it up for several
minutes, and then turn it off.
Engine oil drain bolt
43 Nm (4.3 m·kg, 31 ft·lb)
ECA13410
CAUTION:
8. Fill:
• Crankcase
(with the specified amount of the recommended engine oil)
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 after
warming up the engine.
3. Remove:
• Oil gallery bolt “1”
3-12
ENGINE
only as a reference when measuring the
engine oil pressure.
EWA12980
WARNING
The engine, muffler and engine oil are
extremely hot.
Engine oil pressure
Below specification
•
•
•
•
Above specification
Possible causes
Faulty oil pump
Clogged oil filter
Leaking oil passage
Broken or damaged
oil seal
• Leaking oil passage
• Faulty oil filter
• Oil viscosity too
high
6. Install:
• Oil gallery bolt “1”
4. Install:
• Oil pressure gauge “1”
• Adapter “2”
Oil gallery bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
Pressure gauge
90890-03153
YU-03153
Oil pressure adapter H
90890-03139
ECS2D1001
CAUTION:
Be careful to tighten too much.
EAS20870
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check
• Clutch cable free play “a”
Out of specification → Adjust.
5. Measure:
• Engine oil pressure
(at the following conditions)
Engine oil pressure
230 kPa
(2.3 kg/cm2, 2.3 bar, 32.71 psi)
Engine speed
Approx. 5,000 r/min
Engine oil temperature
100°C (212°F)
Clutch cable free play (at the
end of the clutch lever)
10–15 mm (0.39–0.59 in)
NOTE:
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
3-13
ENGINE
2. Adjust
• Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Turn the adjusting dial “1” in direction “b” or
“c” until the specified clutch cable free play
is obtained.
Direction “b”
Clutch cable free play is increased.
Direction “c”
Clutch cable free play is decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20960
REPLACING THE AIR FILTER ELEMENT
1. Remove:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
2. Remove:
• Air filter case cover “1”
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable,
use the adjusting nut on the engine side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Engine side
a. Loosen the locknut “1”
b. Turn the adjusting nut “2” in direction “a” or
“b” until the specified clutch cable free play
is obtained.
3. Check:
• Air filter element “1”
Damage → Replace.
Direction “a”
Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.
NOTE:
• Replace the air filter element every 40000
km (2400 mi) of operation.
• The air filter needs more frequent service if
you are riding in unusually wet or dusty
areas.
c. Tighten the locknuts.
Locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
3-14
ENGINE
4. Install:
• Air filter case cover
1. Remove:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
2. Check:
• Fuel hose “1”
• Vacuum hose “2”
• Breather hose “3”
Cracks/damage → Replace.
Loose connection → Connect properly.
ECA14400
CAUTION:
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
throttle bodies synchronization, leading to
poor engine performance and possible
overheating.
NOTE:
NOTE:
Before removing the fuel hoses, place a few
rags in the area under where it will be
removed.
When installing the air filter element into the air
filter case cover, make sure that the sealing
surfaces are aligned to prevent any air leaks.
ECA14940
5. Install:
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
CAUTION:
Make sure the fuel tank breather hose is
routed correctly.
EAS21010
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the
throttle body joints and intake manifolds.
1. Remove:
• Throttle bodies
Refer to "THROTTLE BODIES" on page 74.
2. Check:
• Throttle body joints “1”
Cracks/damage → Replace.
3. Install:
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
ECS2D002
CAUTION:
To install the fuel tank, check that the
breather hose is not folded or pinched by
the fuel tank.
3. Install:
• Throttle bodies
Refer to "THROTTLE BODIES" on page 74.
EAS21070
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
• Fuel tank
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the
fuel, vacuum and breather hoses.
3-15
ENGINE
Refer to "FUEL TANK" on page 7-1.
2. Check:
• Crankcase breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
Exhaust pipe nut
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe and exhaust pipe
bracket bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe and muffler bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and rear footrest
bracket bolt
48 Nm (4.8 m·kg, 35 ft·lb)
ECA13450
CAUTION:
Make sure the crankcase breather hose is
routed correctly.
NOTE:
When installing the EXUP cables, make sure
they are parallel and not twisted.
• Upper cable: White metal section “8”
• Lower cable: Black metal section “9”
3. Install:
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
ECS2D003
CAUTION:
To install the fuel tank, check that the
breather hose is not folded or pinched by
the fuel tank.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes and gaskets.
1. Check:
• Exhaust pipe “1”
• Muffler “2”
Cracks/damage → Replace.
• Gaskets “3”
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Exhaust pipe nut “4”
• Exhaust pipe and exhaust pipe bracket bolt
“5”
• Exhaust pipe and muffler bolt “6”
• Muffler and rear footrest bracket bolt “7”
EAS21100
ADJUSTING THE EXUP CABLES
1. Remove:
• EXUP valve pulley cover “1”
3-16
ENGINE
2. Check:
• EXUP system operation
5. Install:
• EXUP valve pulley cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EXUP valve pulley cover bolt
14 Nm (1.4 m·kg, 10 ft·lb)
a. Turn the main switch ON.
b. Check that the EXUP valve operates properly.
EAS28360
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE EXUP SERVO MOTOR
1. Check:
• EXUP servo motor operation
Out of specification → Replace.
3. Check:
• EXUP cable free play (at the EXUP valve
pulley) “a” and “b”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Maximum EXUP cable free play
(at the EXUP valve pulley)
a: Less than 3 mm (0.12 in)
b: Less than 3 mm (0.12 in)
a. Check whether or not the EXUP valve is
seized.
• Disconnect the EXUP cable and check that
the EXUP valve is moved smoothly by
hand.
• When the valve is not moved smoothly,
repair or replace it.
Refer to "ADJUSTING THE EXUP
CABLES" on page 3-16.
b. When the EXUP valve is moved smoothly,
replace the EXUP servo motor.
c. Perform the self-diagnosis mode and check
the operation of EXUP valve by visual
inspection (Code No: 53).
The operation should be carried out as 3second drive in the full open direction, 2second stop and 3-second drive in the full
close direction.
d. Check that the EXUP servo motor pulley
rotates several times.
4. Adjust:
• EXUP cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a.
b.
c.
d.
e.
f.
g.
h.
Turn the main switch to “ON”
Check the EXUP pulley position.
Loosen the locknut “1”.
Loosen the locknut “3”
Turn the adjusting nut “2” in or out.
Tighten the locknut.
Turn the adjusting nut “4” in or out.
Tighten the locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
EXUP cable locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
2. Check:
• Coolant level
The coolant level should be between the
maximum level mark “a” and minimum level
mark “b”.
Below the minimum level mark → Add the
recommended coolant to the proper level.
ECA13470
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-17
ENGINE
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water
may be used.
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Check:
• Coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EAS21120
CHECKING THE COOLING SYSTEM
1. Check:
• Radiator “1”
• Radiator inlet hose “2”
• Radiator outlet hose “3”
• Oil cooler “4”
• Oil cooler inlet hose “5”
• Oil cooler outlet hose “6”
• Water jacket joint “7”
• Water jacket joint inlet hose “8”
• Water pump inlet pipe “9”
• Water pump outlet pipe “10”
Cracks/damage → Replace.
Refer to "RADIATOR" on page 6-1.
EAS21130
CHANGING THE COOLANT
1. Remove:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
2. Remove:
• Coolant reservoir tank
• Coolant reservoir hose
3. Disconnect:
• Coolant reservoir cap “1”
3-18
ENGINE
7. Drain:
• Coolant
(from the water pump inlet pipe and outlet
pipe)
8. Check:
4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cap “1”
• Copper washers “1”
9. Install:
• Coolant drain bolts “2”
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
Coolant drain bolt
10 Nm (1.0 m·Kg, 7.2 ft·lb)
10. Install:
• Coolant reservoir tank
11. Connect:
• Coolant reservoir hose
12. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
The following procedure applies to all of the
coolant drain bolts and copper washers.
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze: water)
Quantity
Total amount
2.25 L
(1.98 lmp qt, 2.38 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
6. Remove:
• Coolant drain bolts “1”
(along with the copper washers)
Handling notes for coolant
3-19
ENGINE
Coolant is potentially harmful and should
be handled with special care.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EWA13040
WARNING
18. Install:
• Rider and passenger seat
Refer to "GENERAL CHASSIS" on page 41.
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13480
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water
may be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
13. Install:
• Radiator cap
14. Fill:
• Coolant reservoir tank
(with the recommended coolant to the maximum level mark “a”)
15. Install:
• Coolant reservoir cap
16. Start the engine, warm it up for several
minutes, and then stop it.
17. Check:
• Coolant level
Refer to "CHECKING THE COOLANT
LEVEL" on page 3-17.
3-20
CHASSIS
EAS21140
EAS21190
CHASSIS
ADJUSTING THE REAR DISC BRAKE
1. Adjust:
• Brake pedal position
EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust:
• Brake lever position
(distance “a” from the throttle grip to the
brake lever)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake pedal position
is obtained.
NOTE:
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
• While pushing the brake lever forward, turn
the adjusting dial “1” until the brake lever is in
the desired position.
• Be sure to align the setting on the adjusting
dial with the arrow mark “2” on the brake
lever holder.
EWA13070
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt “c”
is visible through the hole “d”.
Direction “b”
Distance “a” is the largest.
Direction “c”
Distance “a” is the smallest.
c. Tighten the locknut “1” to specification.
Locknut
18 Nm (1.8 m·kg, 13 ft·lb)
EWA13060
WARNING
• After adjusting the brake lever position,
make sure the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.
• A soft or spongy feeling in the brake lever
can indicate the presence of air in the
brake system. Before the vehicle is operated, the air must be removed by bleeding
the brake system. Air in the brake system
will considerably reduce in loss of control
and possibly an accident. Therefore,
check and if necessary, bleed the brake
system.
EWA13050
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance.
ECA13510
CAUTION:
After adjusting the brake pedal position,
make sure there is no brake drag.
ECA13490
CAUTION:
After adjusting the brake lever position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Rear brake light switch
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH" on page 3-23.
3-21
CHASSIS
the brake fluid and could cause vapor
lock.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
ECA13540
NOTE:
CAUTION:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add
the recommended brake fluid to the proper
level.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
Recommended brake fluid
DOT4
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicators “a” almost touch the brake
disc → Replace the brake pads as a set.
Refer to "FRONT BRAKE" on page 4-18.
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicators “b” almost touch the brake
disc → Replace the brake pads as a set.
Refer to "REAR BRAKE" on page 4-30.
A. Front brake
B. Rear brake
EWA13090
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, 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
3-22
CHASSIS
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• Brake hose “1”
Cracks/damage/wear → Replace.
2. Check:
• Brake hose clamp “2”
Loose Connection → Tighten the clamp
bolt.
2. Check:
• Brake hose clamp “2”
Loose → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged hose.
Refer to "REAR BRAKE" on page 4-30.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged hose.
Refer to "FRONT BRAKE" on page 4-18.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts.
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check:
• Brake hose “1”
Cracks/damage/wear → Replace.
1. Check:
• Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• Rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lifting the brake light switch, hold the main
body “1” of the rear brake light switch so
that it does not rotate and turn the adjusting
3-23
CHASSIS
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”.
nut “2” in direction “a” or “b” until the rear
brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21350
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EWA13100
WARNING
A. Front brake caliper
B. Rear brake caliper
Bleed the hydraulic brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected
or replaced.
• The brake fluid level is very low.
• Brake operation is faulty.
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press
down the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
5 Nm (0.5 m·kg, 3.6 ft·lb)
1. Bleed:
• Hydraulic brake system
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-22.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
3-24
CHASSIS
EWA13110
NOTE:
WARNING
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
After bleeding the hydraulic brake system,
check the brake operation.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:
• Drive chain slack “a”
Out of specification → Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1006
ADJUSTING THE SHIFT PEDAL
1. Adjust:
• Shift pedal position
Drive chain slack
25–35 mm (0.98–1.38 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” to
obtain the correct shift pedal position.
Direction “a”
Shift pedal is raised.
Direction “b”
Shift pedal is lowered.
4. Adjust:
• Drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the wheel axle nut “1”
b. Loosen both locknuts “2”
c. Turn both adjusting bolts “3” in direction “a”
or “b” until the specified drive chain slack is
obtained.
c. Tighten both locknuts.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
ET2D1007
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
ECA13550
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
1. Stand the vehicle on a level surface.
EW2D1005
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
3-25
CHASSIS
Refer to "STEERING HEAD" on page 4-55.
4. Adjust:
• Steering head
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 m·kg, 12 ft·lb)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
e. Tighten the wheel axle nut to specification.
Wheel axle nut
150 Nm (15 m·kg, 108 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1008
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only
kerosene to clean the drive chain. Wipe the
drive chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable for
O-ring chains. Do not use any other lubricants
on the drive chain since they may contain solvents that could damage the O-rings.
b. Loosen the lower ring nut “4” and then
tighten it to specification with a steering nut
wrench “5”.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m·kg, 38 ft·lb)
EAS21510
c. Loosen the lower ring nut “4” completely,
and then tighten it to specification.
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the vehicle on a level surface.
EWA13140
WARNING
EWA13120
Do not overtighten the lower ring nut.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
Lower ring nut (final tightening
torque)
18 Nm (1.8 m·kg, 13 ft·lb)
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 and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• Upper bracket
3-26
CHASSIS
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to "STEERING HEAD" on page 4-55.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the
upper ring nut until their slots are aligned.
h. Install the lock washer “1”.
d. Hold the spring gauge at a 90° angle from
the handlebar, pull the spring gauge, and
then record the measurement when the
handlebar starts to run.
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Steering head tension
200–500 g
5. Install:
• Upper bracket
Refer to "STEERING HEAD" on page 4-55.
6. Measure:
• Steering head tension
e. Repeat the above procedure on the opposite handlebar.
f. If the steering head tension is out of specification (both handlebars should be within
specification), remove the upper bracket
and loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure
the steering head tension again as
described above.
h. Repeat the above procedure until the steering head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Make sure all of the cables and wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie “1” loosely
around the end of the handlebar as shown.
c. Hook a spring gauge “2” onto the plastic
locking tie.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21530
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
3-27
CHASSIS
EWA13120
EWA13150
WARNING
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
• Always adjust both front fork legs evenly.
Uneven adjustment can result in poor
handling and loss of stability.
• Securely support the vehicle so that there
is no danger of it falling over.
2. Check:
• Inner tube “1”
Damage/scratches → Replace.
• Oil seal “2”
Oil leakage → Replace.
Spring preload
ECA13570
CAUTION:
• Grooves are provided to indicate the
adjustment position.
• Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• Spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to "FRONT FORK" on page 4-46.
Direction “a”
Spring preload is increased
(suspension is harder).
Direction “b”
Spring preload is decreased
(suspension is softer).
Spring preload adjusting positions
Minimum
8
Standard
6
Maximum
0
EAS21580
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTE:
Each front fork leg is equipped with a spring
preload adjusting bolt, the right front fork leg is
equipped with a reboumd damping force
adjusting screw and left front fork leg with a
compression damping force adjusting screw.
3-28
CHASSIS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping (Right side front fork)
Compression damping (Left side front fork)
EC2D1006
CAUTION:
ECA13590
CAUTION:
• Never go beyond the maximum or minimum adjustment positions.
• When assembling the front forks, be careful not to assemble them to the opposite
position because there are two kinds of
forks (for the rebound side and for the
compression side).
• Never go beyond the maximum or minimum adjustment positions.
• When assembling the front forks, be careful not to assemble them to the opposite
position because there are two kinds of
forks (for the rebound side and for the
compression side).
1. Adjust:
• Rebound damping
1. Adjust:
• Compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a”
or “b”.
a. Turn the adjusting screw “1” in direction “a”
or “b”.
Direction “a” (turn in)
Rebound damping is increased
(suspension is harder).
Direction “b” (turn out)
Rebound damping is decreased
(suspension is softer).
Direction “a” (turn in)
Compression damping is increased
(suspension is harder).
Direction “b” (turn out)
Compression damping is decreased
(suspension is softer).
Rebound
damping
adjusting
positions
Minimum
26 clicks in direction: “b”*
Standard
15 clicks in direction: “b”*
Maximum
1 clicks in direction: “b”*
Compression damping adjusting
positions
Minimum
26 clicks in direction: “b”*
Standard
5 clicks in direction: “b”*
Maximum
1 clicks in direction: “b”*
* With the adjusting screw fully turned-in
direction “a”
* With the adjusting screw fully turned-in
direction “a”
3-29
CHASSIS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21620
Rebound damping
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
ECA13590
CAUTION:
EWA13120
Never go beyond the maximum or minimum
adjustment positions.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
1. Adjust:
• Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Spring preload
a. Turn the adjusting screw “1” in direction “a”
or “b”.
ECA13590
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
Direction “a”
Rebound damping is increased
(suspension is harder).
Direction “b”
Rebound damping is decreased
(suspension is softer).
1. Adjust:
• Spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
b. Turn the adjusting ring “1” in direction “a” or
“b”.
c. Align the desired position on the adjusting
ring with the stopper “2”
Rebound
damping
adjusting
position
Minimum
12 clicks in direction: “b”*
Standard
6 clicks in direction: “b”*
Maximum
1 clicks in direction: “b”*
Direction “a”
Spring preload is increased
(suspension is harder).
Direction “b”
Spring preload is decreased
(suspension is softer).
* With the adjusting screw fully turned-in
direction “a”
Spring preload adjusting positions
Minimum
1
Standard
3
Maximum
7
3-30
CHASSIS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Tire air pressure (measured on
cold tires):
Basic weight (with oil and a full
fuel tank)
U.S.A.
220kg (485 lb)
California
221kg (487 lb)
Loading condition*
0–90 kg (0–198 lb)
Front
250 kPa (2.5 kg/cm2, 2.5 bar, 36
psi)
Rear
290 kPa (2.9 kg/cm2, 2.9 bar, 42
psi)
Loading condition*
U.S.A.
90–190 kg (198–419 lb)
California
90–189 kg (198–417 lb)
Front
250 kPa (2.5 kg/cm2, 2.5 bar, 36
psi)
Rear
290 kPa (2.9 kg/cm2, 2.9 bar, 42
psi)
High speed riding:
Front
250 kPa (2.5 kg/cm2, 2.5 bar, 36
psi)
Rear
290 kPa (2.9 kg/cm2, 2.9 bar, 42
psi)
Maximum load*
U.S.A.
190 kg (419 lb)
California
189 kg (417 lb)
EAS21650
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
EWA13180
WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE VEHICLE.
* Total weight of rider, passenger, cargo
and accessories.
EWA13190
WARNING
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.
3-31
CHASSIS
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer and of the same design. No guarantee
concerning handling characteristics can be
given if a tire combination other than one
approved by Yamaha is used on this vehicle.
1. Tire tread depth
2. Side wall
3. Wear indicator
Front tire
Size
120/70 ZR17 M/C (58W)
Manufacturer/model
DUNLOP/D221FA
MICHELIN/PILOT ROAD S
Minimum tire tread depth
1.6 mm (0.06 in)
EWA14080
WARNING
Rear tire
Size
190/50 ZR17 M/C (73W)
Manufacturer/model
DUNLOP/D221G
MICHELIN/PILOT ROAD D
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using a tube tire, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recommended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.
EWA13210
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark “2” with the valve installation
point.
A. Tire
B. Wheel
Tube wheel
Tubeless wheel
Tube tire only
Tube or tubeless tire
3-32
CHASSIS
EAS21670
EAS21710
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• Wheel
Damage/out-of-round → Replace.
LUBRICATING THE PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Recommended lubricant
Lithium - soap - based grease
EWA13260
WARNING
EAS21720
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Never attempt to make any repairs to the
wheel.
NOTE:
Recommended lubricant
Lithium - soap - based grease
After a tire or wheel has been changed or
replaced, always balance the wheel.
EAS21730
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
EAS21690
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
inner and outer cables.
Recommended lubricant
Lithium - soap - based grease
EWA13270
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
EAS21740
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
Recommended lubricant
Molybdenum disulfide grease
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS21700
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium - soap - based grease
3-33
ELECTRICAL SYSTEM
• Headlight bulb “1”
EAS21750
ELECTRICAL SYSTEM
EAS21760
CHECKING AND CHARGING THE BATTERY
Refer to "ELECTRICAL COMPONENTS" on
page 8-77.
EAS21770
CHECKING THE FUSES
Refer to "ELECTRICAL COMPONENTS" on
page 8-77.
EAS21780
REPLACING THE HEADLIGHT BULBS
1. Disconnect:
• Headlight coupler “1”
EWA13320
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
5. Install:
• Headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.
ECA13690
CAUTION:
Avoid touching the glass part of the headlight 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 lacquer thinner.
2. Remove:
• Headlight bulb cover “1”
6. Install:
• Headlight bulb holder
7. Install:
• Headlight bulb cover
8. Connect:
• Headlight coupler
9. Connect:
• Headlight assembly coupler
10. Install:
• Headlight assembly bolts
3. Remove:
• Headlight bulb holder “1”
EAS21800
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a”
or “b”.
4. Remove:
3-34
ELECTRICAL SYSTEM
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a”
or “b”.
Direction “a”
Headlight beam moves to the left.
Direction “b”
Headlight beam moves to the right.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-35
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat and battery
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Passenger seat
Rider seat
Battery band
Battery cover
Battery negative lead
Battery positive lead
Battery
Battery seat
Q’ty
1
1
1
1
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
4-1
GENERAL CHASSIS
Removing the front cowling
4
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Inner panel
Headlight assembly coupler
Meter coupler
Front cowling assembly
Rear view mirror
Cowling stay
Meter assembly
Headlight unit
Q’ty
2
1
1
1
2
1
1
1
Remarks
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4-2
GENERAL CHASSIS
Removing the rear fender
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Rider and passenger seat
Q’ty
Licence plate light lead coupler
Turn signal light lead coupler
Reflector
Reflector stay
Licence plate bracket
Mud guard assembly
Rear fender
Tail/brake light lead coupler
Tail/brake light cover
Rear fender side cover (left and right)
Rear fender bracket
Tail/brake light
Tail cover
1
1
3
2
1
1
1
1
1
2
1
1
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4-3
GENERAL CHASSIS
Removing the air filter case
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Intake air temperature sensor lead coupler
Intake air temperature sensor
Air filter case cover
Air filter
Funnel
Air filter case
Air induction system hose
Crankcase breather hose
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Disconnect.
1
1
1
2
1
1
1
For installation, reverse the removal
procedure.
4-4
GENERAL CHASSIS
EAS21840
REMOVING THE COVER
1. Remove:
• Tail cover
• Rear fender
NOTE:
To remove the quick fastener, push its center
with a screwdriver, then pull the fastener out.
EAS21850
INSTALLING THE COVER
1. Install:
• Rear fender
• Tail cover
NOTE:
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the cover and push the pin “a”
in with screwdriver. Make sure that the pin is
flush with the fastener’s head.
4-5
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Brake hose holder (left and right)
Reflector stay
Reflector
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle
Collar (left and right)
Dust cover
Front wheel
Front brake disc (left and right)
Q’ty
2
2
2
2
1
1
2
2
1
2
Remarks
For installation, reverse the removal
procedure.
4-6
FRONT WHEEL
Disassembling the front wheel
Order
1
2
3
Job/Parts to remove
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
Q’ty
2
2
1
Remarks
For assembly, reverse the disassembly procedure.
4-7
FRONT WHEEL
Refer to "CHECKING THE TIRES" on page
3-31 and "CHECKING THE WHEELS" on
page 3-33.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
EAS21900
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove:
• Left brake caliper
• Right brake caliper
Refer to "FRONT BRAKE" on page 4-18.
NOTE:
Do not apply the brake lever when removing
the brake calipers.
3. Elevate:
• Front wheel
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
4.
•
5.
•
•
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• Oil seals
Damage/wear → Replace.
Loosen:
Front wheel axle pinch bolt
Remove:
Front wheel axle
Front wheel
EAS21920
CHECKING THE FRONT WHEEL
1. Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
EWA13460
WARNING
Do not attempt to straighten a bent wheel
axle.
5. Replace:
• Wheel bearings
• Oil seals
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
2. Check:
• Tire
• Front wheel
Damage/wear → Replace.
4-8
FRONT WHEEL
• Adjust the front wheel static balance with the
brake disc installed.
1.
•
2.
•
Remove:
Balancing weight(s)
Find:
Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Remove the wheel bearings “3” with a general bearing puller.
a. Spin the front wheel.
b. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
ECA14130
CAUTION:
c. Turn the front wheel 90° so that the “X1”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
NOTE:
Use a socket “4” that matches the diameter of
the wheel bearing outer race and oil seal.
f.
Repeat steps (c) through (e) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21970
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Front wheel static balance
NOTE:
• After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4-9
FRONT WHEEL
a. Install a balancing weight “1” onto the rim
exactly opposite the heavy spot “X”.
EAS22000
INSTALLING THE FRONT WHEEL (DISC)
The following procedure applies to both of the
brake discs.
1. Lubricate:
• Wheel axle
• Oil seal lips
NOTE:
Start with the lightest weight.
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
NOTE:
Install the tire and wheel with the mark “1”
pointing in the direction of wheel rotation.
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:
• Wheel axle
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
Wheel axle nut
72 Nm (7.2 m·kg, 52 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Front wheel static balance
• Wheel axle pinch bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Wheel axle pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
a. Turn the front wheel and make sure it stays
at each position shown.
ECA14140
CAUTION:
Before tightening the front wheel axle, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
6. Install:
• Brake caliper
Brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
b. If the front wheel does not remain stationary at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-10
FRONT WHEEL
EWA13490
WARNING
Make sure the brake cable is routed properly.
NOTE:
Make sure that there is enough space between
the brake pads before installing the brake calipers onto the brake discs.
4-11
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Rear brake caliper
Locknut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Washer
Rear wheel axle
Adjusting block (left)
Adjusting block (right)
Rear wheel
Brake caliper bracket
Q’ty
1
2
2
1
1
1
1
1
1
1
Remarks
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-12
REAR WHEEL
Removing the brake disc and rear wheel sprocket
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Rear brake disc
Rear wheel sprocket
Coller (left and right)
Dust cover
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Rear wheel
Q’ty
1
1
2
2
1
1
1
6
1
Remarks
For installation, reverse the removal
procedure.
4-13
REAR WHEEL
Disassembling the rear wheel
Order
1
2
3
4
5
6
Job/Parts to remove
Q’ty
1
1
1
1
1
1
Coller
Bearing
Spacer
Oil seal
Circlip
Bearing
Remarks
For assembly, reverse the disassembly procedure.
4-14
REAR WHEEL
EAS22040
REMOVING THE REAR WHEEL (DISC)
1. Stand the vehicle on a level surface.
EWA13120
WARNING
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 rear wheel is elevated.
2. Remove:
• Brake caliper “1”
5.
•
•
•
•
NOTE:
Do not depress the brake pedal when removing the brake caliper.
EAS22090
3. Loosen:
• Locknut “1”
• Adjusting bolt “2”
4.
•
•
•
Remove:
Left collar “1”
Rear wheel drive hub “2”
Rear wheel drive hub damper
Right collar
CHECKING THE REAR WHEEL
1. Check:
• Wheel axle
• Rear wheel
• Wheel bearings
• Oil seals
Refer to "FRONT WHEEL" on page 4-6.
2. Check:
• Tire
• Rear wheel
Damage/wear → Replace.
Refer to "CHECKING THE TIRES" on page
3-31 and "CHECKING THE WHEELS" on
page 3-33.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to "FRONT WHEEL" on page 4-6.
Remove:
Wheel axle nut “1”
Wheel axle “2”
Rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
EAS22110
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• Rear wheel drive hub “1”
Cracks/damage → Replace.
• Rear wheel drive hub dampers “2”
4-15
REAR WHEEL
Damage/wear → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22120
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth “a” wear → Replace
the rear wheel sprocket.
Bent teeth → Replace the rear wheel
sprocket.
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 STATIC BALANCE" on page 4-9.
EAS22160
INSTALLING THE REAR WHEEL (DISC)
1. Lubricate:
• Wheel axle
• Wheel bearings
• Oil seal lips
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Recommended lubricant
Lithium-soap-based grease
2. Replace:
• Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Adjust:
• Drive chain slack
Refer to "ADJUSTING THE DRIVE CHAIN
SLACK" on page 3-25.
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
Drive chain slack
25–35 mm (0.98–1.38 in)
Rear wheel sprocket self-locking nut
100 Nm (10 m·kg, 72 ft·lb)
3. Tighten:
• Wheel axle nut
• Brake caliper bolts
NOTE:
Wheel axle nut
150 Nm (15 m·kg, 108 ft·lb)
Brake caliper bolt (front)
27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear)
22 Nm (2.2 m·kg, 16 ft·lb)
Tighten the self-locking nuts in stages and in a
crisscross pattern.
4-16
REAR WHEEL
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-17
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Brake hose holder
Reflector stay
Reflector
Front brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw
Q’ty
1
1
1
1
2
1
1
2
1
Remarks
For installation, reverse the removal
procedure.
4-18
FRONT BRAKE
Removing the front brake master cylinder
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Brake fluid
Q’ty
Remarks
Drain.
Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324.
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm holder
Brake master cylinder diaphragm
Brake lever
Front brake light switch lead coupler
Front brake light switch
Union bolt
Copper washer
Master cylinder bracket
Master cylinder assembly
1
1
1
1
1
1
1
2
1
1
Disconnect.
For assembly, reverse the disassembly procedure.
4-19
FRONT BRAKE
Disassembling the front brake master cylinder
Order
1
2
Job/Parts to remove
Brake master cylinder kit
Brake master cylinder body
Q’ty
1
1
Remarks
For assembly, reverse the disassembly procedure.
4-20
FRONT BRAKE
Removing the front brake calipers
Order
1
2
3
4
5
6
Job/Parts to remove
Brake fluid
Q’ty
Union bolt
Copper washer
Brake hose
Reflector stay
Reflector
Brake caliper
Remarks
Drain.
Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324.
1
2
1
1
1
1
For installation, reverse the removal
procedure.
4-21
FRONT BRAKE
Disassembling the front brake calipers
Order
1
2
3
4
5
6
7
Job/Parts to remove
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
Q’ty
2
1
1
2
4
8
1
Remarks
For assembly, reverse the disassembly procedure.
4-22
FRONT BRAKE
EAS22220
INTRODUCTION
EWA14100
WARNING
Disc brake components rarely require disassembly. Therefore, always follow these
preventive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on a suitable stand so
that the front wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to "FRONT WHEEL" on page 4-6.
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.
Brake disc thickness limit
4.0 mm (0.16 in)
Brake disc deflection limit
0.1 mm (0.004 in)
5. Adjust:
• Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
4-23
FRONT BRAKE
NOTE:
Brake pad lining thickness
(inner)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
Brake pad lining thickness
(outer)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment steps until the brake disc deflection is
within specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
2. Install:
• Brake pads
• Brake pad spring
NOTE:
Always install new brake pads and a brake pad
spring as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Front wheel
Refer to "FRONT WHEEL" on page 4-6.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper
with your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 m·kg, 3.6 ft·lb)
d. Install new brake pads and a new brake
pad spring.
4-24
FRONT BRAKE
1.
•
•
•
NOTE:
The arrow mark “a” on the brake pad spring
must point in the direction of disc rotation.
Remove:
Union bolt “1”
Copper washers “2”
Brake hose “3”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3.
•
•
•
Install:
Brake pad pins
Brake pad clips
Brake caliper
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22360
Brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston seals “2”
4. 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 3-22.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
a. Secure the brake caliper pistons with a
piece of wood “a”.
b. Blow compressed air into the brake hose
joint opening “b” to force out the left side
pistons from the brake caliper.
EWA13570
WARNING
EAS22300
• Never try to pry out the brake caliper pistons.
• Do not loosen the bolts “3”.
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
4-25
FRONT BRAKE
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
EAS22410
ASSEMBLING THE FRONT BRAKE CALIPERS
EWA13620
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
EAS22390
CHECKING THE FRONT BRAKE CALIPERS
Recommended brake component replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
Recommended brake fluid
DOT4
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
EAS22440
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Install:
• Brake caliper “1”
(temporarily)
• Copper washers
• Brake hose “2”
• Union bolt “3”
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13600
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
EWA13530
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
"CABLE ROUTING" on page 2-39.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
4-26
FRONT BRAKE
“a” touches the projection “b” on the brake
caliper.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
2.
•
3.
•
•
•
•
•
•
5. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
6. 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 3-22.
Remove:
Brake caliper
Install:
Brake pads
Brake pad spring
Brake pad pin
Brake pad clips
Brake caliper
Brake hose holder
Brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
Brake hose holder bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
7. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
Refer to "REPLACING THE FRONT
BRAKE PADS" on page 4-24.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
EAS22490
REMOVING THE FRONT BRAKE MASTER
CYLINDER
Recommended fluid
DOT4
NOTE:
Before removing the front brake master cylinder, drain the brake fluid from the entire brake
system.
EWA13090
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, 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.
1. Disconnect:
• Brake switch couplers “1”
(from the brake switch)
2. Remove:
4-27
FRONT BRAKE
• Union bolt “1”
• Copper washers “2”
• Brake hose “3”
EAS22740
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder “1”
• Brake master cylinder bracket “2”
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
Brake master cylinder bracket
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• Install the brake master cylinder holder with
the “UP” mark “a” facing up.
• Align the end of the brake master cylinder
holder with the punch mark “b” on the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
• There should be more than 11 mm (0.43 in)
for clearance between the right handlebar
switch and the brake master cylinder bracket.
Also, the punch mark should be seen.
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
2. Install:
• Copper washers
• Brake hose
• Union bolt
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER
EWA13530
EWA13520
WARNING
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
"CABLE ROUTING" on page 2-39.
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
Recommended fluid
DOT4
4-28
FRONT BRAKE
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
• 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 3-22.
EC2D1004
CAUTION:
Attach the brake hose so that its angle is
23° to 33° against the straight line in parallel with the ceiling plane of the master cylinder.
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT4
EWA13540
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
ECA13540
CAUTION:
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 3-24.
5. Check:
4-29
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
Order
1
2
3
4
5
6
7
Job/Parts to remove
Screw plug
Brake pad pin
Rear brake caliper
Brake pad shim
Brake pad
Bleed screw
Brake pad spring
Q’ty
1
1
1
4
2
1
1
Remarks
For installation, reverse the removal
procedure.
4-30
REAR BRAKE
Removing the rear brake master cylinder
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Parts to remove
Brake fluid
Q’ty
Remarks
Drain.
Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324.
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Bushing
Union bolt
Copper washer
Brake hose
Brake master cylinder
1
1
1
1
1
1
1
1
2
1
1
For installation, reverse the removal
procedure.
4-31
REAR BRAKE
Disassembling the rear brake master cylinder
Order
1
2
3
4
Job/Parts to remove
Brake master cylinder kit
Hose joint
Bushing
Brake master cylinder body
Q’ty
1
1
1
1
Remarks
For assembly, reverse the disassembly procedure.
4-32
REAR BRAKE
Removing the rear brake caliper
Order
1
2
3
4
Job/Parts to remove
Union bolt
Copper washer
Brake hose
Barke caliper
Q’ty
1
2
1
1
Remarks
For installation, reverse the removal
procedure.
4-33
REAR BRAKE
Disassembling the rear brake caliper
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Screw plug
Brake pad pin
Brake pad
Brake pad shim
Brake pad spring
Brake caliper piston
Brake caliper piston seal
Bleed screw
Q’ty
1
1
2
4
1
1
2
1
Remarks
For assembly, reverse the disassembly procedure.
4-34
REAR BRAKE
EAS22560
INTRODUCTION
Brake disc thickness limit
4.5 mm (0.18 in)
EWA14100
WARNING
5. Adjust:
• Brake disc deflection
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-23.
Disc brake components rarely require disassembly. Therefore, always follow these
preventive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
Brake disc bolt
30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®
6. Install:
• Rear wheel
Refer to "REAR WHEEL" on page 4-12.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness
(inner)
6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness
(outer)
6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
EAS22570
CHECKING THE REAR BRAKE DISC
1. Remove:
• Rear wheel
Refer to "REAR WHEEL" on page 4-12.
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.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-23.
2. Install:
• Brake pad shims
(onto the brake pads)
• Brake pads
• Brake pad spring
Brake disc deflection limit
0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-23.
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4-35
REAR BRAKE
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-22.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper
with your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 m·kg, 3.6 ft·lb)
EAS22590
REMOVING THE REAR BRAKE CALIPER
NOTE:
d. Install a new brake pad shim “3” onto each
new brake pad “4”.
e. Install new brake pads and a new brake
pad spring “5”.
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1.
•
•
•
Remove:
Union bolt “1”
Copper washers “2”
Brake hose “3”
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3.
•
•
•
Install:
Brake caliper
Brake pad pin
Screw plug
Brake caliper bolt (front)
27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear)
22 Nm (2.2 m·kg, 16 ft·lb)
EAS22600
DISASSEMBLING THE REAR BRAKE CALIPER
1. Remove:
• Brake caliper piston “1”
• Brake caliper piston seals “2”
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add
the recommended brake fluid to the proper
level.
4-36
REAR BRAKE
Scratches/wear → Replace the brake caliper assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
EWA13610
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING
a. Secure the brake caliper pistons with a
piece of wood “a”.
b. Blow compressed air into the brake hose
joint opening “b” to force out the piston from
the brake caliper.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
2. Check:
• Brake caliper bracket “1”
Cracks/damage → Replace.
c. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
EAS22640
CHECKING THE REAR BRAKE CALIPER
EWA13620
WARNING
Recommended brake component
replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Recommended fluid
DOT4
4-37
REAR BRAKE
• Brake caliper
Refer to "REPLACING THE REAR BRAKE
PADS" on page 4-35.
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Brake caliper “1”
(temporarily)
Brake caliper bolt (front)
27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear)
22 Nm (2.2 m·kg, 16 ft·lb)
• Copper washers “2”
• Brake hose “3”
• Union bolt “4”
4. Fill:
• Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13530
WARNING
Recommended fluid
DOT4
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
"CABLE ROUTING" on page 2-39.
EWA13090
WARNING
EC2D1010
CAUTION:
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
When installing the brake hose onto the
brake caliper, make sure the brake pipe “a”
touches the projection “b” on the brake caliper.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
2.
•
3.
•
•
•
•
•
5. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
6. 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 3-22.
Remove:
Brake caliper
Install:
Brake pad shims
Brake pads
Brake pad spring
Brake pad pin
Screw plug
4-38
REAR BRAKE
3. Check:
• Brake fluid reservoir
Cracks/damage → Replace.
• Brake fluid reservoir diaphragm
Cracks/damage → Replace.
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
EAS22730
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
7. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
EWA13520
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
EAS22700
REMOVING THE REAR BRAKE MASTER
CYLINDER
1. Remove:
• Union bolt “1”
• Copper washers “2”
• Brake hose “3”
Recommended fluid
DOT4
EAS22740
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
• Copper washers
• Brake hose “1”
• Union bolt “2”
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EW2D1004
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation.
Refer to "CABLE ROUTING" on page 2-39.
EC2D1005
CAUTION:
EAS22720
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection “a” as shown.
CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
4-39
REAR BRAKE
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
6. Adjust:
• Brake pedal position
Refer to "ADJUSTING THE REAR DISC
BRAKE" on page 3-21.
7. Adjust:
• Rear brake light operation timing
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH" on page 3-23.
2. Fill:
• Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT4
EW2D1005
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, 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.
EC2D1010
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-24.
4. 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 3-22.
4-40
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Parts to remove
Front cowling
Q’ty
Front brake light switch connector
Front master cylinder bracket
Front brake master cylinder assembly
Right handlebar switch
Throttle cable housing
Throttle cable
Grip end
Throttle grip
Clutch cable
Handlebar grip
Left handlebar switch
Clutch lever holder
Upper handlebar holder
Handlebar
4-41
2
1
1
1
1
2
2
1
1
1
1
1
1
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Disconnect.
HANDLEBAR
Removing the handlebar
Order
15
Job/Parts to remove
Lower handlebar holder
Q’ty
2
Remarks
For installation, reverse the removal
procedure.
4-42
HANDLEBAR
EAS22860
EWA13120
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Install:
• Lower handlebar holders “1”
2. Remove:
• Handlebar grip “1”
Temporarily tighten the nuts “2”.
NOTE:
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Install:
• Handlebar “1”
• Upper handlebar holder “2”
Upper handlebar holder bolt
24 Nm (2.4 m·kg, 17 ft·lb)
3. Remove:
• Throttle cable housing “1”
• Throttle grip “2”
ECA14250
NOTE:
CAUTION:
While removing the throttle cable housing, pull
back the rubber cover “3”.
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
• The upper handlebar holder should be
installed with the punch mark “a” facing forward.
• Align the match marks “b” on the handlebar
with the upper surface of the lower handlebar
holders.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage → Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS22930
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
4-43
HANDLEBAR
4. Tighten:
• Lower handlebar holder nuts
EW2D1007
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
Lower handlebar holder nut
32 Nm (3.2 m·kg, 23 ft·lb)
NOTE:
5. Install:
• Clutch lever holder “1”
• Clutch cable
There should be 1–3 mm (0.04–0.12 in) of
clearance “a” between the handlebar grip and
the grip end.
NOTE:
Align the slit in the clutch lever holder with the
punch mark "a" in the handlebar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8.
•
•
•
•
6. Install:
• Left handlebar switch
NOTE:
Align the projections “a” on the left handlebar
switch with the hole “b” in the handlebar.
Install:
Throttle grip “1”
Throttle cable hoousing “2”
Throttle cables
Grip end “3”
NOTE:
Align the projections “a” on the throttle cable
housing with the hole “b” in the handlebar.
7. Install:
• Handlebar grip “1”
• Grip end “2”
9. Install:
• Right handlebar switch
Grip end
26 Nm (2.6 m·kg, 19 ft·lb)
NOTE:
• Align the projections "a" on the handlebar
switch with the holes "b" in the handlebar.
• Threre should be 1–3 mm (0.04–0.12 in) of
clearance “c” between the handlebar grip
and the grip end.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Side the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
4-44
HANDLEBAR
10. Install:
• Front brake master cylinder assembly
• Front brake master cylinder holder “1”
Front brake master cylinder
bracket bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
ECS2D1010
CAUTION:
• Install the brake master cylinder bracket
with the “UP” mark facing up.
• First, tighten the upper bolt, then the
lower bolt.
NOTE:
Align the end of the brake master cylinder
holder with the punch mark “a” on the handlebar.
11. Adjust:
• Throttle cable free play
4-45
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
Order
1
2
3
4
5
Job/Parts to remove
Front wheel
Front brake calipers
Q’ty
Front fender
Cap bolt
Upper bracket pinch bolt
Lower bracket pinch bolt
Front fork leg
1
1
1
2
1
Remarks
Refer to "CHECKING THE TIRES"
on page 3-31 and "CHECKING THE
WHEELS" on page 3-33.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-46
FRONT FORK
Disassembling the front fork legs
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Job/Parts to remove
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Fork spring
Dust seal
Oil seal clip
Oil seal
Washer
Damper rod assembly bolt
Copper washer
Damper rod assembly
Inner tube
Outer tube
Remarks
For assembly, reverse the disassembly procedure.
4-47
FRONT FORK
• Nut “3”
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Press down on the spacer with the fork
spring compressor “4”.
b. Install the rod holder “5” between the nut
“3” and the spacer “2”.
NOTE:
Each front fork leg is eqipped with a spring
preload adjusting bolt, the right fork leg is
equipped with a rebound damping force
adjusting screan and left front fprk is equipped
with a compression damping force adjusting
screw. Pay attention not to mistake the right
and left.
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double
ended
YM-01434
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Use the side of the rod holder that is marked
“B”.
NOTE:
c. Hold the spring preload adjusting bolt “6”
and loosen the nut “3”.
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2.
•
•
•
Loosen:
Upper bracket pinch bolts “1”
Cap bolt “2”
Lower bracket pinch bolts “3”
EWA13640
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring
compressor.
f. Remove the spacer and nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Drain:
• Fork oil
NOTE:
Stroke the damper rod “1” several times while
draining the fork oil.
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 the damper adjusting rod)
• Spacers “2”
4-48
FRONT FORK
A. Compression side
B. Rebound side
NOTE:
While holding the damper rod with the damper
rod holder “1”, loosen the damper rod assembly bolt.
Damper rod holder
90890-01423
Damping rod holder
YM-01423
3. Remove:
• Oil seal clip “1”
(with a flat-head screwdriver)
ECA14180
CAUTION:
Do not scratch the inner tube.
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube “1”
• Outer tube “2”
Bends/damage/scratches → Replace.
4. Remove:
• Damper rod assembly bolt
• Damper rod assembly
EWA13650
EC2D1013
WARNING
CAUTION:
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
For the damper rod assembly, the right side
is used for the rebound operation and left
side for the compression. Pay attention not
to mistake the right and left.
NOTE:
The left side (for the compression) damper rod
assembly has the four holes of oil path, unlike
the right side.
2. Measure:
• Spring free length “a”
Out of specification → Replace.
Spring free length
243.5 mm (9.59 in)
Limit
238.6 mm (9.39 in)
4-49
FRONT FORK
• Damper rod assembly bolt
• Copper washer
EC2D1013
CAUTION:
For the damper rod assembly, the right side
is used for the rebound operation and left
side for the compression. Pay attention not
to mistake the right and left.
NOTE:
3. Check:
• Damper rod “1”
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• Damper adjusting rod
Bends/damage → Replace.
The left side (for the compression) damper rod
assembly has the four holes of oil path, unlike
the right side.
ECA14210
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube “2” until it protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
ECA14200
CAUTION:
• The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particularly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
2. Lubricate:
• Inner tube’s outer surface
Recommended oil
Suspension oil 01
EAS23030
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
3. Tighten:
• Damper rod assembly bolt “1”
EWA13660
Damper rod assembly bolt
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
While holding the damper rod assembly with
the damper rod holder “2”, tighten the damper
rod assembly bolt.
NOTE:
• When assembling the front fork leg, be sure
to replace the following parts:
- Oil seal
- Dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
Damper rod holder
90890-01423
Damping rod holder
YM-01423
1. Install:
• Damper rod assembly “1”
• Inner tube “2”
4-50
FRONT FORK
4.
•
•
•
•
6. Install:
• Oil seal clip “1”
Install:
Dust seal “1”
Oil seal clip “2”
Oil seal “3”
Washer “4”
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
ECA14220
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
7. Install:
• Dust seal “1”
(with the fork seal driver weight “2”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442
5. Install:
• Oil seal “1”
(with the fork seal driver “2”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442
8. Install:
• Rod puller “1”
• Rod puller attachment (M 10) “2”
(onto the damper rod “3”)
4-51
FRONT FORK
Rod puller
90890-01437
Rod puller attachment (M10)
90890-01436
11. Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual air.
9. Fill:
• Front fork leg
(with the specified amount of the recommended fork oil)
12. Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the
outer tube fully compressed and without
the fork spring)
Out of specification → Correct.
Quantity
545.0 cm3 (18.43 US oz) (19.18
lmp.oz)
Recommended oil
Suspension oil 01
Front fork leg oil level
91 mm (3.58 in)
ECA14230
CAUTION:
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
NOTE:
Be sure to bleed the front fork.
10. After filling the front fork leg, slowly stroke
the damper rod “1” up and down (at least
ten times) to distribute the fork oil.
13. Install:
• Nut “1”
• Fork spring “2”
• Spacer “3”
• Damper adjusting rod “4”
• Cap bolt “5”
NOTE:
Be sure to stroke the damper rod slowly
because the fork oil may spurt out.
4-52
FRONT FORK
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring and spacer.
f.
Remove the rod puller and the rod puller
attachment.
g. Install the nut “1” and position it as specified “b”.
NOTE:
Install the spring with the smaller pitch “a” facing up “A”.
Distance “b”
12 mm (0.47 in)
d. Press down in the spacer with the fork
spring compressor “1”
e. Pull up the rod puller and install the rod
holder “2” between the damper adjusting
rod locknut “3” and the spacer “4”.
h. Set the cap bolt distance “c” to specification.
Distance “c”
13 mm (0.51 in)
NOTE:
Use the side of the rod holder that is marked
“B”.
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double
ended
YM-01434
i.
j.
Inatall the damper adjusting rod and cap
bolt, and then finger tighten the cap bolt.
Hold the cap bolt and tighten the damper
adjusting rod locknut to specification.
Damper adjusting rod locknut
15 Nm (1.5 m·kg, 11 ft·lb)
k. Remove the rod holder and fork spring
compressor.
4-53
FRONT FORK
EW2D1003
WARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23050
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTE:
3.
•
•
•
Each front fork leg is eqipped with a spring
preload adjusting bolt, the right fork leg is
equipped with a rebound damping force
adjusting screw and left front fork is equipped
with a compression damping force adjusting
screw. Pay attension not to mistake the right
and left.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure the inner fork tube is flush with the
top of the handlebar holder.
2. Tighten:
• Lower bracket pinch bolt “1”
Lower bracket pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
• Cap bolt “2”
Cap bolt
23 Nm (2.3 m·kg, 17 ft·lb)
• Upper bracket pinch bolt “3”
Upper bracket pinch bolt
26 Nm (2.6 m·kg, 19 ft·lb)
EWA13680
WARNING
Make sure the brake hoses are routed properly.
4-54
Adjust:
Spring preload
Rebound damping
Compression damping
Refer to "ADJUSTING THE FRONT FORK
LEGS" on page 3-28.
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
Order
Job/Parts to remove
Front wheel
Q’ty
Front brake calipers
Front cowling
Handlebar
Front fork legs
1
2
3
4
5
6
Main switch connector
Steering stem nut
Upper bracket
Front brake hose joint
Front brake hose joint bracket
Horn
2
1
1
1
1
1
4-55
Remarks
Refer to "FRONT WHEEL" on page
4-6.
Refer to "FRONT BRAKE" on page
4-18.
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "HANDLEBAR" on page 441.
Refer to "FRONT FORK" on page 446.
Disconnect.
STEERING HEAD
Removing the lower bracket
Order
7
8
9
10
11
12
13
14
15
16
17
18
19
Job/Parts to remove
Horn bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Lower bearing
Lower bearing dust seal
Lower bearing inner race
Bearing cover
Upper bearing inner race
Upper bearing
Bearing outer race
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
2
Remarks
For installation, reverse the removal
procedure.
4-56
STEERING HEAD
Damage/pitting → Replace.
EAS23110
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2.
•
•
•
•
Remove:
Upper ring nut “1”
Rubber washer
Lower ring nut “2”
Lower bracket
3. Replace:
• Bearings
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
a. Remove 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 rubber seal and new bearing
races.
Hold the lower ring nut with the ring nut wrench
“3”, and then remove the upper ring nut with
the steering nut wrench “4”.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
ECA14270
CAUTION:
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 disassembled, replace the rubber seal.
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS23120
CHECKING THE STEERING HEAD
1. Wash:
• Bearings
• Bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• Bearings “1”
• Bearing races “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-57
STEERING HEAD
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
Steering stem nut
113 Nm (11.3 m·kg, 82 ft·lb)
EAS23140
INSTALLING THE STEERING HEAD
1. Lubricate:
• Upper bearing
• Lower bearing
• Bearing races
Recommended lubricant
Lithium-soap-based grease
2.
•
•
•
•
Install:
Lower ring nut “1”
Rubber washer “2”
Upper ring nut “3”
Lock washer “4”
Refer to "INSTALLING THE STEERING
HEAD" on page 4-58.
3.
•
•
4.
•
•
Install:
Front brake hose joint bracket
Front brake hose joint
Install:
Upper bracket
Steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
5. Install:
• Front fork legs
Refer to "FRONT FORK" on page 4-46.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts.
6. Tighten:
• Steering stem nut
4-58
REAR SHOCK ABSORBER ASSEMBLY
EAS23160
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Side cover (left and right)
Brake fluid reservoir tank bolt
1
2
3
4
5
6
7
8
9
10
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt/collar
Rear shock absorber assembly
Oil seal/bearing/collar
Collar/self-locking nut/bolt
Connecting arm
Oil seal/bearing/collar
Relay arm
1/1
1/1
1/1
1/1/1
1
6/3/3
1/1/1
2
2/1/1
1
4-59
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "REAR BRAKE" on page 430.
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
Order
Job/Parts to remove
Q’ty
4-60
Remarks
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY
EAS23180
NOTE:
HANDLING THE REAR SHOCK ABSORBER
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
EWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure you understand the following information. The manufacturer cannot be held
responsible for property damage or personal injury that may result from improper
handling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping performance.
2. Remove:
• Rear shock absorber assembly lower bolt
“1”
• Relay arm-to-swingarm bolt “2”
• Connecting arm-to-relay arm bolt “3”
NOTE:
While removing the rear shock absorber
assembly lower bolt, hold the swigarm so that
it does not drop down.
EAS23190
DISPOSING OF A REAR SHOCK
ABSORBER
1. Gas pressure must be released before disposing of a rear shock absorber. To release
the gas pressure, drill a 2–3mm (0.079–
0.118 in) hole through the rear shock
absorber at a point 15–20 mm (0.59–0.79
in) from its end as shown.
3. Remove:
• Rear shock absorber assembly upper bolt
“1”
• Rear shock absorber assembly
NOTE:
Raise the swigarm and then remove the rear
shock absorber assembly from between the
swingarm.
EWA13760
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
EAS23210
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the vehicle on a level surface.
EAS23240
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Rear shock absorber
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
4-61
REAR SHOCK ABSORBER ASSEMBLY
•
•
•
•
Gas leaks/oil leaks → Replace the rear
shock absorber assembly.
Spring
Damage/wear → Replace the rear shock
absorber assembly.
Bushings
Damage/wear → Replace.
Dust seals
Damage/wear → Replace.
Bolts
Bends/damage/wear → Replace.
3. Tighten:
• Rear shock absorber assembly upper nut
Rear shock absorber assembly
upper nut
44 Nm (4.4 m·kg, 32 ft·lb)
• Rear shock absorber assembly lower nut
Rear shock absorber assembly
lower nut
44 Nm (4.4 m·kg, 32 ft·lb)
• Relay-arm-to-swingarm nut
EAS23260
CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arms “1”
• Relay arm “2”
Damage/wear → Replace.
Relay-arm-to-swingarm nut
44 Nm (4.4 m·kg, 32 ft·lb)
2. Check:
• Bearings
• Oil seals
Damage/pitting → Replace.
3. Check:
• Coller
Damage/scratches → Replace.
EAS23300
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
• Spacers
• Bearings
Recommended lubricant
Lithium-soap-based grease
2. Install:
• Rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
4-62
SWINGARM
EAS23330
SWINGARM
Removing the swingarm
Order
Job/Parts to remove
Rear wheel
Q’ty
Rear brake caliper
Rear shock absorber
Drive sprocket
1
2
3
4
5
6
7
Rear fender cover
Drive chain guard
Brake hose holder
Drive chain adjusting bolt/locknut
Pivot shaft nut/washer
Pivot shaft
Swingarm
1
1
1
2/2
1/1
1
1
4-63
Remarks
Refer to "REAR WHEEL" on page 412.
Refer to "REAR BRAKE" on page 430.
Refer to "REAR SHOCK
ABSORBER ASSEMBLY" on page
4-59.
Refer to "ENGINE REMOVAL" on
page 5-1.
SWINGARM
Removing the swingarm
Order
8
9
10
11
12
Job/Parts to remove
Drive chain
Dust cover
Drive chain guide
Spacer
Bearing
Q’ty
1
2
1
1
2
Remarks
For installation, reverse the removal
procedure.
4-64
SWINGARM
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust covers.
EAS23350
REMOVING THE SWINGARM
1. Stand the vehicle on a level surface.
EWA13120
WARNING
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 rear wheel is elevated.
2.
•
•
•
Remove:
Relay arm-to-swingarm bolt “1”
Connecting arm bolt “2”
Rear shock absorber assembly lower bolt
“3”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
EAS23360
When removing the rear shock absorber
assembly lower bolt, hold the swingarm so that
it does not drop down.
CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage → Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
EWA13770
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
3.
•
•
•
•
•
Pivot shaft nut
105 Nm (10.5 m·kg, 76 ft·lb)
b. Measure the swingarm side play “A” by
moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Wash:
Pivot shaft
Dust covers
Spacer
Washers
Bearings
Recommended cleaning solvent
Kerosene
4.
•
•
•
Swingarm side play (at the end
of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement “B”
by moving the swingarm up and down.
4-65
Check:
Dust covers “1”
Spacer “2”
Bearings “3”
Damage/pitting → Replace.
SWINGARM
5. Check:
• Connecting arms “1”
• Relay arm “2”
Damage/wear → Replace.
6. Check:
• Bearings “3”
• Oil seals “4”
Damage/pitting → Replace.
7. Check:
• Collars “5”
Damage/scratches → Replace.
3. Install:
• Rear shock absorber assembly
• Rear wheel
Refer to "INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY" on page 4-62
and "INSTALLING THE REAR WHEEL
(DISC)" on page 4-16.
4. Adjust:
• Drive chain slack
Refer to "ADJUSTING THE DRIVE CHAIN
SLACK" on page 3-25.
Drive chain slack
25–35 mm (0.98–1.38 in)
EAS23380
INSTALLING THE SWINGARM
1. Lubricate:
• Bearings
• Spacers
• Dust covers
• Pivot shaft
Recommended lubricant
Lithium-soap-based grease
2.
•
•
•
Install:
Swingarm
Pivot shaft “1”
Pivot shaft nut “2”
4-66
CHAIN DRIVE
EAS23400
CHAIN DRIVE
Removing the drive chain
Order
1
2
Job/Parts to remove
Drive sprocket
Q’ty
Drive chain guard
Drive chain
Remarks
Refer to "ENGINE REMOVAL" on
page 5-1.
1
1
For installation, reverse the removal
procedure.
4-67
CHAIN DRIVE
EAS23410
REMOVING THE DRIVE CHAIN
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
2. Check:
• Drive chain
Stiffness → Clean and lubricate or replace.
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• Drive chain
(with the drive chain cutter)
NOTE:
Only cut the drive chain if it or the swingarm is
to be replaced.
EAS23440
CHECKING THE DRIVE CHAIN
1. Measure:
• Measure the dimension between 15-links
on the inner side “a” and outer side “b” of
the roller and calculate the dimension
between pin centers.
• Dimension “c” between pin centers = (Inner
dimension “a” + Outer dimension “b”)/2
• 15-link section “c” of the drive chain
Out of specification → Replace the drive
chain, front drive sprocket and rear drive
sprocket as a set.
3. Clean:
• Drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECA14290
CAUTION:
15-link drive chain section limit
(maximum)
239.3 mm (9.42 in)
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive
chain side plates. Never use high-pressure water or air, steam, gasoline, certain
solvents (e.g., benzine), or a coarse brush
to clean the drive chain. High-pressure
methods could force dirt or water into the
drive chain’s internals, and solvents will
deteriorate the O-rings. A coarse brush
can also damage the O-rings. Therefore,
use only kerosene to clean the drive
chain.
• Do not soak the drive chain in kerosene
for more than ten minutes, otherwise the
O-rings can be damaged.
NOTE:
• While measuring the 15-link section, push
down on the drive chain to increase its tension.
• Perform this measurement at two or three different places.
4-68
CHAIN DRIVE
• Drive sprocket
More than 1/4 tooth “a” wear → Replace
the drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
b. Correct
1. Drive chain roller
2. Drive chain sprocket
EAS23470
CHECKING THE REAR WHEEL SPROCKET
Refer to "CHECKING AND REPLACING THE
REAR WHEEL SPROCKET" on page 4-16.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• O-rings “1”
Damage → Replace the drive chain.
• Drive chain rollers “2”
Damage/wear → Replace the drive chain.
• Drive chain side plates “3”
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain and
make sure the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
EAS23480
CHECKING THE REAR WHEEL DRIVE HUB
Refer to "CHECKING THE REAR WHEEL
DRIVE HUB" on page 4-15.
EAS28800
INSTALLING THE DRIVE CHAIN
1. Lubricate:
• Drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
2. Install:
• Drive sprocket
• Lock washer
• Drive sprocket nut
Refer to "ENGINE REMOVAL" on page 51.
Drive sprocket nut
85 Nm (8.5 m·kg, 61 ft·lb)
5. Lubricate:
• Drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EAS23460
CHECKING THE DRIVE SPROCKET
1. Check:
4-69
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the drive sprocket
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Q’ty
2
1
1
1
1
1
1
1
Locknut
Shift rod
Shift arm
Drive sprocket cover
Drive sprocket nut
Lock washer
Drive sprocket
Plate
Remarks
For installation, reverse the removal
procedure.
5-1
ENGINE REMOVAL
Removing the exhaust pipe
5
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
1
2
3
4
5
EXUP pulley cover
EXUP servo motor cover
EXUP cables
EXUP servo motor
O2 sensor
1
1
2
1
1
6
7
8
9
10
11
Exhaust pipe assembly
Exhaust pipe gasket
Muffler
Muffler gasket
Muffler cover
Muffler end cover
1
4
1
1
1
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
For installation, reverse the removal
procedure.
5-2
ENGINE REMOVAL
Disassembling the exhaust valve pipe
Order
1
2
3
4
Job/Parts to remove
Q’ty
1
1
1
1
Nut
Pulley
Spring
Spring seat
Remarks
For assembly, reverse the disassembly procedure.
5-3
ENGINE REMOVAL
Disconnecting the leads and hoses
Order
Job/Parts to remove
Fuel tank
Air filter case
Q’ty
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
1
2
3
4
5
Battery negative lead
Battery positive lead
Clutch cable
Ground lead
Stator coil assembly coupler
1
1
1
2
1
5-4
Remarks
Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "THROTTLE BODIES" on
page 7-4.
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
Refer to "OIL COOLER" on page 64.
Refer to "AIR INDUCTION SYSTEM" on page 7-13.
Refer to "ELECTRIC STARTER" on
page 5-39.
Disconnect.
ENGINE REMOVAL
Disconnecting the leads and hoses
Order
6
7
8
9
10
Job/Parts to remove
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Cylinder identification sensor coupler
Speed sensor coupler
5-5
Q’ty
1
1
1
1
1
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For assembly, reverse the removal
procedure.
ENGINE REMOVAL
Removing the engine
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Right front engine mounting bolt 1
Left front engine mounting bolt
Upper self-locking nut
Upper engine mounting bolt
Lower self-locking nut
Lower engine mounting bolt
Engine mounting adjust bolt
Engine
Q’ty
1
1
1
1
1
1
2
1
Remarks
For assembly, reverse the removal
procedure.
5-6
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE
1. Install:
• Right front engine mounting bolt 2 “1”
Refer to "CYLINDER HEAD" on page 5-18.
2. Tighten:
• Right front engine mounting bolt 2
Right front engine mounting
bolt 2
50 Nm (5.0 m·kg, 36 ft·lb)
7. Tighten:
• Engine mounting adjust bolts
3. Install:
• Engine mounting adjust bolts
(temporarily tighten)
4. Install:
• Engine
5. Install:
• Lower engine mounting bolt “1”
• Upper engine mounting bolt “2”
• Self-locking nuts
Engine mounting adjust bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
Use the pivot shaft wrench “1” and pivot shaft
wrench adapter “2” to tighten the engine
mounting adjust bolts.
Pivot shaft wrench
90890-01471
Frame spanner socket
YM-01471
Pivot shaft wrench adapter
90890-01476
NOTE:
Do not fully tighten the bolts and nuts.
6. Install:
• Left front engine mounting bolt “1”
(temporarily tighten)
• Right front engine mounting bolt 1 “2”
(temporarily tighten)
5-7
ENGINE REMOVAL
Left front engine mounting bolt
45 Nm (4.5 m·kg, 33 ft·lb)
Right front engine mounting
bolt 1
45 Nm (4.5 m·kg, 33 ft·lb)
8. Tighten:
• Lower self-locking nut “1”
• Upper self-locking nut “2”
Upper self-locking nut
51 Nm (5.1 m·kg, 37 ft·lb)
Lower self-locking nut
51 Nm (5.1 m·kg, 37 ft·lb)
NOTE:
First tighten the lower self-locking nut, and
then tighten the upper self-locking nut.
9. Tighten:
• Left front engine mounting bolt ”1”
• Right front engine mounting bolt 1 ”2”
5-8
CAMSHAFTS
EAS23760
CAMSHAFTS
Removing the cylinder head cover
Order
Job/Parts to remove
Fuel tank
Throttle body assembly
Q’ty
Radiator assembly
Air cut-off valve
1
2
3
4
5
6
7
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
Cylinder identification sensor
O-ring
Remarks
Refer to "FUEL TANK" on page 7-1.
Refer to "THROTTLE BODIES" on
page 7-4.
Refer to "RADIATOR" on page 6-1.
Refer to "AIR INDUCTION SYSTEM" on page 7-13.
4
4
1
1
1
1
1
For assembly, reverse the removal
procedure.
5-9
CAMSHAFTS
Removing the camshafts
Order
Job/Parts to remove
Pickup rotor cover
Q’ty
1
2
3
4
5
Camshaft sprocket bolt
Timing chain tensioner
Timing chain tensioner gasket
Intake camshaft cap
Dowel pin
4
1
1
3
6
6
7
Exhaust camshaft cap
Dowel pin
3
6
8
9
10
Intake camshaft
Exhaust camshaft
Camshaft sprocket
1
1
2
Remarks
Refer to "CRANKSHAFT POSITION
SENSOR" on page 5-37.
Loosen.
Refer to "REMOVING THE CAMSHAFTS" on page 5-11.
Refer to "REMOVING THE CAMSHAFTS" on page 5-11.
For assembly, reverse the removal
procedure.
5-10
CAMSHAFTS
EAS23810
REMOVING THE CAMSHAFTS
1. Remove:
• Pickup rotor cover
Refer to "CRANKSHAFT POSITION SENSOR" on page 5-37.
2. Align:
• “T” mark “a” on the pickup rotor
(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark “a” on the
pickup rotor with the crankcase mating surface “b”.
5. Remove:
• Camshaft caps “1”
• Dowel pins
ECA13720
CAUTION:
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Remove:
• Intake camshaft “1”
• Exhaust camshaft “2”
3. Loosen:
• Camshaft sprocket bolts “1”
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “3”.
Camshaft wrench
90890-04143
4. Remove:
• Timing chain tensioner “1”
• Gasket
5-11
CAMSHAFTS
3. Measure:
• Camshaft runout
Out of specification → Replace.
EAS23850
CHECKING THE CAMSHAFTS
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
Camshaft runout limit
0.03 mm (0.0012 in)
Camshaft lobe dimension limit
Intake camshaft “a”
32.50–32.60 mm
(1.280–1.284 in)
Limit
32.40 mm (1.276 in)
Intake camshaft “b”
24.95–25.05 mm
(0.982–0.986 in)
Limit
24.85 mm (0.978 in)
Exhaust camshaft “a”
30.70–30.80 mm
(1.209–1.213 in)
Limit
30.60 mm (1.205 in)
Exhaust camshaft “b”
22.95–23.05 mm
(0.904–0.908 in)
Limit
22.85 mm (0.900 in)
4. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap-clearance
0.028–0.062 mm
(0.0011–0.0024 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft
caps).
b. Position strip of Plastigauge® “1” onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the
inner caps out.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap clearance with the Plastigauge®.
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
d. Remove the camshaft caps and then measure the width of the Plastigauge® “2”.
5-12
CAMSHAFTS
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace
the camshaft sprockets and the timing
chain as a set.
a.
b.
1.
2.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
1/4 tooth
Correct
Timing chain roller
Camshaft sprocket
EAS23950
CHECKING THE TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
• Timing chain guide (exhaust side) “1”
• Timing chain guide (intake side) “2”
• Timing chain guide (top side) “3”
Damage/wear → Replace the defective
part(s).
Camshaft journal diameter
22.459–22.472 mm
(0.8842–0.8847 in)
EAS23870
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET
1. Check:
• Timing chain “1”
Damage/stiffness → Replace the timing
chain and camshaft and camshaft sprocket
as a set.
EAS23960
CHECKING THE TIMING CHAIN TENSIONER
1. Remove:
• Timing chain tensioner housing “1”
• Timing chain tensioner rod “2”
• Timing chain tensioner spring “3”
5-13
CAMSHAFTS
b. Squeeze the timing chain tensioner clip “2”
and push the timing chain tensioner rod “3”.
NOTE:
Squeeze the timing chain tensioner clip, and
then remove the timing chain tensioner spring
and timing chain tensioner rod.
NOTE:
When the timing chain tensioner rod “3” is
pushed while holding the grip of the timing
chain tensioner clip “2”, make sure not to
release the timing chain tensioner rod “3”
before releasing the timing chain tensioner clip
“2”. (Otherwise, the timing chain tensioner rod
“3” may run off.)
2.
•
•
•
Check:
Timing chain tensioner housing
Timing chain tensioner rod
Timing chain tensioner spring
Damage/wear → Replace.
3. Install:
• Timing chain tensioner spring
• Timing chain tensioner rod “1”
c. Hook the clip “4” to the timing chain tensioner rod “3”.
NOTE:
NOTE:
Prior to installing the timing chain tensioner
rod, drain the engine oil from the timing chain
tensioner housing.
Hook the timing chain tensioner rod pin “5” to
the center of the clip “4”. After the installation,
check that the clip “4” can come off by its own
weight by pushing the timing chain tensioner
rod “3” at the position of installation.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the timing chain tensioner spring and
timing chain tensioner rod “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-14
CAMSHAFTS
EAS24000
INSTALLING THE CAMSHAFTS
1. Align:
• “T” mark “a” on the pickup rotor
(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When position #1 is at TDC, align the “T”
mark “a” with the crankcase mating surface
“b”.
4.
•
•
•
Install:
Dowel pins
Intake camshaft caps
Exhaust camshaft caps
NOTE:
• Make sure each camshaft cap is installed in
its original place. Refer to the identification
marks as follows:
“I”: Intake side camshaft cap mark
“E”: Exhaust side camshaft cap mark
“L”: Left side camshaft cap mark
“R”: Right side camshaft cap mark
• Make sure the arrow mark “a” on each camshaft points towards the right side of the
engine.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Intake camshaft sprocket “1”
• Exhaust camshaft sprocket “2”
(with the camshaft sprockets temporarily
tightened)
NOTE:
Install the camshaft sprockets as a illustration.
5. Install:
• Camshaft cap bolts
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
3. Install:
• Exhaust camshaft “1”
• Intake camshafts “2”
(with the camshaft sprockets temporarily
tightened)
NOTE:
Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the inner
caps out.
NOTE:
Make sure the punch mark “a” on each camshaft faces up.
EC2D1001
CAUTION:
• Lubricate the camshaft cap bolts with the
engine oil.
5-15
CAMSHAFTS
• Timing chain tensioner “1”
• Timing chain tensioner bolts “2”
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or
improper valve timing.
Timing chain tensioner bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
EC2D1003
6. Tighten:
• Camshaft sprocket bolts “1”
CAUTION:
The arrow mark “a” on the timing chain tensioner should face up.
Camshaft sprocket bolt
24 Nm (2.4 m·kg, 17 ft·lb)
EW2D1006
WARNING
Always use a new gasket.
Camshaft wrench
90890-04143
EC2D1002
CAUTION:
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
9. Turn:
• Crankshaft
(several turns clockwise)
10. Check:
• “T” mark “a”
Make sure the “T” mark on the pickup rotor
is aligned with the crankcase mating surface “b”.
• Camshaft punch mark “c”
Make sure the punch mark “c” on the camshaft is aligned with the camshaft cap
arrow mark “d”.
Out of alignment → Adjust.
Refer to the installation steps above.
7. Align:
• Camshaft punch mark “a”
Align the camshaft punch mark “a” and the
camshaft cap arrow mark “b”.
Camshaft wrench
90890-04143
8. Install:
• Gasket
5-16
CAMSHAFTS
11. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to "ADJUSTING THE VALVE
CLEARANCE" on page 3-4.
12. Install:
• Pickup coil rotor cover
"CRANKSHAFT POSITION SENSOR" on
page 5-37.
5-17
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
Order
Job/Parts to remove
Q’ty
Engine
Refer to
"ENGINE REMOVAL" on page 5-1.
Refer to
"CAMSHAFTS" on page 5-9.
Refer to
"CAMSHAFTS" on page 5-9.
Intake camshaft
Exhaust camshaft
1
2
3
4
5
6
7
Remarks
Cylinder head
Cylinder head gasket
Dowel pin
Coolant pipe
O-ring
Thermo wax outlet hose
Right front engine mounting bolt 2
1
1
2
1
1
1
1
For assembly, reverse the removal
procedure.
5-18
CYLINDER HEAD
EAS24120
REMOVING THE CYLINDER HEAD
1. Remove:
• Intake camshaft
• Exhaust camshaft
Refer to "REMOVING THE CAMSHAFTS"
on page 5-11.
2. Remove:
• Cylinder head nuts
• Cylinder head bolts
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After
all of the nuts are fully loosened, remove
them.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24240
INSTALLING THE CYLINDER HEAD
1. Check:
• Cylinder head bolts “1”
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• Spark plug bore threads
• Valve seats
Cylinder head bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
2. Check:
• Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder head.
NOTE:
Retighten the cylinder head bolts to specification, before installing the cylinder head.
Maximum cylinder head
warpage
0.10 mm (0.0039 in)
2. Install:
5-19
CYLINDER HEAD
5. Install:
• Exhaust camshaft
• Intake camshaft
Refer to "INSTALLING THE CAMSHAFTS"
on page 5-15.
• Gasket “1”
• Dowel pins
3. Install:
• Cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
4. Tighten:
• Cylinder head nuts “1” – “10”
Cylinder head nut (1st)
19 Nm (1.9 m·kg, 14 ft·lb)
Cylinder head nut (2nd)
67 Nm (6.7 m·kg, 48 ft·lb)
• Cylinder head bolts “11” “12”
Cylinder head bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
NOTE:
• First, tighten the nuts “1” – “10” to approximately 19 Nm (1.9 m·kg, 14 ft·lb) with a
torque wrench, and then tighten the 67 Nm
(6.7 m·kg, 48 ft·lb).
• 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.
5-20
VALVES AND VALVE SPRINGS
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Parts to remove
Cylinder head
Q’ty
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve stem seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve stem seal
12
12
24
12
12
12
12
12
12
8
8
16
8
8
8
5-21
Remarks
Refer to "CYLINDER HEAD" on
page 5-18.
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order
16
17
18
Job/Parts to remove
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Q’ty
8
8
8
Remarks
For installation, reverse the removal
procedure.
5-22
VALVES AND VALVE SPRINGS
EAS24280
NOTE:
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor attachment “3”.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor
attachment
90890-04108
Valve spring compressor
adapter 22 mm
YM-04108
Valve spring compressor
attachment
90890-04114
Valve spring compressor
adapter 19.5 mm
YM-04114
1. Remove:
• Valve lifter “1”
• Valve pad “2”
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
• Valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to "CHECKING THE VALVE SEATS"
on page 5-25.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
4.
•
•
•
•
•
NOTE:
There should be no leakage at the valve seat
“1”.
Remove:
Upper spring seat “1”
Valve spring “2”
Valve stem seal “3”
Lower spring seat “4”
Valve “5”
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• Valve cotters “1”
5-23
VALVES AND VALVE SPRINGS
EAS24290
NOTE:
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C (212°F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover “1”.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” Valve stem diameter “b”
Valve-stem-to-valve-guide
ance
Intake
0.010 – 0.037 mm
(0.0004 – 0.0015)
Limit
0.08 mm (0.0032 in)
Exhaust
0.025 – 0.052 mm
(0.0010 – 0.0020 in)
Limit
0.10 mm (0.0039 in)
clear-
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valveguide clearance.
NOTE:
2. Replace:
• Valve guide
After replacing the valve guide, reface the
valve seat.
5-24
VALVES AND VALVE SPRINGS
Intake
Valve guide remover (ø4)
90890-04111
YM-04111
Exhaust
Valve guide remover (ø4.5)
90890-04116
YM-04116
Intake
Valve guide installer (ø4)
90890-04112
YM-04112
Exhaust
Valve guide installer (ø4.5)
90890-04117
YM-04117
Intake
Valve guide reamer (ø4)
90890-04113
YM-04113
Exhaust
Valve guide reamer (ø4.5)
90890-04118
YM-04118
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout
0.01 mm (0.0004 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• Valve margin thickness “a”
Out of specification → Replace the valve.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• Valve seat width “a”
Out of specification → Replace the cylinder
head.
Valve margin thickness
0.5–0.9 mm (0.0197–0.0354 in)
Limit
0.5 mm (0.02 in)
5-25
VALVES AND VALVE SPRINGS
NOTE:
Valve seat width
Intake
0.90–1.10 mm
(0.0354–0.0433 in)
Exhaust
0.90–1.10 mm
(0.0354–0.0433 in)
Limit
1.6 mm (0.063 in)
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
5-26
VALVES AND VALVE SPRINGS
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
j. Measure the valve seat width “c” again. If
the valve seat width is out of specification,
reface and lap the valve seat.
2. Measure:
• Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
Compressed valve spring force
(installed)
Intake valve spring
127.4–144.6 N
(12.99–14.74 kg, 28.64–32.51
lb)
at 32.65 mm (1.285 in)
Exhaust valve spring
133.0–153.0 N
(13.56–15.60 kg, 29.90–34.39
lb)
at 32.82 mm (1.292 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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.
Valve spring free length
Intake valve spring
40.5 mm (1.60 in)
Limit
38.5 mm (1.47 in)
Exhaust valve spring
40.5 mm (1.60 in)
Limit
38.5 mm (1.47 in)
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
Spring tilt limit
Intake valve spring
1.8 mm (0.07 in)
Exhaust valve spring
1.8 mm (0.07 in)
5-27
VALVES AND VALVE SPRINGS
3.
•
•
•
•
•
EAS24320
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
• Valve lifter
Damage/scratches → Replace the valve
lifters and cylinder head.
Install:
Valve “1”
Lower spring seat “2”
Valve stem seal “3”
Valve spring “4”
Upper spring seat “5”
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its original place. Refer to the following embossed
marks.
Right and left intake valve (-s): “5VY:”
Middle intake valve (-s): “5VY.”
Exhaust valve (-s): “5VY”.
• Install the valve springs with the larger pitch
“a” facing up.
EAS24330
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
4. Install:
• Valve cotters “1”
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
“2” and the valve spring compressor attachment “3”.
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
5-28
VALVES AND VALVE SPRINGS
• Each valve lifter and valve pad must be reinstalled in its original position.
Valve spring compressor
90890-04019
YM-04019
Intake
Valve spring compressor
attachment
90890-04114
YM-04114
Exhaust
Valve spring compressor
attachment
90890-04108
YM-04108
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a softface hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
6. Install:
• Valve pad “1”
• Valve lifter “2”
NOTE:
• Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.
• The valve lifter must move smoothly when
rotated with a finger.
5-29
GENERATOR
EAS24480
GENERATOR
Removing the generator
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Engine oil
1
2
3
4
5
6
7
8
9
10
Startor coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Startor coil assembly
Dowel pin
Bearing housing
Collar
1
1
1
1
2
1
1
2
1
1
5-30
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
Disconnect.
GENERATOR
Removing the generator
Order
11
12
13
14
15
16
Job/Parts to remove
Bearing
Startor coil assembly lead holder
Idler gear
Idler gear shaft
Washer
Bearing
Q’ty
1
1
1
1
1
1
Remarks
For assembly, reverse the removal
procedure.
5-31
GENERATOR
EAS24490
REMOVING THE GENERATOR
1. Remove:
• Plug
• Generator rotor cover “1”
NOTE:
• While pushing generator rotor, remove the
generator rotor cover.
• Loosen each bolt 1/4 of a turn a time, in
stages and in a crisscross pattern.
• After all of the bolts are fully loosened,
remove them.
EAS24500
INSTALLING THE GENERATOR
1. Install:
• Idle gear shaft
• Idle gear “1”
• Washer
• Idle gear shaft bolt “2”
Idle gear shaft bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
2. Remove:
• Generator rotor and starter clutch assembly “1”
2. Install
• Generator rotor and starter clutch assembly “1”
3.
•
•
•
Remove:
Idle gear shaft bolt “1”
Idle shaft
Idle gear “2”
3. Install:
• Generator rotor cover gasket
• Generator rotor cover “1”
5-32
GENERATOR
Generator rotor cover bolt (M6)
12 Nm (1.2 m·kg, 8.7 ft·lb)
Generator rotor cover bolt (M8)
22 Nm (2.2 m·kg, 16 ft·lb)
NOTE:
• First tighten the M8 bolts and then tighten the
M6 bolts.
• Tighten the generator rotor cover bolts in
stages and in a crisscross pattern.
5-33
STARTER CLUTCH
EAS24550
STARTER CLUTCH
Removing the starter clutch
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Generator rotor
Damper
Driven gear
Washer
Starter clutch drive gear
Collar
Washer
Spacer
O-ring
Q’ty
1
3
1
1
1
1
1
1
1
Remarks
For assembly, reverse the removal
procedure.
5-34
STARTER CLUTCH
EAS24560
REMOVING THE STARTER CLUTCH
1. Remove:
• Spacer “1”
• O-ring “2”
• Washer “3”
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers “1”
Damage/wear → Replace.
2.
•
•
•
3.
•
•
•
Remove:
Starter clutch drive gear “1”
Collar “2”
Washer “3”
2. Check:
• Starter clutch idle gear “1”
• Starter clutch drive gear “2”
Burrs/chips/roughness/wear → Replace
the defective part(s).
Remove:
Driven gear “1”
Dampers “2”
Generator rotor “3”
3. Check:
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
ET2D1009
CHECKING THE DAMPER
1. Check:
• Dampers “1”
Damage/wear → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto
the starter clutch “2” and hold the starter
clutch.
b. When turning the starter clutch drive gear
counterclockwise “A”, the starter clutch and
the starter clutch drive gear should engage,
5-35
STARTER CLUTCH
otherwise the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch drive gear
clockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be
replaced.
3. Install:
• Washer “1”
• O-ring “2”
• Spacer “3”
NOTE:
Lubricate the engine oil to O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24600
INSTALLING THE STARTER CLUTCH
1. Install:
• Generator rotor “1”
• Damper “2”
• Driven gear “3”
NOTE:
• The hole side of the damper is installed to
the generator side.
• Lubricate the engine oil “4”.
2.
•
•
•
Install
Starter clutch drive gear “1”
Collar “2”
Washer “3”
Refer to "CHECKING THE STARTER
CLUTCH" on page 5-35.
5-36
CRANKSHAFT POSITION SENSOR
EAS24520
CRANKSHAFT POSITION SENSOR
Removing the crankshaft position sensor
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Engine oil
1
2
3
4
5
6
Crankshaft position sensor lead coupler
Crankshaft position sensor
O-ring
Pickup rotor cover
Gasket
Cover
1
1
1
1
1
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
Disconnect.
For assembly, reverse the removal
procedure.
5-37
CRANKSHAFT POSITION SENSOR
EAS24530
REMOVING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
• Crankshaft position sensor lead coupler
2. Remove:
• Crankshaft position sensor
• O-ring
• Pickup coil rotor cover “1”
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Connect
• Crankshaft position sensor lead coupler
EAS24540
INSTALLING THE CRANKSHAFT POSITION
SENSOR
1. Install:
• Gasket
• Pickup rotor cover “1”
Pickup rotor cover
12 Nm (1.2 m·kg, 8.7 ft·lb)
• O-ring
• Crankshaft posision sensor
Crankshaft position sensor bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
5-38
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Throttle body assembly
1
2
Starter motor lead
Starter motor
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Refer to "THROTTLE BODIES" on
page 7-4.
1
1
For assembly, reverse the removal
procedure.
5-39
ELECTRIC STARTER
Disassembling the starter motor
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Q’ty
1
1
1
1
1
1
2
2
1
1
O-ring
Front cover
Lock washer
Washer
Starter motor yoke
Armature assembly
O-ring
Starter motor lead
Brush holder
Rear cover
Remarks
For assembly, reverse the disassembly procedure.
5-40
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR
1. Check:
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter
motor.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance “1”
0.0250–0.0350 Ω at 20°C (68°F)
Insulation resistance “2”
Above 1 MΩ at 20°C (68°F)
Commutator wear limit
27.0 mm (1.06 in)
b. If any resistance is out of specification,
replace the starter motor.
3. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Brush length “a”
Out of specification → Replace the brushes
as a set.
Mica undercut
0.7 mm (0.03 in)
Brush length wear limit
5.0 mm (0.20 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
4. Measure:
• Armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
Brush spring force
7.65–10.0 N
(780–1021 gf, 27.54–36.03 oz)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
5-41
ELECTRIC STARTER
NOTE:
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
starter motor rear covers.
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
• Brush seat “1”
EAS24810
INSTALLING THE STARTER MOTOR
1. Install:
• Starter motor “1”
• Starter motor bolts “2”
NOTE:
Align the tab “a” on the brush seat with the tab
“b” in the starter motor rear cover.
Starter motor bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
2. Connect:
• Starter motor lead “3”
2. Install:
• Armature “1”
3. Install:
• Starter motor yoke “1”
• O-rings “2”
• Starter motor rear cover “3”
• Starter motor assembling bolts
Starter motor assembling bolt
5 Nm (0.5 m·kg, 3.6 ft·lb)
5-42
CLUTCH
EAS25060
CLUTCH
Removing the clutch cover
Order
1
2
3
4
5
Job/Parts to remove
Engine oil
Q’ty
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Oil filler cap
Remarks
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
1
1
1
2
1
For installation, reverse the removal
procedure.
5-43
CLUTCH
Removing the pull lever shaft
Order
1
2
3
4
5
6
Job/Parts to remove
Circlip
Pull lever
Pull lever spring
Pull lever shaft
Oil seal
Bearing
Q’ty
2
1
1
1
1
2
Remarks
For installation, reverse the removal
procedure.
5-44
CLUTCH
Removing the clutch
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Job/Parts to remove
Compression spring
Pressure plate
Pull rod
Bearing
Friction plate 1
Clutch plate 1
Friction plate 2
Wire circlip
Clutch plate 2
Friction plate 3
Clutch damper spring
Clutch damper spring seat
Clutch boss nut
Washer
Clutch boss assembly
Thrust plate
Clutch housing
Bearing
Q’ty
6
1
1
1
1
7
7
1
1
1
1
1
1
1
1
1
1
1
5-45
Remarks
CLUTCH
Removing the clutch
Order
Job/Parts to remove
Q’ty
5-46
Remarks
For assembly, reverse the removal
procedure.
CLUTCH
4. Remove:
• Clutch plate 1 “1”
• Friction plate 2
EAS25080
REMOVING THE CLUTCH
1. Remove:
• Clutch cover “1”
• Gasket
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
5. Straighten the clutch boss nut rib “1”.
2.
•
•
•
•
Remove:
Compression spring bolts “1”
Compression springs
Pressure plate “2”
Pull rod “3”
6. Loosen:
• Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the universal clutch holder “3”, loosen the clutch boss
nut.
Universal clutch holder
90890-04086
YM-91042
3. Remove:
• Friction plate 1 “1”
7.
•
•
•
5-47
Remove:
Clutch boss nut
Washer
Clutch boss assembly
CLUTCH
1. Check:
• Friction plate
Damage/wear → Replace the friction
plates as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
• Thrust plate
8. Remove:
• Wire circlip “1”
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip “1” and disassemble the
built-in damper unless there is serious clutch
chattering.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.9 - 3.1 mm (0.114 - 0.122 in)
Limit
2.8 mm (0.110 in)
9. Remove:
• Clutch plate 2 “1”
• Friction plate 3 “2”
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• Clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge
“1”)
Out of specification → Replace the clutch
plates as a set.
10. Remove:
• Clutch damper spring “1”
• Clutch damper spring seat “2”
Clutch plate warpage limit
0.1 mm (0.0039 in)
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
5-48
CLUTCH
2. Check:
• Bearing
Damage/wear → Replace the bearing and
clutch housing.
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• Clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
Clutch spring free length
52.5 mm (2.07 in)
Limit
49.9 mm (1.96 in)
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
• Pressure plate “1”
Cracks/damage → Replace.
• Bearing “2”
Damage/wear → Replace.
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
erratic clutch operation.
EAS25220
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
5-49
CLUTCH
• Pull lever shaft pinion gear teeth “1”
• Pull rod teeth “2”
Damage/wear → Replace the pull rod and
pull lever shaft pinion gear as a set.
3. Install:
• Wire circlip “1”
2. Check:
• Pull rod bearing
Damage/wear → Replace.
4. Install:
• Clutch housing “1”
NOTE:
EAS25240
Align the projection of clutch housing “a” and
hollow of the oil pump drive gear “b”.
INSTALLING THE CLUTCH
1. Install:
• Clutch damper spring seat “1”
• Clutch damper spring “2”
5.
•
•
•
2. Install:
• Friction plate 3 “1”
• Clutch plate 2 “2”
NOTE:
Install:
Thrust plate
Clutch boss assembly “1”
Washer
• Clutch boss nut “2”
Lubricate the engine oil.
Clutch boss nut
95 Nm (9.5 m·kg, 69 ft·lb)
NOTE:
• Install the washer on the main axle with the
“OUT” mark facing away from the vehicle.
5-50
CLUTCH
• Lock the threads on the clutch boss nut by
staking them with a drift punch at the point
aligned with the groove in the axle.
• While holding the clutch boss assembly “1”
with the clutch holding tool “3”, tighten the
clutch boss nut.
Universal clutch holder
90890-04056
YM-91042
8. Install:
• Friction plate 1 “1”
NOTE:
Install the last friction plate shifting half phase.
9.
•
•
•
•
•
6. Lubricate
• Friction plates
• Clutch plates
(with the recommended lubricant)
Install:
Bearing
Pull rod “1”
Pressure plate “2”
Clutch springs
Clutch spring bolts “3”
Clutch spring bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Recommended lubricant
Engine oil
NOTE:
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
7. Install:
• Friction plate 2
• Clutch plate 1 “1”
5-51
CLUTCH
12. Tighten
• Clutch cover bolts “1”
10. Install:
• Pull lever
Clutch cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
NOTE:
Install the pull lever with the “O“ mark facing
toward lower side.
• Clutch cover bolt “2”
Clutch cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
NOTE:
Tighten the clutch cover bolts in a stages and
in a crisscross pattern.
11. Install:
• Clutch cover
• Clutch cover gasket
NOTE:
• Install the pull rod so that the teeth a face
towards the rear of the vehicle. Then, install
the clutch cover.
• Apply oil onto the bearing.
• Apply molybdenum disulfide grease onto the
pull rod.
• When installing the clutch cover, push the
pull lever and check that the punch mark “a”
on the pull lever aligns with the mark “b” on
the clutch cover. Make sure that the pull rod
teeth and pull lever shaft pinion gear are
engaged.
• Tighten the clutch cover bolts in stages and
in a crisscross pattern.
13. Adjust:
• Clutch cable free play
Refer to "ADJUSTING THE CLUTCH
CABLE FREE PLAY" on page 3-13.
5-52
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Clutch assembly
Shift arm and shift rod
Q’ty
Circlip
Washer
Shift shaft
Collar
Shift shaft spring
Washer
Stopper screw
Stopper lever
Washer
Oil seal
Bearing
Bearing
Stopper lever spring
1
1
1
1
1
1
1
1
1
1
1
1
1
5-53
Remarks
Refer to "CLUTCH" on page 5-43.
Refer to "ENGINE REMOVAL" on
page 5-1.
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order
Job/Parts to remove
Q’ty
5-54
Remarks
For installation, reverse the removal
procedure.
SHIFT SHAFT
ET2D1011
REMOVING THE SHIFT SHAFT
1. Remove:
• Clutch assembly
Refetr to "CLUTCH" on page 5-43
2. Remove:
• Shift arm
• Shift rod
Refetr to "ENGINE REMOVAL" on page 51
3. Remove:
• Circlip “1”
• Washer “2”
(left side of the engine)
4.
•
•
•
•
EAS25420
CHECKING THE SHIFT SHAFT
1. Check:
• Shift shaft “1”
Bends/damage/wear → Replace.
• Shift shaft spring “2”
• Collar “3”
Damage/wear → Replace.
Remove
Shift shaft “1”
Shift shaft spring “2”
Collar
Washer
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
• Stopper lever “1”
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
5.
•
•
•
•
Remove:
Stopper lever spring “1”
Stopper screw “2”
Stopper lever “3”
Washer
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
• Washer
• Stopper lever “1”
• Stopper screw “2”
Stopper screw
22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE®
5-55
SHIFT SHAFT
• Stopper lever spring “3”
2.
•
•
•
•
• Shift rod
• Shift arm
Refer to "ENGINE REMOVAL" on page 51.
5. Install:
• Clutch assembly
Refer to "CLUTCH" on page 5-43.
Install:
Washer
Collar
Shift shaft spring “1”
Shift shaft “2”
NOTE:
• Mesh the stopper lever with the shift drum
segment assembly.
• Lubricate the oil seal lips with lithium soap
base grease.
• Install the end of the shift shaft spring onto
the shift shaft spring stopper.
3. Install:
• Washer “1”
• Circlip “2”
4. Install:
5-56
OIL PUMP
EAS24920
OIL PUMP
Removing the oil pan and oil pump
Order
Job/Parts to remove
Engine oil
Q’ty
Remarks
1
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
Refer to "ENGINE REMOVAL" on
page 5-1.
Refer to "ENGINE REMOVAL" on
page 5-1.
Refer to "ENGINE REMOVAL" on
page 5-1.
Refer to "ENGINE REMOVAL" on
page 5-1.
Refer to "CLUTCH" on page 5-43.
Refer to "OIL COOLER" on page 64.
Refer to "OIL COOLER" on page 64.
Disconnect.
EXUP cables
O2 sensor
Muffler
Exhaust pipe assembly
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
1
Oil level switch lead coupler
5-57
OIL PUMP
Removing the oil pan and oil pump
Order
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Job/Parts to remove
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer
Oil pipe
Oil delivery pipe
Relief valve assembly
Oil/water pump assembly drive chain
guide
Collar
Oil/water pump assembly drive
sprocket
Washer
Oil/water pump assembly drive chain
Dowel pin
5-58
Q’ty
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
Remarks
OIL PUMP
Removing the oil pan and oil pump
Order
18
Job/Parts to remove
Oil/water pump assembly
Q’ty
1
Remarks
For assembly, reverse the removal
procedure.
5-59
OIL PUMP
Disassembling the oil pump
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Oil/water pump driven sprocket
Collar
Oil pump housing
Bearing
Pin
Oil pump outer roter
Oil pump inner roter
Pin
Q’ty
1
1
1
1
2
1
1
1
Remarks
For assembly, reverse the disassembly procedure.
5-60
OIL PUMP
EAS24930
EAS24960
REMOVING THE OIL PAN
1. Remove:
• Oil level switch “1”
• Oil pan “2”
• Oil pan gasket
• Dowel pins
CHECKING THE OIL PUMP
1. Check:
• Oil pump driven gear “1”
• Oil pump rotor housing “2”
• Oil pump cover
Cracks/damage/wear → Replace the
defective part(s).
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
Inner-rotor-to-outer-roter-tipclearance
0.01–0.10 mm
(0.0004–0.0039 in)
Limit
0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housingclearance
0.09–0.15 mm
(0.0035–0.0059 in)
Limit
0.22 mm (0.0087 in)
EAS25620
CHECKING THE SPROCKET AND CHAIN
1. Check:
• Oil/water pump assembly drive sprocket “1”
Cracks/damage/wear → Replace the
defective part(-s).
2. Check:
• Oil/water pump assembly drive chain “1”
Damage/stiffness → Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
1. Oil pump inner rotor
2. Oil pump outer rotor
3. Oil pump housing
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
5-61
OIL PUMP
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
• Relief valve body “1”
• Relief valve “2”
• Spring “3”
• O-ring “4”
Damage/wear → Replace the defective
part(s).
EAS25600
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:
• Oil nozzle “1”
Damage/wear → Replace the oil nozzles.
• O-ring “2”
Damage/wear → Replace.
• Oil nozzle passage
Obstruction → Blow out with compressed
air.
EAS24980
CHECKING THE OIL DELIVERY PIPES
1. Check:
• Oil delivery pipe “1”
• Oil pipe “2”
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2.
•
•
•
•
EAS24990
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer “1”
Damage → Replace.
Contaminants → Clean with solvent.
5-62
Install:
Pin “1”
Inner rotor “2”
Outer rotor “3”
Oil pump housing “4”
OIL PUMP
NOTE:
When installing the inner rotor, align the pin “1”
in the oil pump shaft with the groove in the
inner rotor “2”.
2.
•
•
•
•
3. Install:
• Oil/water pump driven sprocket “1”
Install:
Washer
Oil/water pump assembly drive chain “1”
Oil/water pump assembly drive sprocket “2”
Collar
NOTE:
Install the oil/water pump assembly drive chain
“1” onto the oil/water pump assembly drive
sprocket “2”.
Oil/water pump driven sprocket
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
EC2D1008
CAUTION:
5VY mark of the oil/water pump driven gear is
installed at oil pump side.
After installing the oil/water pump assembly drive chain and drive sprocket, make
sure the oil/water pump turns smoothly.
4. Check:
• Oil pump operation
Refer to "CHECKING THE OIL PUMP" on
page 5-61.
3. Install:
• Oil/water pump assembly drive chain guide
“1”
NOTE:
EAS25030
Oil/water pump assembly drive
chain guide bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
INSTALLING THE OIL/WATER PUMP
ASSEMBLY
1. Install:
•
•
•
•
Oil ring
Oil/water pump assembly “1”
Dowel pin
Bolts “2”
NOTE:
“UP” mark of the oil/water pump assembly
drive chain guide is upward.
Oil/water pump assembly bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
5-63
OIL PUMP
EAS25050
INSTALLING THE OIL PAN
1. Install:
• Dowel pins
4. Install:
• Oil delivery pipe “1”
Oil delivery pipe bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
• Gasket
• Oil pan “1”
Oil pan bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
• Oil level switch “2”
Oil level switch bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
• Engine oil drain bolt “3”
Engine oil drain bolt
43 Nm (4.3 m·kg, 31 ft·lb)
5. Install:
• Relief valve “1”
EWA12820
WARNING
• O-ring
• Oil strainer “2”
Always use new copper washers.
NOTE:
Oil strainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
• Tighten the oil pan bolts in stages and in a
crisscross pattern.
• Lubricate the oil level switch O-ring with
engine oil.
• O-ring
• Oil pipe “3”
• O-ring
• Drain pipe “4”
• O-ring
5-64
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
Order
Job/Parts to remove
Air filter case
Q’ty
Throttle body assembly
Engine
Cylinder head
Generator
Starter clutch
Shift shaft
Crankshaft position sensor
Clutch
5-65
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "THROTTLE BODIES" on
page 7-4.
Refer to "ENGINE REMOVAL" on
page 5-1.
Refer to "CYLINDER HEAD" on
page 5-18.
Refer to "GENERATOR" on page 530.
Refer to "STARTER CLUTCH" on
page 5-34.
Refer to "SHIFT SHAFT" on page 553.
Refer to "CRANKSHAFT POSITION
SENSOR" on page 5-37.
Refer to "CLUTCH" on page 5-43.
CRANKCASE
Separating the crankcase
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Oil pump
Starter motor
Q’ty
Timing chain
Timing chain guide (intake side)
Pin
Timing chain guide (exhaust side)
Left side cover
O-ring
Lower crankcase
Dowel pin
Damper
Remarks
Refer to "OIL PUMP" on page 5-57.
Refer to "ELECTRIC STARTER" on
page 5-39.
1
1
2
1
1
1
1
3
1
For assembly, reverse the removal
procedure.
5-66
CRANKCASE
EAS25550
NOTE:
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
• Crankcase bolts
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
NOTE:
EAS25580
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed
air.
M9 x 105 mm (4.1 in) bolts: “1” – “10”
M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 x 60 mm (2.4 in) bolts: “12”, “16”
M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 x 65 mm (2.5 in) bolts: “17”, “18”
M6 x 60 mm (2.4 in) bolt and washer: “22”
M6 x 60 mm (2.4 in) bolts: “24”, “25”
M6 x 50 mm (2.0 in) bolts: “20”, “26”
M8 x 50 mm (2.0 in) bolts: “13” – “15”
ET2D1014
CHECKING THE BEARING AND OIL SEALS
1. Check:
• Bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• Oil seals
Damage/wear → Replace.
EAS25650
ASSEMBLING THE CRANKCASE
1. Lubricate:
• Crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
• Sealant
3. Remove:
• Lower crankcase
ECA13900
Yamaha bond No. 1215
(Three Bond No.1215®)
90890-85505
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
4.
•
5.
•
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2–3 mm
(0.08–0.12 in) of the crankshaft journal bearings.
Remove:
Dowel pins
Remove:
Crankshaft journal lower bearing
(from the lower crankcase)
5-67
CRANKCASE
Crankcase bolt
Bolt “1”–“10”
1st: 20 Nm (2.0 m·kg, 14 ft·lb)
2nd*: 20 Nm (2.0 m·kg, 14 ft·lb)
3rd: +60°
Bolt “11”–“16”
24 Nm (2.4 m·kg, 17 ft·lb)
Bolt “17”–“26”
12 Nm (1.2 m·kg, 8.7 ft·lb)
*Following the tightening order, loosen the
bolt one by one and then retighten it to the
specific torque.
3. Install:
• Dowel pin
4. Set the shift drum assembly and transmission gears in the neutral position.
5. Install:
• Lower crankcase “1”
(onto the upper crankcase “2”)
ECA13980
CAUTION:
Before tightening the crankcase bolts,
make sure the transmission gears shift correctly when the shift drum assembly is
turned by hand.
6. Install:
• Crankcase bolts
NOTE:
•
•
•
•
Lubricate the bolt threads with engine oil.
Install a washer on bolts “1” – “10” and “22”.
Seal bolt “18”
Tighten the bolts in the tightening sequence
cast on the crankcase.
M9 x 105 mm (4.1 in) bolts: “1” – “10”
M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 x 60 mm (2.4 in) bolts: “12”, “16”
M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 x 65 mm (2.5 in) bolts: “17”, “18”
M6 x 60 mm (2.4 in) bolt and washer: “22”
M6 x 60 mm (2.4 in) bolts: “24”, “25”
M6 x 50 mm (2.0 in) bolts: “20”, “26”
M8 x 50 mm (2.0 in) bolts: “13” – “15”
5-68
CRANKSHAFT
EAS25950
CRANKSHAFT
Removing the connecting rods and pistons
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Parts to remove
Lower crankcase
Q’ty
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring
Cylinder
Cylinder gasket
Remarks
Refer to "CRANKCASE" on page 565.
4
4
4
8
4
4
4
4
4
4
1
1
For installation, reverse the removal
procedure.
5-69
CRANKSHAFT
Removing the crankshaft
Order
Job/Parts to remove
Crankcase
Q’ty
Separate.
Refer to "CRANKCASE" on page 565.
Refer to "REMOVING THE CONNECTING RODS AND PISTONS"
on page 5-71.
Connecting rod and connecting rod
caps
1
2
3
4
5
6
7
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Washer
Crankshaft drive gear
Pin
Pickup rotor
Remarks
1
5
5
1
1
1
1
For assembly, reverse the disassembly procedure.
5-70
CRANKSHAFT
EAS26030
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
• Connecting rod cap “1”
• Big end bearings
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
NOTE:
• Idetify the position of each big end bearing
so that it can be reinstalled in its original
place.
• After removing the connecting rods and connecting rod caps, care should be taken not to
damage the mating surfaces of the connecting rods and connecting rod caps.
2.
•
•
•
3.
•
•
•
4.
•
•
•
Remove:
Cylinder
Cylinder gasket
Cylinder stud bolts
Remove:
Piston pin clips “1”
Piston pin “2”
Piston “3”
Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
EC2D1006
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put identification marks on the piston crown.
• Before removing the piston pin, deburr the
piston pin clip groove and the piston pin bore
area. If both areas are debarred and the piston pin is still difficult to remove, remove it
with the piston pin puller set “4”.
EAS25980
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
• Crankshaft assembly
• Crankshaft journal upper bearings
(from the upper crankcase)
Refer to "CRANKSHAFT" on page 5-69.
5-71
CRANKSHAFT
4 mm (0.16 in) “a” from the bottom edge of
the piston
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
Piston size “P”
76.975 - 76.990 mm
(3.0305 - 3.0311 in)
EAS24390
CHECKING THE CYLINDER AND PISTON
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
Cylinder bore “C”
Wear limit
Taper limit “T”
Out of round “R”
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
77.00 – 77.01 mm
(3.0315 – 3.0319 in)
77.06 mm (3.03 in)
0.005 mm (0.0002 in)
0.005 mm (0.0002 in)
“C”
=
maximum of D1 – D6
“T”
=
maximum of D1 or D2 – maximum
of D5 or D6
“R”
=
maximum of D1 D3 or D5 –
minimum of D2 D4 or D6
Piston-to-cylinder clearance
0.010–0.035 mm
(0.0004–0.0014 in)
Limit: 0.120 mm (0.0047 in)
f.
If out of specification, replace the cylinder,
and the piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
b. If out of specification, replace the cylinder,
and the pistons and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
5-72
CRANKSHAFT
Piston ring side clearance
Top ring
0.030–0.065 mm
(0.0012–0.0026 in)
Limit
0.115 mm (0.0045 in)
2nd ring
0.020–0.055 mm
(0.0008–0.0022 in)
Limit
0.115 mm (0.0045 in)
Piston ring end gap
Top ring
0.15–0.25 mm
(0.0059–0.0098 in)
Limit
0.50 mm (0.0197 in)
2nd ring
0.30–0.45 mm
(0.0118–0.0177 in)
Limit
0.80 mm (0.0315 in)
Oil ring
0.10–0.40 mm
(0.0039–0.0157 in)
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to all of the
piston pins.
1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• Piston pin outside diameter “a”
Out of specification → Replace the piston
pin.
2. Install:
• Piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
Piston pin bore outside diameter
16.991–17.000 mm
(0.6689–0.6693 in)
Limit
16.971 mm (0.6682 in)
5 mm (0.20 in) “a”
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification → Replace the piston.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
5-73
CRANKSHAFT
end bearings must be installed in their original positions.
Piston pin bore inside diameter
17.002–17.013 mm
(0.6694–0.6698 in)
Limit
17.043 mm (0.6710 in)
a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rods
halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower bearing into the connecting rod cap.
NOTE:
Align the projections “a” on the big end bearings with the notches “b” in the connecting rod
and connecting rod cap.
4. Calculate:
• Piston-pin-to-position clearance
Out of specification → Replace the position
pin and piston as a set.
Piston-pin-to-pistonclearance =
Piston pin bore size Piston pin outside diameter
Piston-pin-to-piston clearance
0.002–0.022 mm
(0.0001–0.009 in)
Limit
0.072 mm (0.0028 in)
c. Put a piece of Pleastigauge® “1” on the
crankshaft pin.
ET2D1017
CHECKING THE BIG END BEARINGS
1. Measure:
• Crankshaft-pin-to-big-end-bearing crearance
Out of specification → Replace the big end
bearings.
d. Assemble the connecting rod halves.
Crankshaft-pin-to-big-end-bearing clearance
0.034–0.058 mm
(0.0013–0.0023 in)
Limit
0.09 mm (0.0035 in)
NOTE:
• Do not move the connecting rod or crankshaft until the clearance measurement has
been completed.
• Lubricate the bolt threads with molybdenum
disulfide grease.
• Make sure that the “Y” mark “c” on the connecting rod faces towards the left side of the
crankshaft.
• Make sure that the characters “d” on both the
connecting rod and connecting rod cap are
aligned.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to all of the
connecting rods.
ECA14900
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the correct
creankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big
5-74
CRANKSHAFT
j.
Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condition.
k. Tighten the connecting rod bolts.
e. Tighten the connecting rod bolts.
Connecting rod bolt
20 Nm (2.0 m·kg, 14 ft·lb)
+150°
NOTE:
Install by carrying out the following procedures
in order to assemble in the most suitable condition.
EC2D1014
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Connecting rod bolt
29.4 Nm (3.0 m·kg, 21 ft·lb)
l. Clean the connecting rod bolts.
m. Tighten the connecting rod bolts.
n. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod
“3”.
NOTE:
• First, tighten the bolts to 15 Nm (1.5 m·kg, 11
ft·lb).
• Retighten the bolts to 29.4 Nm (3.0 m·kg, 21
ft·lb).
f.
g.
h.
i.
•
•
Replace the connecting rod bolts with new
ones.
Clean the connecting rod bolts.
After installing big end bearing, assemble
the connecting rod and connecting rod cap
once using a single unit of the connecting
rod.
Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching
the surface.
Side machined face “a”
Thrusting faces (4 places at front and rear)
“b”
o. Tighten the bolt further to reach the specified angle (150° ).
NOTE:
To install the big end bearing, care should be
taken not to install it at an angle and the position should not be out of alignment.
5-75
CRANKSHAFT
p. After the installation, check that the section
shown “a” is flush with each other by touching the surface.
• Side machined face “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• Big end bearings (P1 – P4)
NOTE:
EWA13120
• The numbers “A” stamped into the crankshaft wed and the numbers “1” on the connecting rods are used to determine the
replacement big end bearings sizes.
• “P1” - ”P4” refer to the bearings shown in the
crankshaft illustration.
WARNING
• When the bolt is tightened more than the
specified angle, do not loosen the bolt
and then retighten it.
Replace the bolt with a new one and perform the procedure again.
• If they are not flush with each other,
remove the connecting rod bolt and big
end bearing and restart from step “e”. In
this case, make sure to replace the connecting rod bolt.
For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are “5”
and “2” respectively, then the bearing size
for “P1” is:
“P1” (connecting rod) – “P1”
EC2D1015
(crankshaft) =
5 – 2 = 3 (brown)
CAUTION:
• Do not use a torque wrench to tighten the
nut to the specified angle.
• Tighten the bolt until it is at the specified
angles.
BIG END BEARING COLOR CODE
1
Blue
2
Black
3
Brown
4
Green
q. Remove the connecting rod and big end
bearings.
Refer to "REMOVING THE CONNECTING
RODS AND PISTONS" on page 5-71.
r. Measure the compressed Plastigauge®
width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings.
5-76
CRANKSHAFT
(with the recommended lubricant)
EAS26190
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:
• Top ring “1”
• 2nd ring “2”
• Upper oil ring rail “3”
• Oil ring expander “4”
• Lower oil ring rail “5”
Recommended lubricant
Engine oil
4. Offset:
• Piston ring end gaps
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers “a” face up.
a.
b.
c.
d.
e.
5.
•
•
•
2. Install:
• Piston “1”
(onto the respective connecting rod “2”)
• Piston pin “3”
Top ring
Lower oil ring rail
Upper oil ring rail
2nd ring
Oil ring expander
Lubricate:
Crankshaft pins
Big end bearings
Connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
• Piston pin clip “4”
6. Check:
• Cylinder stud bolts “1”
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark “a” on the connecting rod faces left when the arrow mark
“b” on the piston is pointing up as shown.
• Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3.
•
•
•
Cylinder stud bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
7. Install:
Lubricate:
Piston
Piston rings
Cylinder
• Cylinder gasket “2”
5-77
CRANKSHAFT
NOTE:
• Install by carrying out the following procedures in order to assemble in the most suitable condition.
• First tighten the bolts to 15 Nm (1.5 m·kg, 11
ft·lb)
• Retighten the bolts to 29.4 Nm (3.0 m·kg, 21
ft·lb)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Replace the connecting rod bolts with new
ones.
b. Clean the connecting rod bolts.
c. After installing the big end bearing, assemble the connecting rod and connecting rod
cap once using a single unit of the connecting rod.
d. Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching
the surface.
8. Install:
• Big end bearings
(onto the connecting rods and connecting
rod caps)
NOTE:
• Align the projections “a” on the big end bearings with the notches “b” in the connecting
rods and connecting rod caps.
• Be sure to reinstall each big end bearing in
its original place.
• Make sure that the characters “c” a on both
the connecting rod and connecting rod cap
are aligned.
NOTE:
To install the big end bearing, care should be
taken not to install it at an angle and the position should not be out of alignment.
a. Side machined face
b. Thrusting faces (4 places at front and rear)
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condition.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10. Install:
• Piston assemblies “1”
(into the cylinder)
9. Tighten:
• Connecting rod bolts
Connecting rod bolt
29.4 Nm (3.0 m·kg, 21 ft·lb)
NOTE:
While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
5-78
CRANKSHAFT
ECA14980
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
a. Clean the connecting rod bolts.
b. Tighten the connecting rod bolts.
c. Put a mark “1” on the connecting rod bolt
“2” and the connecting rod cap “3”.
11. Install:
• Cylinder assembly “1”
• Connecting rod caps “2”
NOTE:
• Make sure that the “Y” marks “a” on the connecting rods face towards the left side of the
crankshaft.
• Make sure that the characters on both the
connecting rod and connecting rod cap are
aligned.
d. Tighten the bolt further to reach the specified angle (150°).
e. After the installation, check that the section
shown “a” is flush with each other by touching the surface.
a. Side machined face
12. Tighten:
• Connecting rod bolts
EWA13990
WARNING
• When the bolt is tightened more than the
specified angle, do not loosen the bolt
and then retighten it. Replace the bolt
with a new one and perform the procedure again.
Connecting rod bolt
20 Nm (2.0 m·kg, 14 ft·lb)+150°
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5-79
CRANKSHAFT
• If they are not flush with each other,
remove the connecting rod bolt and big
end bearing and restart from step “9”. In
this case, make sure to replace the connecting rod bolt.
ECA14680
CAUTION:
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is at the specified
angles.
ET2D1020
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
• Crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification → Replace the crankshaft journal bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26070
CHECKING THE CRANKSHAFT
1. Measure:
• Crankshaft runout
Out of specification → Replace the crankshaft.
Crankshaft-journal-to-crankshaft-journal-bearing clearance
0.014–0.037 mm
(0.0006–0.0015 in)
Limit
0.10 mm (0.0039 in)
Crankshaft runout
Less than 0.03 mm (0.0012 in)
EC2D1008
CAUTION:
2.
•
•
•
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
Bearing surfaces
Scratches/wear → Replace the crankshaft.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the crankshaft journal bearings,
cranshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on
a bench.
c. Install the crankshaft journal upper bearings “1” and the crankshaft into the upper
crankcase.
ET2D1019
CHECKING THE CRANKSHAFT DRIVE
SPROCKET
1. Check:
• Crankshaft drive sprocket “1”
Cracks/damage/wear → Replace the
defective part(s).
NOTE:
Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the
upper crankcase.
5-80
CRANKSHAFT
Crankcase bolt
Bolt “1”–“10”
1st: 20 Nm (2.0 m·kg, 14 ft·lb)
2nd: 20 Nm (2.0 m·kg, 14 ft·lb)
3rd: +60°
Bolt “11”–“16”
24 Nm (2.4m·kg, 17 ft·lb)
Bolt “17”–“26”
12 Nm (1.2m·kg, 8.7 ft·lb)
M9 x 105 mm (4.1 in) bolts: “1”–“10”
M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 x 60 mm (2.4 in) bolts: “12”, “16”
M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 x 65 mm (2.5 in) bolts: “17”, “18”
M6 x 60 mm (2.4 in) bolt and washer: “22”
M6 x 60 mm (2.4 in) bolts: “24”, “25”
M6 x 50 mm (2.0 in) bolts: “20”, “26”
M8 x 50 mm (2.0 in) bolts: “13”–“15”
* Following the tightening order, loosen the
bolt one by one and then retighten it to the
specific torque.
d. Put a piece of Plastigauge® “2” on each
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
NOTE:
Lubricate the crankcase bolt threads with
engine oil.
Refer to "CRANKCASE" on page 5-65.
e. Install the crankshaft journal lower bearings “1” into the lower crankcase and
assemble the crankcase halves.
NOTE:
• Align the projections “a” of the crankshaft
journal lower bearings with the notches “b” in
the lower crankcase.
• Do not move the crankshaft until the clearance measurement has been completed.
f.
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Meaure the compressed Plastigauge®
width “c” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification, select replacement crankshaft journal
bearings.
Tighten the bolts to specification in the
tightening sequence cast on the crankcase.
5-81
CRANKSHAFT
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• Crankshaft journal bearings (J1–J5)
NOTE:
• The numbers “A” stamped into the crankshaft web and the numbers “1” stamped into
the lower crankcase are used to determine
the replacement crankshaft journal bearing
sizes.
• “J1–J5” refer to the bearings shown in the
crankshaft illustration.
• If “J1–J5” are the same, use the same size
for all of the bearings.
• If the size is the same for all “J1 to J5” one
digit for that size is indicated. (Crankcase
side only)
EAS26200
INSTALLING THE CRANKSHAFT
1. Install:
• Crankshaft journal upper bearings “1”
(into the upper crankcase)
For example, if the crankcase “J1” and
crankshaft web “J1” numbers are “6” and
“2” respectively, then the bearing size for
“J1” is:
“J1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
0
White
1
Blue
2
Black
3
Brown
4
Green
2. Lubricate:
• Crankshaft journal upper bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-82
CRANKSHAFT
NOTE:
• Align the projections “a” on the crankshaft
journal upper bearings with the notches “b” in
the upper crankcase.
• Be sure to install each crankshaft journal
upper bearing in its original place.
3.
•
4.
•
5.
•
•
•
Install:
Crankshaft
Install:
Crankcase (lower)
Refer to "CRANKCASE" on page 5-65.
Install:
Pin
Pickup rotor “1”
Drive sprocket “2”
Drive sprocket bolt
60 Nm (6.0 m·kg, 43 ft·lb)
5-83
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Crankcase lower
Q’ty
Drive axle assembly
Circlip
Oil seal
Bearing
Washer
Shift fork guide bar retainer
Spring
Shift fork guide bar
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”
Main axle retainer
1
1
1
1
1
2
2
2
1
1
1
1
1
5-84
Remarks
Separate.
Refer to "CRANKCASE" on page 565.
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order
14
15
16
17
Job/Parts to remove
Main axle assembly
Oil pipe
O-rng
Oil baffle plate
Q’ty
1
1
2
1
Remarks
For installation, reverse the removal
procedure.
5-85
TRANSMISSION
Disassembling the main axle assenbly
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Parts to remove
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle
Bearing housing
Bearing
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
For assembly, reverse the disassembly procedure.
5-86
TRANSMISSION
Disassembling the drive axle assenbly
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Job/Parts to remove
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip
6th wheel gear
Circlip
Washer
Collar
2nd wheel gear
Collar
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-87
Remarks
TRANSMISSION
Disassembling the drive axle assenbly
Order
21
22
23
Job/Parts to remove
Oil seal
Bearing
Drive axle
Q’ty
1
1
1
Remarks
For assembly, reverse the disassembly procedure.
5-88
TRANSMISSION
EAS26250
REMOVING THE TRANSMISSION
1. Remove:
• Drive axle asseembly “1”
• Shift drum retainers “2”
• Shift fork guide bars
• Shift fork “L” and “R”
• Shift drum assembly
• Shift fork “C”
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to all of the
shift forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace
the shift fork.
2. Remove:
• Bearing housing “1”
• Main axle assembly “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert two bolts “3” of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
b. Tighten the bolts until they contact the
crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
EWA12840
WARNING
Do not attempt to straighten a bent shift
fork guide bar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• Oil pipe “1”
• Bearing “2”
5-89
TRANSMISSION
Out of specification → Replace the main
axle.
Main axle runout limit
0.08 mm (0.0032 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift
forks and shift fork guide bar as a set.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
EAS26270
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• Shift drum grooves “1”
Damage/scratches/wear → Replace the
shift drum assembly.
• Shift drum segment “2”
Damage/wear → Replace the shift drum
assembly.
• Shift drum bearing “3”
Damage/pitting → Replace the shift drum
assembly.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
EAS26280
CHECKING THE TRANSMISSION
1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”)
5-90
TRANSMISSION
EAS26350
INSTALLING THE TRANSMISSION
1. Install:
• Bearing “1”
NOTE:
Make the seal side of bearing face to the outside and install it close to the right end face of
the crankcase.
• Oil pipe “2”
3.
•
•
•
•
Install:
Shift fork “L” “1” and “R” “2”
Drive axle assembly “3”
Shift fork guide bar
Shift fork guide bar retainer “4”
Shift fork guide bar retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
NOTE:
• Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove
in the 5th wheel gear on the drive axle.
• Make sure that the drive axle bearing circlip
“a” is inserted into the grooves in the upper
crankcase.
2. Install:
• Main axle assembly “1”
• Bearing housing “2”
Bearing housing bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
•
•
•
•
Shift fork “C”
Shift drum assembly
Shift fork guide bar
Shift fork guide bar retainer
Shift fork guide bar retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
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”, “L”.
• Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
• Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
5-91
TRANSMISSION
4. Check:
• Transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
5-92
RADIATOR
EAS26380
RADIATOR
Removing the radiator
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Air filter case
Coolant
1
2
3
4
5
6
7
8
9
Radiator side covers
Coolant reservoir hose
Radiator front cover
Radiator
Radiator fan motor
Radiator inlet hose
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
2
1
1
1
2
1
1
1
1
6-1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS" on
page 4-1.
Drain.
Refer to "CHANGING THE COOLANT" on page 3-18.
RADIATOR
Removing the radiator
Order
10
11
Job/Parts to remove
Water pump inlet pipe
O-ring
Q’ty
1
1
Remarks
For installation, reverse the removal
procedure.
6-2
6
RADIATOR
EAS26390
CHECKING THE RADIATOR
1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to "RADIATOR" on page 6-1.
EAS26400
INSTALLING THE RADIATOR
1. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to "CHANGING THE COOLANT" on
page 3-18.
2. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-3.
2. Check:
• Radiator hoses
• Radiator pipes
Cracks/damage → Replace.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
93.3 - 122.7 kPa
(0.93 - 1.23 kg/cm2, 0.9 - 1.2
bar, 13.5 - 17.8 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator cap tester adapter “2” to the radiator
cap “3”.
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester
adapter
YU-33984
6-3
OIL COOLER
EAS26410
OIL COOLER
Removing the oil cooler
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Parts to remove
Engine oil
Q’ty
Remarks
Drain.
Refer to "CHANGING THE ENGINE
OIL" on page 3-11.
Oil cooler inlet hose
Oil cooler bolt
Washer
Oil cooler
O-ring
Water pump outlet pipe
O-ring
Water jacket joint inlet hose
O-ring
Water jacket joint
Stay
O-ring
1
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the removal
procedure.
6-4
OIL COOLER
3. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to "CHANGING THE COOLANT" on
page 3-18.
• Crankcase
(with the specified amount of the recommended engine oil)
Refer to "CHANGING THE ENGINE OIL"
on page 3-11.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
5. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-3.
EAS26420
CHECKING THE OIL COOLER
1. Check:
• Oil cooler
Cracks/damage → Replace.
2. Check:
• Oil cooler inlet hose
• Oil cooler outlet hose
Cracks/damage/wear → Replace.
EAS26430
INSTALLING THE OIL COOLER
1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• O-ring
• Oil cooler “1”
• Washer “2”
• Oil cooler bolt “3”
Oil cooler bolt
63 Nm (6.3 m·kg, 46 ft·lb)
NOTE:
• Before installing the oil cooler, lubricate the
oil cooler bolt and O-ring with a thin coat of
engine oil.
• Make sure the O-ring is positioned properly.
• Align the projection “a” on the oil cooler with
the slot “b” in the crankcase.
6-5
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat assembly
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Air filter case
Coolant
1
2
3
4
Thermostat assembly outlet hose
Thermostat assembly
Thermostat assembly inlet hose
Band
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS" on
page 4-1.
Drain.
Refer to "CHANGING THE COOLANT" on page 3-18.
1
1
1
2
For installation, reverse the removal
procedure.
6-6
THERMOSTAT
Disassembling the thermostat assembly
Order
1
2
3
4
Job/Parts to remove
Thermostat housing cover
Thermostat
Thermostat housing
O-ring
Q’ty
1
1
1
1
Remarks
For assembly, reverse the disassembly procedure.
6-7
THERMOSTAT
• Thermostat housing “2”
Cracks/damage → Replace.
EAS26450
CHECKING THE THERMOSTAT
1. Check:
• Thermostat
Does not open at 71 – 85°C (160 – 185°F)
→ Replace.
EAS26460
ASSEMBLING THE THERMOSTAT ASSEMBLY
1. Install:
• Thermostat housing “1”
• Thermostat “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “3” in a container
“4” filled with water.
b. Slowly heat the water “2”.
c. Place a thermometer “1” in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
• O-ring “3”
• Thermostat housing cover “4”
Thermostat housing cover nut
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
Install the thermostat with its breather hole “a”
facing up.
EAS26480
INSTALLING THE THERMOSTAT ASSEMBLY
1. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to "CHANGING THE COOLANT" on
page 3-18.
2. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• Radiator cap opening pressure
A. Fully closed
B. Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Thermostat housing cover “1”
6-8
THERMOSTAT
Below the specified pressure → Replace
the radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-3.
6-9
WATER PUMP
EAS26500
WATER PUMP
Removing the impeller shaft
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Oil/water pump assembly
Oil pump roter
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)
Water pump seal
Oil seal
Bearing
O-ring
Q’ty
Remarks
Refer to "OIL PUMP" on page 5-57.
Refer to "OIL PUMP" on page 5-57.
1
1
2
1
1
1
1
1
For installation, reverse the removal
procedure.
6-10
WATER PUMP
EAS26520
DISASSEMBLING THE WATER PUMP
1. Remove:
• Water pump seal “1”
• Water pump housing “2”
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
EAS26540
2.
•
•
•
CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover “1”
• Water pump housing “2”
• Impeller “3”
• Rubber damper “4”
• Rubber damper holder “5”
• Water pump seals
• Oil seal
Cracks/damage/wear → Replace.
Remove:
Oil seal “1”
Bearing “2”
Water pump housing “3”
NOTE:
Tap out the bearing and oil seal from the outside of the water pump housing.
2. Check:
• Bearing
Rough movement → Replace.
3. Check:
• Water pump outlet pipe
Cracks/damage/wear → Replace.
3. Remove:
• Rubber damper holder “1”
• Rubber damper “2”
(from the impeller, with a thin, flat-head
screwdriver)
EAS26560
ASSEMBLING THE WATER PUMP
1. Install:
• Oil seal “1”
(into the water pump housing “2”)
NOTE:
Do not scratch the impeller shaft.
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its out surface.
• Install the oil seal with a socket that matches
its outside diameter.
6-11
WATER PUMP
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
2. Install:
• Water pump seal “1”
ECA14080
CAUTION:
Never lubricate the water pump seal surface with oil or grease.
4. Measure:
• Impeller shaft tilt
Out of specification → Repeat steps (3)
and (4).
NOTE:
• Install the water pump seal with the special
tools.
• Before installing the water pump seal, apply
Yamaha bond No.1215 (Three Bond
No.1215® ) “2” to the water pump housing
“3”.
ECA14090
CAUTION:
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
Mechanical seal installer “4”
90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing
driver “5”
90890-04058
Bearing driver 40 mm
YM-04058
Yamaha bond No. 1215 (Three
Bond No.1215®)
90890-85505
1. Straightedge
2. Impeller
A. Push down.
3. Install:
• Rubber damper holder “1”
• Rubber damper “2”
6-12
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel hose
Fuel sender coupler
Fuel pump coupler
Fuel tank drain hose
Fuel tank breather hose
Fuel tank
Fuel tank cover
Fuel pump
1
1
1
1
1
1
1
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
7-1
FUEL TANK
EAS26630
ECA14720
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose connector cover
• Fuel hose
• Fuel sender coupler
• Fuel pump coupler
• Fuel tank breather hose
• Fuel tank drain hose
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EAS26670
CHECKING THE FUEL PUMP BODY
1. Check:
• Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump
assembly.
2. Check:
• Diaphragms and gaskets
Turn/fatigue/cracks → Replace fuel pump
assembly.
3. Check:
• Valves
Cracks/damage → Replace fuel pump
assembly.
EC2D1009
CAUTION:
• Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank be careful when removing
the fuel hoses, since there may be fuel
remaining in it.
NOTE:
• To remove the fuel hose from the fuel injection pipe, slide the cover “a” on the end of the
hose in the direction of the arrow shown and
then remove the hose.
• Before removing the hoses, place a few rags
in the area under where it will be removed.
EAS26690
CHECKING THE FUEL PUMP OPERATION
1. Check:
• Fuel pump operation
Refer to "CHECKING THE FUEL PRESSURE" on page 7-8.
EAS26710
INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump
Fuel pump bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
NOTE:
3. Remove:
• Fuel tank
• Do not damage the installation surface of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump as shown in the illustration.
• Align the projection “a” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in stages in a
crisscross pattern and to the specified
torque.
NOTE:
Do not set the fuel tank down so that the installation surface of the fuel pump is directly under
the tank. Be sure to lean the fuel tank in an
upright position.
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
• Fuel pump
7-2
7
FUEL TANK
ET2D1023
INSTALLING THE FUEL TANK
1. Install:
• Fuel hose
• Fuel hose connector cover
ECA14740
CAUTION:
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holders are in the correct position, otherwise the fuel hose will not be
properly installed.
NOTE:
Install the fuel hose connector securely onto
the fuel tank until a distinct “click” is heard, and
then make sure that it does not come loose.
To install the fuel hose from the fuel injection
hose, slide the cover “a” on the end of the hose
in the direction of arrow shown.
2.
•
•
•
•
Install:
Fuel sender coupler
Fuel pump coupler
Fuel tank breather hose
Fuel tank drain hose
NOTE:
There is white paint mark on the fuel tank
breather hose.
Refer to "CABLE ROUTING" on page 2-39.
7-3
THROTTLE BODIES
EAS26970
THROTTLE BODIES
Removing the throttle bodies
Order
Job/Parts to remove
Rider and passenger seat
Q’ty
Fuel tank
Air filter case
1
2
3
4
5
6
7
8
9
10
Sub-wire harness coupler
Coolant temperature sensor coupler
Thermo wax inret hose
Thermo wax outlet hose
Idle adjust screw wire
Throttle body joint clamp
Throttle bodies
Throttle cables
Throttle body joint
Fuel hose
7-4
2
1
1
1
1
4
1
2
4
1
Remarks
Refer to "GENERAL CHASSIS" on
page 4-1.
Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS" on
page 4-1.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Loosen.
Disconnect.
Disconnect.
THROTTLE BODIES
Removing the throttle bodies
Order
Job/Parts to remove
Q’ty
7-5
Remarks
For installation, reverse the removal
procedure.
THROTTLE BODIES
Removing the injectors
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Job/Parts to remove
Throttle position sensor coupler
Sub-throttle position sensor coupler
Sub-throttle motor assembly coupler
Intake air pressure sensor coupler
Cylinder #1-injector coupler
Cylinder #2-injector coupler
Cylinder #3-injector coupler
Cylinder #4-injector coupler
Sub-wire harness
Negative pressure hose
Intake air pressure sensor
Fuel distributor
Injector
Spring
Thermo wax assembly
Idle adjust screw wire
Link cover
Cotter pin
7-6
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
2
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Loosen.
THROTTLE BODIES
Removing the injectors
Order
19
20
21
22
23
Job/Parts to remove
Washer
Link
Sub-throttle servo motor assembly
Throttle position sensor
Throttle body assembly
Q’ty
2
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
7-7
THROTTLE BODIES
EAS26980
CHECKING THE INJECTORS
1. Check:
• Injectors
Damage → Replace.
c. Connect the pressure gauge “2” and
adapter “3” to the fuel hose (fuel tank to primary injector fuel rail).
EAS26990
CHECKING THE THROTTLE BODIES
1. Check:
• Throttle bodies
Cracks/damage → Replace the throttle
bodies as a set.
2. Check:
• Fuel passages
Obstructions → Clean.
Vacuum/pressure pump gauge
set
90890-06756
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03176
YM-03176
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle bodies in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1033
CHECKING THE FUEL PRESSURE
1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rider and passenger seat.
Refer to "GENERAL CHASSIS" on page 41.
b. Disconnect the fuel hose (fuel tank to primary injector fuel rail) “1” from the primary
injector fuel rail.
d. Start the engine.
e. Measure the fuel pressure.
Fuel pressure
324 kPa (46.1 psi) (3.24 kg/
cm²)
EW2C01008
Faulty → Replace the fuel pump.
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pressure in the fuel lines could cause fuel to
spurt out when removing the hoses.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS27020
ADJUSTING THE THROTTLE POSITION
SENSOR
NOTE:
Before adjusting the throttle position sensor,
the engine idling speed should be properly
adjusted.
7-8
THROTTLE BODIES
1. Check:
• Throttle position sensor
Refer to "CHECKING THE THROTTLE
POSITION SENSOR" on page 8-97.
2. Adjust:
• Throttle position sensor angle
ET2D1024
ADJUSTING THE SUB-THROTTLE POSITION SENSOR
1. Check:
• Sub-throttle position sensor
Refer to "CHECKING THE SUB-THROTTLE POSITION SENSOR" on page 8-97.
2. Adjust:
• Sub-throttle position sensor full open angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the throttle position sensor coupler to the wire harness.
b. Connect the digital circuit tester to the
throttle position sensor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the nut “1” of the worm shaft of the
sub-throttle counterclockwise until it contacts with the full open stopper.
b. When the dimension of “a” sections of the
throttle bodies #3 and #4 is measured with
a micrometer caliper, adjust with the
adjuster “2” of the output shaft section of
the sub-throttle servo motor so that the
dimension is in a range from 24.2 to 24.6
mm (0.95 to 0.97 in.)
• Positive tester probe
yellow terminal “1”
• Negative tester probe
black/blue terminal “2”
Digital circuit tester
90890-03174
Sub-throttle dimension “a”
24.2–24.6 mm (0.95–0.97 in)
c. After adjusting the dimension of “a” sections of the throttle bodies #3 and #4, measure the dimension of “a” sections of #1
and #2.
d. If the dimension of “a” sections of the throttle bodies #1 and #2 is different from the
dimension of “a” sections of the throttle
bodies #3 and #4, adjust it to the same
dimension as the measurement value
adjusted for the throttle bodies #3 and #4,
using the tuning screw “3” located between
the throttle bodies #2 and #3.
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
the measured voltage is within the specified range.
Throttle position sensor voltage
0.63–0.73 V
e. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
THROTTLE BODIES
4. Adjust:
• Sub-throttle position sensor voltage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the sub-throttle position sensor
coupler to the wire harness.
b. Connect the digital circuit tester to the subthrottle position sensor.
• Positive tester probe
Green/Yellow terminal “1”
• Negative tester probe
Black/Blue terminal “2”
Digital circuit tester
90890-03174
A. Front side
B. Rear side
c. Move the sub-throttle position sensor to
adjust to be in the specified range.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Primary opening
Sub-throttle position sensor
voltage
0.97–1.07 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. After performing the full open angle of the
sub-throttle position sensor, turn the nut of
the worm shaft clockwise, measure the
dimension of “b” section with a micrometer
caliper or other device and adjust so that
the dimension is in a range from 8.1 to 8.5
mm (0.32 to 0.33 in).
d. After adjusting the sub-throttle position
sensor voltage, tighten the sub-throttle
position sensor screws.
NOTE:
• After setting up the sub-throttle position sensor, check that the sub-throttle position sensor output voltage is 0.4 V or more with the
nut of worm shaft turned to the full close side
until it stops.
• When the sub-throttle position sensor output
voltage is 0.4 V or more, check that the subthrottle position sensor output voltage is 4.6
V or less with the nut of worm shaft turned to
the full open side until it stops.
Sub-throttle dimension “b”
8.1–8.5 mm (0.32–0.33 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Connect
• Sub-throttle motor assembly coupler
EAS2D1011
CHECKING THE SUB-THROTTLE SERVO
MOTOR
1. Check:
• Sub-throttle servo motor operation
A. Front side
B. Rear side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-10
THROTTLE BODIES
Out of specification → Replace.
a. Before adjusting the distance, push the rod
“b” in order to be fitted in several times by
hand.
b. Measure the outside air temperature, and
adjust the distance “a” by turning the
adjusting screw “2”. Refer to the thermo
wax tolerance table based on the measured outside air temperature for correct
adjustment.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check whether or not the sub-throttle valve
is seized.
1 Turn the nut of worm shaft of the sub-throttle servo motor by hand to check that the
sub-throttle valve is moved smoothly by
hand.
2 If it is not moved smoothly, disconnect the
link between the sub-throttle servo motor
and sub-throttle valve, and then check
whether or not the sub-throttle valve is
moved smoothly by hand.
Refer to "THROTTLE BODIES" on page 74.
3 When the sub-throttle valve is not moved
smoothly, repair or replace it since the
cause is the seizure of sub-throttle valve
body itself.
When it moved smoothly at Step (1) and
(2), replace the sub-throttle servo motor.
b. Perform the self-diagnosis mode and check
the operation of sub-throttle valve by visual
inspection (Code No: 56).
The operation should be carried out as 5second drive in the full open direction, 2second stop and 5-second drive in the full
close direction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAT2D1004
CHECKING THE THERMO WAX
1. Check:
• Thermo wax “1”
Damage → Replace the thermo wax
assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
• Setup tolerance of the longitudinal axis
should be ± 0.2 mm ( ± 0.008 in).
• After adjusting the thermo wax, check that
the first idling is released at the coolant temperature around 60°C (140°F) by idling.
• If the first idling is not released around 60°C
(140°F), make sure to set it again. (When the
coolant temperature is low, adjust the distance between the end faces longer or adjust
ET2D1025
ADJUSTING THE THERMO WAX
1. Adjust:
• Thermo wax the end face distance “a”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
7-11
THROTTLE BODIES
it shorter when the coolant temperature is
high.)
• In case of turning the adjusting bolt two-third
turn, the temperature varies about 10°C
(50°F).
7-12
AIR INDUCTION SYSTEM
EAS27040
AIR INDUCTION SYSTEM
Removing the air cut-off valve assembly and hoses
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Air cut-off valve coupler
Air cut-off valve hose 1
Air cut-off valve hose 2
Air cut-off valve hose 3
Air cut-off valve
Reed valve cap
Reed valve assembly
Plate
Q’ty
1
1
1
1
1
2
2
4
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For assembly, reverse the removal
procedure.
7-13
AIR INDUCTION SYSTEM
EAS27060
CHECKING THE AIR INDUCTION SYSTEM
Air injection
The air induction system burns unburned
exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the
emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed
valve opens, allowing secondary air to flow into
the exhaust port. The required temperature for
burning the unburned exhaust gases is
approximately 600 to 700°C.
Air cut-off valve
The air cut-off valve is controlled by the signals
from the ECU in accordance with the combustion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is
being driven. However, if the coolant temperature is below the specified value, the air cut-off
valve remains open and allows the air to flow
into the exhaust pipe until the temperature
becomes higher than the specified value.
A. From the air cleaner
B. To the cylinder head
1. Check:
• Hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
• Pipes
Cracks/damage → Replace.
2. Check:
• Reed valve “1”
• Reed valve stopper
• Reed valve seat
Cracks/damage → Replace the reed valve.
3. Measure:
• Reed valve bending limit “a”
7-14
AIR INDUCTION SYSTEM
Out of specification → Replace the reed
valve.
Plate
Reed valve assembly
Reed valve cap
2. Install:
Air cut-off valve
Air cut-off valve hose 1
Air cut-off valve hose 2
Air cut-off valve hose 3
Air cut-off valve coupler
Reed valve bending limit
0.4 mm (0.016 in)
4. Check:
• Air cut-off valve
Cracks/damage → Replace.
5. Check
• Air induction system solenoid
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (Ω × 1) to the air
induction system solenoid terminals as
shown.
• Positive tester probe
Brown terminal “1”
• Negative tester probe
Brown/Red terminal “2”
c. Measure the air induction system solenoid
resistance.
Air induction system solenoid
resistance
18–22Ω at 20°C (68°F)
d. Out of specification → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS27070
INSTALLING THE AIR INDUCTION SYSTEM
1. Install:
7-15
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
R/W
Br/W R/Y
R/B
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
W/Y
Gy
R/B B R/B
G/W
22
P/B
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-1
B D B
B Y/L
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27110
CIRCUIT DIAGRAM
R/Y
Dg
L/W
IGNITION SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
10.Starting circuit cut-off relay
11.Relay unit (diode)
13.Neutral switch
14.Sidestand switch
16.Crankshaft position sensor
20.Lean angle sensor
22.ECU
23.Ignition coil #1
24.Ignition coil #2
25.Ignition coil #3
26.Ignition coil #4
27.Spark plug
54.Engine stop switch
58.Clutch switch
74.Fuse (ignition)
8
8-2
IGNITION SYSTEM
EAS27150
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
1 Check the fuses.
(Main and ignition)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the spark plugs.
Refer to "CHECKING THE SPARK
PLUGS" on page 3-9.
NG→
Re-gap or replace the spark plugs.
OK↓
4 Check the ignition spark gap.
Refer to "CHECKING THE IGNITION COILS" on page 8-91.
OK→
Ignition system is OK.
NG↓
5 Check the ignition coils.
Refer to "CHECKING THE IGNITION COILS" on page 8-91.
NG→
Replace the ignition coils.
NG↓
6 Check the crankshaft position sensor.
Refer to "CHECKING THE
CRANKSHAFT POSITION SENSOR" on page 8-92.
NG→
Replace the crankshaft position sensor
OK↓
7 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
8-3
IGNITION SYSTEM
8 Check the engine stop switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the right handlebar switch.
OK↓
9 Check the neutral switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the neutral switch.
OK↓
10 Check the sidestand switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the sidestand switch.
OK↓
11 Check the clutch switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the clutch switch.
OK↓
12 Check the starting circuit cut-off
relay.
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
13 Check the lean angle sensor.
Refer to "CHECKING THE LEAN
ANGLE SENSOR" on page 8-93.
NG→
Replace the lean angle sensor.
OK↓
14 Check the entire ignition system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-1.
NG→
Properly connect or repair the ignition
system’s wiring
OK↓
Replace the ECU
8-4
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
Br/W R/Y
R/B
R/W
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
W/Y
Gy
R/B B R/B
G/W
22
P/B
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-5
B D B
B Y/L
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
ELECTRIC STARTING SYSTEM
EAS27160
ELECTRIC STARTING SYSTEM
EAS27170
CIRCUIT DIAGRAM
R/Y
Dg
L/W
ELECTRIC STARTING SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
8. Starter relay
9. Starter motor
10.Starting circuit cut-off relay
11.Relay unit (diode)
13.Neutral switch
14.Sidestand switch
54.Engine stop switch
55.Start switch
58.Clutch switch
74.Fuse (ignition)
8-6
ELECTRIC STARTING SYSTEM
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed),
the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever 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 conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot
reach the starter motor. When at least one of the above conditions has been met the starting circuit
cut-off relay is closed and the engine can be started by pressing the starter switch.
8-7
ELECTRIC STARTING SYSTEM
a. WHEN THE TRANSMISSION IS IN NEUTRAL
b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Starting circuit cut-off relay
7. Diode
8. Clutch switch
9. Sidestand switch
10.Neutral switch
11.Start switch
12.Starter relay
13.Starter motor
8-8
ELECTRIC STARTING SYSTEM
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the fuses.
(Main and ignition)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the starter motor operation.
Refer to "CHECKING THE STARTOR MOTOR OPERATION" on
page 8-93.
NG→
Replace the starter motor.
OK↓
4 Check the starter motor.
Refer to "CHECKING THE
STARTER MOTOR" on page 5-41.
NG→
Repair or replace the starter motor.
OK↓
5 Check the relay unit (starting circuit
cut-off relay).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
6 Check the relay unit (diode).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
7 Check the starter relay.
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the starter relay.
OK↓
8-9
ELECTRIC STARTING SYSTEM
8 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
9 Check the engine stop switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the right handlebar switch.
OK↓
10 Check the neutral switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the neutral switch.
OK↓
11 Check the sidestand switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the sidestand switch.
OK↓
12 Check the clutch switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the clutch switch.
OK↓
13 Check the start switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the right handlebar switch.
OK↓
14 Check the entire starting system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-5.
NG→
Properly connect or repair the starting
system’s wiring
OK↓
The starting system circuit is OK.
8-10
1
OFF
R
Br/L
L/Y L/B
R
Br/L
L/B L/Y
Br/L
B
R
W W W
74
2
R
B
ON
R/W
W
W
W
W
W
W
3
R/G
R
L/B
Br/L
L/Y
R
82
R
R
5
R
6
R
B
B
4
R
R
8-11
9
8
7
R/W L/W
B
B
R
L/W
R/W
R
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
R
B
CHARGING SYSTEM
2.
3.
5.
6.
Rectifier/regulator
A.C.magneto
Fuse (main)
Battery
8-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
1 Check the fuse.
(Main)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse.
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the startor coil.
Refer to "CHECKING THE STATOR
COIL" on page 8-93.
NG→
• Replace the startor assembly.
OK↓
4 Check the rectifier/regulator.
Refer to "CHECKING THE RECTIFIER/REGULATOR" on page 8-94.
NG→
Replace the rectifier/regulator.
OK↓
5 Check the entire charging system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-11.
NG→
Properly connect or repair the charging system’s wiring.
OK↓
This circuit is OK.
8-13
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
R/W
Br/W R/Y
R/B
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
W/Y
Gy
R/B B R/B
G/W
22
P/B
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-15
B D B
B Y/L
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
R/Y
Dg
L/W
LIGHTING SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
22.ECU
47.High beam indicator light
50.Meter light
59.Dimmer switch
69.Headlight
70.License plate light
71.Tail/brake light
72.Headlight relay (on/off)
73.Headlight relay (dimmer)
76.Fuse (headlight)
8-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter
light.
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the each bulbs and bulb
sockets condition.
Refer to "CHECKING THE BULBS
AND BULB SOCKETS" on page 884.
NG→
Replace the bulb(s) and bulb
socket(s).
OK↓
2 Check the fuses.
(Main, and headlight)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
3 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
4 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
5 Check the dimmer switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
The dimmer switch is faulty. Replace
the left handlebar switch.
OK↓
6 Check the rear brake light switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
The rear brake light switch is faulty.
Replace the rear brake light switch.
OK↓
7 Check the headlight relay (on/off).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the headlight relay.
OK↓
8-17
LIGHTING SYSTEM
8 Check the headlight relay (dimmer)
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the headlight relay.
OK↓
9 Check the entire lighting system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-15.
NG→
Properly connect or repair the lighting
system’s wiring.
OK↓
This circuit is OK.
8-18
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
R/W
Br/W R/Y
R/B
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-19
B D B
B Y/L
22
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
G/W
P/B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
Gy
R/B B R/B
W/Y
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS27280
CIRCUIT DIAGRAM
R/Y
Dg
L/W
SIGNALING SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
10.Starting circuit cut-off relay
13.Neutral switch
15.Fuel pump
18.Speed sensor
22.ECU
40.Fuel level warning light
41.Oil level warning light
42.Neutral indicator light
43.Tacho meter
44.Multi function meter
46.Coolant temperature indicator light
48.Turn signal indicator light (left)
49.Turn signal indicator light (right)
51.Oil level switch
53.Front brake light switch
56.Rear brake light switch
60.Hazard switch
61.Turn signal switch
62.Horn switch
63.Horn
64.Turn signal relay
65.Front turn signal/position light (left)
66.Front turn signal/position light (right)
67.Rear turn signal light (left)
68.Rear turn signal light (right)
71.Tail/brake light
75.Fuse (signal)
8-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the fuses.
(Main, ignition and signal)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
4 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
Check the signaling system
The horn fails to sound.
1 Check the horn switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the left handlebar switch.
OK↓
2 Check the horn.
Refer to "CHECKING THE HORN"
on page 8-94.
NG→
Replace the horn.
OK↓
8-21
SIGNALING SYSTEM
3 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system wiring.
OK↓
This circuit is OK.
The tail/brake light fails to come on.
1 Check the tail/brake light bulb and
socket.
Refer to "CHECKING THE BULBS
AND BULB SOCKETS" on page 884.
NG→
Replace the tail/brake light bulb,
socket or both.
OK↓
2 Check the front brake light switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the front brake light switch.
OK↓
3 Check the rear brake light switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the rear brake light switch.
OK↓
4 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1 Check the turn signal bulb.
Refer to "CHECKING THE BULBS
AND BULB SOCKETS" on page 884.
NG→
Replace the turn signal bulb.
OK↓
2 Check the turn signal switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the left handlebar switch.
OK↓
8-22
SIGNALING SYSTEM
3 Check the turn signal relay.
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the turn signal relay.
OK↓
4 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
The neutral indicator light fails to come on.
1 Check the neutral switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the neutral switch.
OK↓
2 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
The oil level warning light fails to come on.
1 Check the oil level switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the oil level switch.
OK↓
2 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
The fuel level warning light fails to come on.
1 Check the fuel sender.
Refer to "CHECKING THE FUEL
SENDER" on page 8-95.
NG→
Replace the fuel pump assembly.
OK↓
8-23
SIGNALING SYSTEM
2 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
The speedometer fails to operate.
1 Check the speed sensor.
Refer to "CHECKING THE SPEED
SENSOR" on page 8-95.
NG→
Replace the speed sensor.
OK↓
2 Check the entire signaling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
Replace the meter assembly.
8-24
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
Br/W R/Y
R/B
R/W
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
W/Y
Gy
R/B B R/B
G/W
22
P/B
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-25
B D B
B Y/L
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
COOLING SYSTEM
EAS27300
COOLING SYSTEM
EAS27310
CIRCUIT DIAGRAM
R/Y
Dg
L/W
COOLING SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
22.ECU
37.Coolant temperature sensor
74.Fuse (ignition)
77.Radiator fan motor relay
78.Fuse (radiator fan motor left)
79.Fuse (radiator fan motor right)
80.Radiator fan motor (left)
81.Radiator fan motor (right)
8-26
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the fuses.
(Main, ignition and radiator fan
motor)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
4 Check the radiator fan motor (left
and right).
Refer to "CHECKING THE RADIATOR FAN MOTOR" on page 8-96.
NG→
The radiator fan motor is faulty and
must be replaced.
OK↓
5 Check the radiator fan motor relay.
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the radiator fan motor relay.
OK↓
6 Check the coolant temperature.
Refer to "CHECKING THE COOLANT TEMPERATURE SENSOR"
on page 8-96.
NG→
Replace the coolant temperature sensor.
OK↓
7 Check the entire cooling system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-25.
NG→
Properly connect or repair the cooling
system’s wiring.
OK↓
This circuit is OK.
8-27
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
R/W
Br/W R/Y
R/B
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
W/Y
Gy
R/B B R/B
G/W
22
P/B
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-29
B D B
B Y/L
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
FUEL INJECTION SYSTEM
EAS27330
FUEL INJECTION SYSTEM
EAS27340
CIRCUIT DIAGRAM
R/Y
Dg
L/W
FUEL INJECTION SYSTEM
1. Main switch
4. Fuse (backup)
5. Fuse (main)
6. Battery
7. Fuse (fuel injection)
10.Starting circuit cut-off relay
11.Relay unit (diode)
12.Fuel pump relay
13.Neutral switch
14.Sidestand switch
15.Fuel pump
16.Crankshaft position sensor
17.Cylinder identification sensor
18.Speed sensor
19.Atmospheric pressure sensor
20.Lean angle sensor
21.O2 sensor
22.ECU
23.Ignition coil #1
24.Ignition coil #2
25.Ignition coil #3
26.Ignition coil #4
27.Spark plug
28.Injector #1
29.Injector #2
30.Injector #3
31.Injector #4
33.Sub-throttle position sensor
34.EXUP servo motor
35.Intake air pressure sensor
36.Throttle position sensor
37.Coolant temperature sensor
38.Intake air temperature sensor
44.Multi function meter
54.Engine stop switch
74.Fuse (ignition)
8-30
FUEL INJECTION SYSTEM
EAS27370
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the fuses.
(Main, backup, fuel injection and
ignition)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the spark plugs.
Refer to "CHECKING THE SPARK
PLUGS" on page 3-9.
NG→
Re-gap or replace the spark plugs.
OK↓
4 Check the ignition coils.
Refer to "CHECKING THE IGNITION COILS" on page 8-91.
NG→
Replace the ignition coils.
OK↓
5 Check the crankshaft position sensor.
Refer to "CHECKING THE
CRANKSHAFT POSITION SENSOR" on page 8-92.
NG→
Replace the crankshaft position sensor.
OK↓
6 Check the relay unit (fuel pump
relay).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
7 Check the fuel pump.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the fuel pump.
OK↓
8-31
FUEL INJECTION SYSTEM
8 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
9 Check the engine stop switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the right handlebar switch.
OK↓
10 Check the neutral switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the neutral switch.
OK↓
11 Check the sidestand switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the sidestand switch.
OK↓
12 Check the clutch switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the clutch switch.
OK↓
13 Check the relay unit (starting circuit
cut-off relay).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
14 Check the lean angle sensor.
Refer to "CHECKING THE LEAN
ANGLE SENSOR" on page 8-93.
NG→
Replace the lean angle sensor.
OK↓
15 Check the cylinder identificatin sensor.
Refer to "CHECKING THE CYLINDER IDENTIFICATION SENSOR"
on page 8-99.
NG→
Reeplace the cylinder identification
sensor.
OK↓
16 Check the speed sensor.
Refer to "CHECKING THE SPEED
SENSOR" on page 8-95.
NG→
Replace the spped sensor.
OK↓
8-32
FUEL INJECTION SYSTEM
17 Checking the atmospheric pressure
sensor.
Refer to "CHECKING THE ATMOSPHERIC PRESSURE SENSOR"
on page 8-99.
NG→
Replace the atmospheric pressure
sensor.
OK↓
18 Check the injector.
Refer to "CHECKING THE INJECTORS" on page 7-8.
NG→
Replace the injector.
OK↓
19 Check the throttle position sensor.
Refer to "CHECKING THE THROTTLE POSITION SENSOR" on page
8-97.
NG→
Replace the throttle position sensor.
OK↓
20 Check the sub-throttle position sensor.
Refer to "CHECKING THE SUBTHROTTLE POSITION SENSOR"
on page 8-97.
NG→
Replace the sub-throttle position sensor.
OK↓
21 Check the intake air pressure sensor.
Refer to "CHECKING THE INTAKE
AIR PRESSURE SENSOR" on
page 8-99.
NG→
Replace the intake air pressure sensor
OK↓
22 Check the coolant temperature
sensor.
Refer to "CHECKING THE COOLANT TEMPERATURE SENSOR"
on page 8-96.
NG→
Replace the coolant temperature sensor.
OK↓
23 Check the inatke air temperature
sensor.
Refer to "CHECKING THE INTAKE
AIR TEMPERATURE SENSOR" on
page 8-100.
NG→
Replace the intake air temperature
sensor.
OK↓
8-33
FUEL INJECTION SYSTEM
24 Check the entire ignition system’s
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-1.
NG→
Properly connect or repair the ignition
system’s wiring
OK↓
Replace the ECU.
8-34
FUEL INJECTION SYSTEM
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system
is operating normally. If this function detects a malfunction in the system, it immediately operates the
engine under substitute characteristics and illuminates the engine trouble warning light to alert the
rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault
code is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an
appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by
illuminating the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the odometer/tripmeter/fuel reserve tripmeter LCD. 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
Warning light indicaECU operation
tion
Flashing*
Warning provided
when unable to start
engine
Remains on
Malfunction detected
FI operation
Vehicle operation
Operation stopped
Cannot be operated
Operated with substitute characteristics in
accordance with the
description of the malfunction
Can or cannot be operated depending on the
fault code
* The warning light flashes when any one of the conditions listed below is present and the start
switch is pushed:
11:
Cylinder identification sensor
30:
Lean angle sensor
(latch up detected)
12:
Crankshaft position sensor
41:
Lean angle sensor
(open or short-circuit)
19:
Sidestand switch
(open circuit in the wire to the ECU)
50:
ECU internal malfunction
(faulty ECU memory)
Checking the engine trouble warning light
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on
under these conditions, the warning light (LED) may be defective.
8-35
FUEL INJECTION SYSTEM
a.
b.
c.
d.
Main switch “OFF”
Main switch “ON”
Engine trouble warning light off
Engine trouble warning light on for 1.4 seconds
EAS27362
SELF-DIAGNOSTIC FUNCTION TABLE
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for each sensor in order to provide the engine with alternate operating instructions
that enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic Function table
Fault
code No.
11
12
13
14
15
16
17
18
19
20
Item
Cylinder identification sensor
Crankshaft position
sensor
Intake air pressure
sensor
(open or short circuit)
Intake air pressure
sensor hose line
(piping system)
Throttle position sensor
(open or short circuit)
Throttle position sensor
(stuck)
EXUP servo motor
potention circuit
(open or short circuit)
EXUP servo motor
(stuck)
Sidestand switch
(open circuit in the
wire to the ECU)
Able/
unable
to start
Able/
unable
to drive
Unable
Able
Unable
Unable
Able
Able
Intake air pressure sensor:
faulty intake air pressure sensor system.
Able
Able
Throttle position sensor:
open or short circuit detected.
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Unable
Able
Able
Symptom
No normal signals are received from the
cylinder identification sensor when the
engine is started or while the vehicle is
being driven.
No normal signals are received from the
crankshaft position sensor.
Intake air pressure sensor:
open or short circuit detected.
Throttle position sensor is stuck.
EXUP servo motor potension circuit:
open or short circuit detected.
EXUP servo motor is stuck.
Open circuit in the input line of ECU No.24
terminal is detected when start switch is
pressed from the sidestand switch to the
ECU.
Intake air pressure
When the main switch is turned to “ON”,
sensor or atmothe atmospheric pressure sensor voltage
spheric pressure sen- and intake air pressure sensor voltage difsor
fer greatly.
8-36
FUEL INJECTION SYSTEM
Fault
code No.
21
22
23
24
30
Item
Coolant temperature
sensor
(open or short circuit)
Intake air temperature
sensor
(open or short circuit)
Atmospheric pressure
sensor
(open or short circuit)
O2 sensor
Lean angle sensor
(latch up detected)
Cylinder-#1 ignition
coil
(open circuit)
33
Cylinder-#2 ignition
coil
(open circuit)
34
Cylinder-#3 ignition
coil
(open circuit)
35
Cylinder-#4 ignition
coil
(open circuit)
36
Able/
unable
to start
Able/
unable
to drive
Coolant temperature sensor:
open or short circuit detected.
Able
Able
Intake air temperature sensor:
open or short circuit detected.
Able
Able
Atmospheric pressure sensor:
open or short circuit detected.
Able
Able
Symptom
No normal signal is received from the O2
Able
sensor.
No normal signal is received from the lean
Unable
angle sensor.
Primary lead of the cylinder-#1 ignition
Able
coil:
(dependopen circuit detected.
ing on
the number of
faulty
cylinders)
Primary lead of the cylinder-#2 ignition
Able
coil:
(dependopen circuit detected.
ing on
the number of
faulty
cylinders)
Primary lead of the cylinder-#3 ignition
Able
coil:
(dependopen circuit detected.
ing on
the number of
faulty
cylinders)
Primary lead of the cylinder-#4 ignition
Able
coil:
(dependopen circuit detected.
ing on
the number of
faulty
cylinders)
8-37
Able
Unable
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty
cylinders)
Able
(depending on
the number of
faulty
cylinders)
FUEL INJECTION SYSTEM
Fault
code No.
Item
Injector
(open circuit)
Symptom
Injector:
open circuit detected.
39
41
42
43
44
46
47
48
50
Lean angle sensor
Lean angle sensor:
(open or short-circuit) open or short circuit detected.
Speed sensor
No normal signals are received from the
speed sensor.
Neutral switch
Neutral switch:
open or short circuit detected.
Fuel system voltage
Power supply to the injectors and the fuel
(monitoring voltage)
pump is not normal.
Error in writing the
An error is detected while reading or writamount of CO adjust- ing on EEPROM (CO adjustment value).
ment on EEPROM
Vehicle system power Power supply to the fuel injection system
supply
is not normal.
(monitoring voltage)
Sub-throttle servo
sub-throttle servo motor potention:open or
motor potention (open short circuit detected.
or short circuit)
Sub-throttle servo
motor (lock)
ECU internal malfunction
(memory check error)
Start unable warning
–
A lock of the sub-throttle servo motor is
detected.
ECU memory is faulty. (When this malfunction is detected in the ECU, the fault
code number might not appear on the
meter.)
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 detected with the fault code of
No.11, 12, 19, 30, 41 or 50.
Able/
Able/
unable unable
to start to drive
Able
Able
(depend- (depending on
ing on
the num- the number of
ber of
faulty
faulty
cylincylinders)
ders)
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Unable
Unable
Unable
Able/
unable
to start
Able/
unable
to drive
Unable
Unable
Communication error with the meter
Fault
code No.
Er-1
Item
Symptom
ECU internal malfunc- No signals are received from the ECU.
tion
(output signal error)
8-38
FUEL INJECTION SYSTEM
Fault
code No.
Er-2
Er-3
Er-4
Able/
unable
to start
Able/
unable
to drive
No signals are received from the ECU
within the specified duration.
Unable
Unable
Data from the ECU cannot be received
correctly.
Unable
Unable
Non-registered data has been received
from the meter.
Unable
Unable
Item
ECU internal malfunction
(output signal error)
ECU internal malfunction
(output signal error)
ECU internal malfunction
(input signal error)
Symptom
EAS27400
NOTE:
TROUBLESHOOTING METHOD
If fault codes are displayed, repeat steps (1) to
(4) until no fault code number is displayed.
The engine operation is not normal and the
engine trouble warning light comes on.
1. Check:
• Fault code number
5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation
table (Diagnostic code No.62)”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
a. Check the fault code number displayed on
the meter.
b. Identify the faulty system with the fault
code. Refer to “Self-Diagnostic Function
table”.
c. Identify the probable cause of malfunction.
Refer to “Diagnostic code table”.
Turning the main switch to “OFF” will not erase
the malfunction history.
The engine operation is not normal but the
engine trouble warning light does not come
on.
1. Check the operation of following sensors
and actuators in the Diagnostic mode.
Refer to “Sensor operation table” and
“Actuator operation table”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Checking and repair the probable cause of
malfunction.
Fault code No.
Fault code No.
Check and repair.
Check and repair.
Refer to "TROUBLE- Refer to Self-Diagnostic Function table.
SHOOTING
DETAILS" on page 848.
Monitor the operation
of the sensors and
actuators in the diagnostic mode. Refer to
“Sensor operation
table” and “Actuator
operation table”.
01: Throttle position sensor (throttle angle)
02: Atmospheric pressure sensor
05: Intake air pressure sensor
06: Coolant temperature sensor
07: Vehicle speed pulse
09: Fuel system voltage (battery bolt)
21: Neutral switch
30: Ignition coil #1
31: Ignition coil #2
32: Ignition coil #3
33: Ignition coil #4
36: Injector #1
37: Injector #2
38: Injector #3
39: Injector #4
48: AI system solenoid
53: EXUP servo motor
56: Sub-throttle servo motor
3. Perform ECU reinstatement action.
Refer to “Reinstatement method” of table in
“TROUBLESHOOTING DETAILS”.
4. Turn the main switch to “OFF” and back to
“ON”, then check that no fault code number
is displayed.
8-39
FUEL INJECTION SYSTEM
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.
EAS27420
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue
to press the buttons for 8 seconds or more.
NOTE:
• All displays on the meter disappear except the odometer/tripmeter/fuel reserve tripmeter display.
• “dI” appears on the odometer/tripmeter/fuel reserve tripmeter LCD.
4. Press the “SELECT” button to select the diagnostic mode “dI”.
5. After selecting “dI”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or
more to activate the diagnostic mode. The diagnostic code number “d01” appears on the clock
LCD.
6. Set the engine stop switch to “ ”.
7. Select the diagnostic code number corresponding to the fault code number by pressing the
“SELECT” and “RESET” buttons.
NOTE:
• The diagnostic code number appears on the LCD meter (d01–70).
• To decrease the selected diagnostic code number, press the “RESET” button. Press the “RESET”
button for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers.
8. Verify the operation of the sensor or actuator.
• Sensor operation
8-40
FUEL INJECTION SYSTEM
The data representing the operating conditions of the sensor appears on the odometer/tripmeter/fuel reserve tripmeter 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 “
9. Turn the main switch to “OFF” to cancel the diagnostic mode.
8-41
” again.
FUEL INJECTION SYSTEM
Fault code table
Fault
code
No.
11
12
13
14
15
16
17
18
19
20
Symptom
• No normal signals are
received from the cylinder identification sensor
when the engine is
started or while the vehicle is being driven.
No normal signals are
received from the crankshaft position sensor.
Intake air pressure sensor:
open or short circuit
detected.
Intake air pressure sensor:
faulty intake air pressure
sensor system.
Throttle position sensor:
open or short circuit
detected.
Probable cause of malfunction
•
•
•
•
•
Open or short circuit in sub wire harness.
Open or short circuit in wire harness.
Defective cylinder identification sensor.
Improperly installed sensor.
Malfunction in ECU.
•
•
•
•
•
•
•
•
•
•
Open or short circuit in wire harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Improperly installed sensor.
Malfunction in ECU.
Open or short circuit in wire harness.
Open or short circuit in sub wire harness.
Defective intake air pressure sensor.
Malfunction in ECU.
Intake air pressure sensor hose is
detached, clogged, kinked, or pinched.
Malfunction in ECU.
Open or short circuit in wire harness.
Open or short circuit in sub wire harness.
Defective throttle position sensor.
Improperly installed throttle position sensor.
Malfunction in ECU.
Stuck throttle position sensor.
Malfunction in ECU.
Open or short circuit in sub wire harness.
Detective EXUP servo motor (potention circuit).
Open or short circuit in sub wire harness.
Stuck EXUP servo motor (mechanism).
Stuck EXUP servo motor (motor).
Open circuit in wire harness (ECU Coupler).
Malfunction in ECU.
•
•
•
•
•
•
•
•
•
•
Throttle position sensor:
stuck
EXUP servo motor potention circuit: open or short
circuit detected.
EXUP servo motor is stuck. •
•
•
Open circuit is detected in •
the input line of ECU No.24 •
terminal is detected when
the start switch is pressed.
When the main switch is
•
turned to “ON”, the atmospheric pressure sensor
•
voltage and intake air pressure sensor voltage differ
•
greatly.
Atmospheric pressure sensor hose is
clogged.
Intake air pressure sensor hose is clogged,
kinked, or pinched.
Malfunction of the atmospheric pressure
sensor in the intermediate electrical potential.
• Malfunction of the intake air pressure sensor in the intermediate electrical potential.
• Malfunction in ECU.
8-42
Diagnostic
code No.
—
—
03
03
01
01
53
53
20
02
03
FUEL INJECTION SYSTEM
Fault
code
No.
Symptom
21
Coolant temperature sensor: open or short circuit
detected.
22
Intake air temperature sensor: open or short circuit
detected.
23
Atmospheric pressure sensor: open or short circuit
detected.
24
30
No normal signal is
received from the O2 sensor.
No normal signal is
received from the lean
angle sensor.
33
Open circuit detected in the
primary lead of the cylinder#1 ignition coil.
34
Open circuit detected in the
primary lead of the cylinder#2 ignition coil.
35
Open circuit detected in the
primary lead of the cylinder#3 ignition coil.
36
Open circuit detected in the
primary lead of the cylinder#4 ignition coil.
39
Open circuit detected in a
injector.
Probable cause of malfunction
• Open or short circuit in wire harness.
• Defective coolant temperature sensor.
• Improperly installed coolant temperature
sensor.
• Malfunction in ECU.
• Open or short circuit in wire harness.
• Defective intake air temperature sensor.
• Improperly installed intake air temperature
sensor.
• Malfunction in ECU.
• Open or short circuit in sub wire harness.
• Defective atmospheric pressure sensor.
• Improperly installed atmospheric pressure
sensor.
• Malfunction in ECU.
• Open or short circuit in wire harness.
• Defective O2 sensor.
• Improperly installed O2 sensor.
• Malfunction in ECU.
• Vehicle has overturned.
• Defective lean angle sensor.
• Improperly installed lean angle sensor.
• Malfunction in ECU.
• Open circuit in wire harness.
• Malfunction in ignition coil.
• Malfunction in a component of ignition cutoff circuit system.
• Malfunction in ECU.
• Open circuit in wire harness.
• Malfunction in ignition coil.
• Malfunction in a component of ignition cutoff circuit system.
• Malfunction in ECU.
• Open or short circuit in wire harness.
• Malfunction in ignition coil.
• Malfunction in a component of ignition cutoff circuit system.
• Malfunction in ECU.
• Open or short circuit in wire harness.
• Malfunction in ignition coil.
• Malfunction in a component of ignition cutoff circuit system.
• Malfunction in ECU.
• Open or short circuit sub-wire- harness.
• Open or short circuit in wire harness.
• Improperly installed injector.
• Defective injector.
8-43
Diagnostic
code No.
06
05
02
—
08
30
31
32
33
36
37
38
39
FUEL INJECTION SYSTEM
Fault
code
No.
41
42
43
44
46
47
48
50
Er-1
Er-2
Er-3
Er-4
Symptom
Probable cause of malfunction
Lean angle sensor: open or • Open or short circuit in wire harness.
short circuit detected.
• Defective lean angle sensor.
• Malfunction in ECU.
No normal signals are
• Open or short circuit in wire harness.
recieved from the speed
• Malfunction in speed sensor.
sensor.
• Malfunction in ECU.
Neutral switch:
• Open or short circuit in wire haraness.
open or short circuit
• Malfunction in neutral switch.
detected.
• Malfunction in ECU.
Power supply to the injec• Open circuit in wire harness.
tors and the fuel pump is
• Malfunction in ECU.
not normal.
An error is detected while
• Malfunction in ECU. (The CO adjustment
reading or writing on
value is not properly written on or read from
EEPROM (CO adjustment
the internal memory).
value).
Power supply to the fuel
• Malfunction in the charging system.
injection system relay is not Refer to "CHARGING SYSTEM" on page 8normal.
11.
Sub-throttle servo motor
• Open or short circuit in wire harness.
potention circuit:
• Detective Sub-throttle servo motor (potenopen or short circuit
tion circuit).
detected.
Sub-throttle servo motor is • Open or short circuit in wire harness.
stuck.
• Stuck Sub-throttle servo motor (mechanism).
• Stuck Sub-throttle servo motor (motor).
Faulty ECU memory. (When • Malfunction in ECU. (The program and data
this malfunction is detected
are not properly written on or read from the
in the ECU, the fault code
internal memory.)
number might not appear
on the meter.)
No signals are received
• Open or short circuit in wire harness.
from the ECU.
• Malfunction in meter.
• Defective wire connection of the ECU coupler.
• Malfunction in ECU.
No signals are received
• Improper connection in wire harness.
from the ECU within the
• Malfunction in meter.
specified duration.
• Malfunction in ECU.
Data from the ECU cannot • Improper connection in wire harness.
be received correctly.
• Malfunction in meter.
• Malfunction in ECU.
Non-registered data has
• Improper connection in wire harness.
been received from the
• Malfunction in meter.
meter.
• Malfunction in ECU.
8-44
Diagnostic
code No.
08
07
21
09
60
—
56
56
—
—
—
—
—
FUEL INJECTION SYSTEM
Sensor operation table
Diagnostic
code
No.
01
Item
Atmospheric pressure
02
Intake air pressure
03
Intake air temperature
05
Coolant temperature
06
Vehicle speed pulse
07
Lean angle sensor
• Upright
• Overturned
Fuel system voltage
(battery voltage)
Check with throttle valve
fully closed.
95–100
Check with throttle valve
fully opened.
Displays the atmospheric
Compare the actually meapressure.
sured atmospheric pressure with the meter display
value.
Displays the cylinder-#1
Set the engine stop switch
intake air pressure.
to “ ” then operate the
throttle while pushing the
start switch “ ”. (If the display value changes, the
performance is OK.)
Displays the intake air temCompare the actually meaperature.
sured air temperature with
the meter display value.
Displays the coolant tempera- Compare the actually meature.
sured coolant temperature
with the meter diaplay
value.
0–999
Check that the number
increases when the rear
wheel is rotated. The number is cumulative and does
not reset each time the
wheel is stopped.
Remove the lean angle
sensor and incline it more
0.4–1.4
than 65 degrees.
3.7–4.4
Approximately 12.0
ON
OFF
Set the engine stop switch
to “ ” and then compare
with the actually measured
battery voltage. (If the battery voltage is lower,
recharge the battery.)
Set ON/OFF the sidestand
switch (with the transmission in gear).
ON
OFF
Set ON/OFF the neutral
switch (shift the transmission).
09
20
21
Checking method
Throttle position sensor signal
• Fully closed position
15–18
• Fully opened position
08
Meter display
Sidestand switch
• Stand retracted
• Stand extended
Neutral switch
• Neutral
• In gear
8-45
FUEL INJECTION SYSTEM
Diagnostic
code
No.
Item
EEPROM fault cylinder No
• No fault
• Fault detected
60
Malfunction history code
• No history
• History exists
61
Malfunction history code
erasure
• No history
• History exists
62
Malfunction code reinstate
• No mulfunction code
• Malfunction code exists
63
70
Control number
Meter display
00
01–04 (fault cylinder No.)
• (If more than one cylinder is
defective, the display
changes every two seconds
to show all the detected cylinder numbers. When all
cylinder numbers are
shown, the display repeats.)
00
Fault codes 11–50
• (If more than one code
number is detected, the display changes every two
seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats.)
Checking method
—
—
00
—
Fault codes 01-28
To erase the history, set the
engine stop switch to “ “ .
• (If more than one code
number is detected, the display alternates every two
seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
00
—
Fault code 24
To reinstate, set the engine
• (If more than one code
stop switch to “ “ .
number is detected, the display changes every two
seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats.)
0–255
—
8-46
FUEL INJECTION SYSTEM
Actuator operation table
Diagnostic
code
No.
Item
Cylinder-#1 ignition coil
30
Cylinder-#2 ignition coil
31
Cylinder-#3 ignition coil
32
Cylinder-#4 ignition coil
33
Injector #1
36
Injector #2
37
Injector #3
38
Injector #4
39
Air induction system solenoid
48
Actuation
Checking method
Actuates the cylinder-#1 ignition coil five times at one second intervals.
Illuminates the engine trouble warning light.
Actuates the cylinder-#2 ignition coil five times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the cylinder-#3 ignition coil five times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the cylinder-#4 ignition coil five times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the injector #1 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the injector #2 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the injector #3 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the injector #4 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Actuates the Air induction
system solenoid five times at
one-second intervals.
Illuminates the engine trouble warning light.
Check the spark five times.
• Connect an ignition
checker.
8-47
Check the spark five times.
• Connect an ignition
checker.
Check the spark five times.
• Connect an ignition
checker.
Check the spark five times.
• Connect an ignition
checker.
Check the operating sound
of the injector #1 five times.
Check the operating sound
of the injector #2 five times.
Check the operating sound
of the injector #3 five times.
Check the operating sound
of the injector #4 five times.
Check the operating sound
of the Air induction system
solenoid five times.
FUEL INJECTION SYSTEM
Diagnostic
code
No.
Item
Fuel injection system relay
50
Radiator fan motor relay
51
Headlight relay
52
Exup servo motor
53
Sub-throttle servo motor
56
Actuation
Checking method
Actuates the fuel injection
system relay five times at
one-second intervals.
Illuminates the engine trouble warning light.
(The engine trouble warning
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
Actuates the radiator fan
motor relay five times at onesecond intervals. (ON 2 seconds, OFF 3 seconds)
Illuminates the engine trouble warning light.
Actuates the headlight relay
for five times every five-second. (ON 2 seconds, OFF 3
seconds)
Illuminates the engine trouble warning light.
Actuate the servo motor turns
to close side and to open
side.
Illuminates the engine trouble warning light only while
the motor is runnning.
Actuate the servo motor turns
to close side and to open
side.
Illuminates the engine trouble warning light only while
the motor is runnning.
Check the operating sound
of the fuel injection system
relay five times.
Check the operating sound
of the Radiator fan motor
relay five times.
Check the operating sound
of the headlight relay five
times.
Check the operating sound
of the EXUP servo motor.
Check the operating sound
of the Sub-throttle servo
motor.
EAS27460
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order
given.
After the check and service of the malfunctioning part has been completed, reset the meter display
according to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to Self-Diagnostic Function table.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to "DIAGNOSTIC
MODE" on page 8-40.
8-48
FUEL INJECTION SYSTEM
No normal signals are received from the cylinder identifiFault code No. 11 Symptom
cation sensor when the engine is started or while the
vehicle is being driven.
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Installed condition of cylinder identifi- Check for looseness or pinching. Starting the
1
cation sensor.
engine and
Connections
• Check the coupler for any pins operate it at
idle.
• Cylinder identification sensor couthat may be pulled out.
pler
• Check the locking condition of
2
• Main wire harness ECU coupler
the couplers.
• Sub-wire harness coupler
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between the cylinder identification sensor coupler and ECU
3
coupler
(Blue–Blue)
(White/Black–White/Black)
(Black/Blue–Black/Blue)
Defective cylinder identification sen• Replace if defective.
sor.
Refer to "CHECKING THE
4
CYLINDER IDENTIFICATION
SENSOR" on page 8-99.
8-49
FUEL INJECTION SYSTEM
No normal signals are received from the crankshaft position sensor.
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
1
Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the
tion sensor
engine.
2
Connections
• Check the couplers for any pins
• Crankshaft position sensor coupler
that may have pulled out.
• Main wire harness ECU coupler
• Check the locking condition of
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
3
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU coupler.
(Gray–Gray)
(Black/Blue–Black/Blue)
4
Defective crankshaft position sensor. • Replace if defective.
Refer to "CHECKING THE
CRANKSHAFT POSITION
SENSOR" on page 8-92.
Fault code No.
12
Symptom
8-50
FUEL INJECTION SYSTEM
Fault code No. 13 Symptom Intake air pressure sensor:open or short circuit detected.
Diagnostic code No.
03
Intake air pressure sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turn the main
• Intake air pressure sensor coupler
that may have pulled out.
switch to ON.
• Main wire harness ECU coupler
• Check the locking condition of
1
• Sub-wire harness coupler
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub wire harness.
open or short circuit.
• Between intake air pressure
sensor coupler and ECU cou2
pler
(Black/Blue–Black/Blue)
(Pink/White–Pink/White)
(Blue–Blue)
Defective intake air pressure sensor
• Execute the diagnostic mode.
(Code No.03)
• Replace if defective.
3
Refer to "CHECKING THE
INTAKE AIR PRESSURE SENSOR" on page 8-99.
Intake air pressure sensor: faulty intake air pressure sensor system.
Diagnostic code No.
03
Intake air pressure sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Intake air pressure sensor hose
• Check the intake air pressure
Starting the
sensor hose condition.
engine and
1
• Repair or replace the sensor
operate it at
hose.
idle.
Connections
• Check the couplers for any pins
• Intake air pressure sensor coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of
2
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Defective intake air pressure sensor
• Execute the diagnostic mode.
(Code No.03)
• Replace if defective.
3
Refer to "CHECKING THE
INTAKE AIR PRESSURE SENSOR" on page 8-99.
Fault code No.
14
Symptom
8-51
FUEL INJECTION SYSTEM
Fault code No. 15 Symptom Throttle position sensor:open or short circuit detected.
Diagnostic code No.
01
Throttle position sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Installed condition of throttle position • Check for looseness or pinchTurning the
sensor.
ing.
main switch to
1
• Check that is installed in the
“ON”.
specified position.
Connections
• Check the couplers for any pins
• Throttle position sensor coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of
2
• Sub-wire harness coupler
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between throttle position sensor
3
coupler and ECU coupler
(Black/Blue–Black/Blue)
(Yellow–Yellow)
(Blue–Blue)
Throttle position sensor lead wire open • Check for open circuit and
circuit output voltage check.
replace the throttle position sensor.
(Black/Blue–Yellow)
Open circuit
Output voltage
item
4
Ground wire
5V
open circuit
Output wire
0V
open circuit
Power supply
0V
wire open circuit
Defective throttle position sensor.
• Execute the diagnostic mode.
(Code No.01)
• Replace if defective.
5
Refer to "CHECKING THE
THROTTLE POSITION SENSOR" on page 8-97.
8-52
FUEL INJECTION SYSTEM
Fault code No.
16 Symptom
Stuck throttle position sensor detected.
Diagnostic code No.
01
Throttle position sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Installed condition of throttle position • Check the installed area for
Reinstated by
sensor.
looseness or pinching.
starting the
• Check that is installed in the
engine, operat1
specified position.
ing it at idle, and
Refer to "THROTTLE BODIES" then racing it.
on page 7-4 section.
Defective throttle position sensor.
• Execute the diagnostic mode.
(Code No.01)
2
• Replace if defective.
Refer to "THROTTLE BODIES"
on page 7-4 section.
Fault code No.
17 Symptom EXUP servo motor circuit:open or short circuit detected.
Diagnostic code No.
53
EXUP servo motor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
• EXUP servo motor coupler
that may be pulled out.
main switch to
• Main wire harness ECU coupler
• Check the locking condition of “ON”.
1
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between EXUP servo motor
2
coupler and ECU coupler
(Blue–Blue)
(White/Red–White/Red)
(Black/Blue–Black/Blue)
Defective EXUP servo motor (poten- • Execute the diagnostic mode.
tion circuit).
(Code No.53)
• Replace if defective.
3
Refer to "CHECKING THE
EXUP SERVO MOTOR" on
page 3-17.
8-53
FUEL INJECTION SYSTEM
Fault code No.
18 Symptom
Diagnostic code No.
53
Item/components and probable
Order
cause
Connections
• EXUP servo motor coupler
• Main wire harness ECU coupler
1
Open or short circuit in wire harness.
2
Defective EXUP servo motor
3
4
Defective EXUP valve, pulley, and
cables
EXUP servo motor is stuck.
EXUP servo motor
Reinstatement
method
• Check the couplers for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of “ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
• Repair or replace if there is an
open or short circuit.
• Between EXUP servo motor
coupler and ECU coupler.
(Black/Green–Black/Green)
(Black/Red–Black/Red)
• Execute the diagnostic mode.
(Code No.53)
• Replace if defective.
Refer to "CHECKING THE
EXUP SERVO MOTOR" on
page 3-17.
Replace if defective.
Check or maintenance job
Open circuit is detected in the input line of ECU No.24 terminal is difected when the start switch is pressed.
Diagnostic code No.
20
Sidestand switch
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Execute the diagnostic mode.
If the transmis• Main wire harness ECU coupler
(Code No.20)
sion is in gear,
• Check the coupler for any pins retracting the
that may be pulled out.
sidestand.
1
• Check the locking condition of If the transmisthe coupler.
sion is in neu• If there is a malfunction, repair it tral,
and connect the coupler
reconnecting
securely.
the wiring.
Open or short circuit in wire harness • Repair or replace if there is an
or sub lead.
open or short circuit.
2
• Between sidestand switch coupler and ECU coupler
(Black–Black)
Defective sidestand switch
• Replace if defective.
3
Refer to "CHECKING THE
SWITCHES" on page 8-81.
Fault code No.
19
Symptom
8-54
FUEL INJECTION SYSTEM
When the main switch is turned to “ON”, the atmospheric
Fault code No. 20 Symptom pressure sensor voltage and intake air pressure sensor
voltage differ greatly.
02
Atmospheric pressure sensor
Diagnostic code No.
03
Intake air pressure sensor
Reinstatement
Item/components and probable
Check or maintenance job
Order
method
cause
Defective intake air pressure sensor or • Execute the diagnostic mode.
Turning the
atmospheric pressure sensor.
(Code Nos. 02, 03)
main switch to
• Replace if defective.
“ON”.
Refer to "CHECKING THE
1
INTAKE AIR PRESSURE SENSOR" on page 8-99 or
"CHECKING THE ATMOSPHERIC PRESSURE SENSOR" on page 8-99.
Coolant temperature sensor:open or short circuit
detected.
Diagnostic code No.
06
Coolant temperature sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the coupler for any pins Turning the
• Coolant temperature sensor coupler that may be pulled out.
main switch to
• Main wire harness ECU coupler
• Check the locking condition of “ON”.
1
• Sub-wire harness coupler
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between coolant temperature
2
sensor coupler and ECU coupler.
(Green/White–Green/White)
(Black/Blue–Black/Blue)
Defective coolant temperature sensor. • Execute the diagnostic mode.
(Code No.06)
• Replace if defective.
3
Refer to "CHECKING THE
COOLANT TEMPERATURE
SENSOR" on page 8-96.
Fault code No.
21
Symptom
8-55
FUEL INJECTION SYSTEM
Intake air temperature sensor:open or short circuit
detected.
Diagnostic code No.
05
Intake air temperature sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
• Intake air temperature sensor couthat may be pulled out.
main switch to
pler
• Check the locking condition of “ON”.
1
• Main wire harness ECU coupler
the couplers.
• Sub-wire harness coupler
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between intake air temperature
2
sensor coupler and ECU coupler.
(Brown/White–Brown/White)
(Black/Blue–Black/Blue)
Defective intake air temperature sen- • Execute the diagnostic mode.
sor.
(Code No.05)
• Replace if defective.
3
Refer to "CHECKING THE
INTAKE AIR TEMPERATURE
SENSOR" on page 8-100.
Fault code No.
22
Symptom
8-56
FUEL INJECTION SYSTEM
Atmospheric pressure sensor:open or short circuit
detected.
Diagnostic code No.
02
Atmospheric pressure sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
• Atmospheric pressure sensor couthat may be pulled out.
main switch to
pler
• Check the locking condition of “ON”.
1
• Main wire harness ECU coupler
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub wire harness 2.
open or short circuit.
• Between atmospheric pressure
sensor coupler and ECU cou2
pler.
(Black/Blue–Black/Blue)
(Pink–Pink)
(Blue–Blue)
Defective atmospheric pressure sen- • Execute the diagnostic mode.
sor.
(Code No.02)
• Replace if defective.
3
Refer to "CHECKING THE
ATMOSPHERIC PRESSURE
SENSOR" on page 8-99.
Fault code No.
23
Symptom
8-57
FUEL INJECTION SYSTEM
No normal signal is received from the O2 sensor.
Fault code No.
24 Symptom
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Installed
state
of
O
sensor.
Check
for
looseness
or
pinching.
Start
and warm
1
2
Connections
• Check the couplers for any pins up the engine
until the cool• O2 sensor coupler
that may be pulled out.
• Check the locking condition of ant tempera• Main wire harness ECU coupler
ture rises over
2
the couplers
• If there is a malfunction, repair it 60 °C.
when acceleratand connect the coupler
ing the throttle,
securely.
the waring light
Open or short circuit in wire harness. • Repair or replace if there is an
is turned off, or
open or short circuit.
it is reset by the
• Between O2 sensor coupler and
diagnostic
ECU coupler.
mode (Code
3
(Gray/Green–Gray/Green)
No.63).
(Black/Blue–Black/Blue)
(Pink/Black–Pink/Black)
(Red/White–Red/White)
Check fuel pressure.
• Refer to "THROTTLE BODIES"
4
on page 7-4.
Defective O2 sensor.
• Replace if defective.
5
Fault code No.
30 Symptom No normal signal is received from the lean angle sensor.
Diagnostic code No.
08
Lean angle sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
1
The vehicle has overturned.
Raise the vehicle upright.
Turning the
Installed state of the lean angle sen- Check the installed direction and main switch to
2
”ON” (however,
sor
condition of the sensor.
Connections
• Check the coupler for any pins the engine cannot be restarted
• Lean angle sensor coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of unless the main
switch is first
3
the coupler.
• If there is a malfunction, repair it turned to
“OFF”).
and connect the coupler
Defective lean angle sensor
4
securely.
• Execute the diagnostic mode.
(Code No.08)
• Replace if defective.
Refer to "CHECKING THE
LEAN ANGLE SENSOR" on
page 8-93.
8-58
FUEL INJECTION SYSTEM
Open circuit detected in the primary lead of the cylinder#1 ignition coil.
Diagnostic code No.
30
Cylinder-#1 ignition coil
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Starting the
• Cylinder-#1 ignition coil coupler
that may be pulled out.
engine and
• Main wire harness ECU coupler
• Check the locking condition of operating it at
1
• Sub-wire harness 1 coupler
the couplers.
idle.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub-wire harness 1.
open or short circuit.
• Between cylinder-#1 ignition
2
coil coupler and ECU coupler.
(Red/Black–Red/Black)
(Orange–Orange)
Defective cylinder-#1 ignition coil
• Execute the diagnostic mode.
(Code No.30)
• Test the primary and secondary
coils for continuity.
3
• Replace if defective.
Refer to "CHECKING THE
IGNITION COILS" on page 891.
Fault code No.
33
Symptom
8-59
FUEL INJECTION SYSTEM
Open circuit detected in the primary lead of the cylinder#2 ignition coil
Diagnostic code No.
31
Cylinder-#2 ignition coil
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Starting the
• Cylinder-#2 ignition coil coupler
that may be pulled out.
engine and
• Main wire harness ECU coupler
• Check the locking condition of operating it at
1
• Sub-wire harness 1 coupler
the couplers.
idle.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub-wire harness 1.
open or short circuit.
• Between cylinder-#2 ignition
2
coil coupler and ECU coupler.
(Red/Black–Red/Black)
(Gray/Red–Gray/Red)
Defective cylinder-#2 ignition coil.
• Execute the diagnostic mode.
(Code No.31)
• Test the primary and secondary
coils for continuity.
3
• Replace if defective.
Refer to "CHECKING THE
IGNITION COILS" on page 891.
Fault code No.
34 Symptom
8-60
FUEL INJECTION SYSTEM
Open circuit detected in the primary lead of the cylinder#3 ignition coil
Diagnostic code No.
32
Cylinder-#3 ignition coil
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Starting the
• Cylinder-#3 ignition coil coupler
that may be pulled out.
engine and
• Main wire harness ECU coupler
• Check the locking condition of operating it at
1
• Sub-wire harness 1 coupler
the couplers.
idle.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub-wire harness 1.
open or short circuit.
• Between cylinder-#3 ignition
2
coil coupler and ECU coupler.
(Red/Black–Red/Black)
(Orange/Green–Orange/Green)
Defective cylinder-#3 ignition coil.
• Execute the diagnostic mode.
(Code No.32)
• Test the primary and secondary
coils for continuity.
3
• Replace if defective.
Refer to "CHECKING THE
IGNITION COILS" on page 891.
Fault code No.
35
Symptom
8-61
FUEL INJECTION SYSTEM
Open circuit detected in the primary lead of the cylinder#4 ignition coil
Diagnostic code No.
33
Cylinder-#4 ignition coil
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Starting the
• Cylinder-#4 ignition coil coupler
that may be pulled out.
engine and
• Main wire harness ECU coupler
• Check the locking condition of operating it at
1
• Sub-wire harness 1 coupler
the couplers.
idle.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness • Repair or replace if there is an
and/or sub-wire harness 1.
open or short circuit.
• Between cylinder-#4 ignition
2
coil coupler and ECU coupler.
(Red/Black–Red/Black)
(Gray/Green–Gray/Green)
Defective cylinder-#4 ignition coil.
• Execute the diagnostic mode.
(Code No.33)
• Test the primary and secondary
coils for continuity.
3
• Replace if defective.
Refer to "CHECKING THE
IGNITION COILS" on page 891.
Fault code No.
36
Symptom
8-62
FUEL INJECTION SYSTEM
Fault code No.
39
Symptom
36
37
Diagnostic code No.
38
39
Item/components and probable
Order
cause
Connections
• Injector coupler
• Main wire harness ECU coupler
1
• Sub-wire harness coupler
•
•
•
Open or short circuit in wire harness
and/or sub-wire harness.
•
•
2
Defective primary injector.
3
•
•
Open circuit detected in a injector.
Injector #1
Injector #2
Injector #3
Injector #4
Reinstatement
Check or maintenance job
method
Check the couplers for any pins Start the engine
that may be pulled out.
and operating it
Check the locking condition of at idle.
the couplers.
If there is a malfunction, repair it
and connect the copler
securely.
Repair or replace if there is an
open or short circuit.
Between primary injector coupler and ECU coupler.
(Red/Blue-Red/Blue)
#1: (Red/Black–Red/Black)
#2: (Green/Black–Green/Black)
#3: (Blue/Black–Blue/Black)
#4: (Orange/Black–Orange/
Black)
Execute the diagnostic mode.
(Code Nos.36, 37, 38, 39)
Replace if defective.
Refer to "CHECKING THE
INJECTORS" on page 7-8.
8-63
FUEL INJECTION SYSTEM
Fault code No. 41 Symptom
Lean angle sensor:open or short circuit detected.
Diagnostic code No.
08
Lean angle sensor
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
• Lean angle sensor coupler
that may be pulled out.
main switch to
• Main wire harness ECU coupler
• Check the locking condition of “ON”.
1
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in lead.
• Repair or replace if there is an
open or short circuit.
• Between lean angle sensor
2
coupler and ECU coupler.
(Blue–Blue)
(Yellow/Green–Yellow/Green)
(Black/Blue–Black/Blue)
Defective lean angle sensor.
• Execute the diagnostic mode.
(Code No.08)
• Replace if defective.
3
Refer to "CHECKING THE
LEAN ANGLE SENSOR" on
page 8-93.
8-64
FUEL INJECTION SYSTEM
A. No normal signals are received from the speed senFault code No.
42 Symptom
sor.
B. Open circuit is detected in the neutral switch.
A
07
Speed sensor
Diagnostic code No.
B
21
Neutral switch
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Installed state of speed sensor.
• Check for looseness or pinchStarting the
A-1
ing.
engine, and
Connections
• Check the couplers for any pins activating the
speed sensor
• Speed sensor coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of by operating the
vehicle at 20 to
A-2
the couplers.
• If there is a malfunction, repair it 30 km/h.
and connect the coupler
securely.
Open or short circuit in lead.
• Repair or replace if there is an
open or short circuit.
• Between speed sensor coupler
A-3
and ECU coupler.
(Blue–Blue)
(White/Yellow–White/Yellow)
(Black/Blue–Black/Blue)
Defective speed sensor
• Execute the diagnostic mode.
(Code No.07)
• Replace if defective.
A-4
Refer to "CHECKING THE
SPEED SENSOR" on page 895.
8-65
FUEL INJECTION SYSTEM
A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
A
07
Speed sensor
Diagnostic code No.
B
21
Neutral switch
Reinstatement
Item/components and probable
Check or maintenance job
Order
method
cause
Installed state of neutral switch.
• Check for looseness or pinchStarting the
B-1
ing.
engine, and
Connections
• Check the couplers for any pins activating the
speed sensor
• Neutral switch coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of by operating the
vehicle at 20 to
B-2
the couplers.
• If there is a malfunction, repair it 30 km/h.
and connect the coupler
securely.
Open circuit in neutral switch lead.
• Repair or replace if there is an
open or short circuit.
• Between neutral switch coupler
and relay unit coupler
B-3
(Sky blue–Sky blue)
• Between relay unit coupler and
ECU coupler.
(Blue/Yellow–Blue/Yellow)
Defective neutral switch.
• Execute the diagnostic mode.
(Code No.21)
B-4
• Replace if defective.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
Faulty shift drum (neutral detection
• Replace if defective.
B-5 area).
Refer to "TRANSMISSION" on
page 5-84.
Fault code No.
42
Symptom
8-66
FUEL INJECTION SYSTEM
Power supply to the injectors and fuel pump is not normal.
Diagnostic code No.
09
Fuel system voltage (battery voltage)
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Starting the
• Relay unit coupler (fuel pump relay)
that may be pulled out.
engine and
• Main wire harness ECU coupler
• Check the locking condition of operating it at
1
the couplers.
idle.
• If there is a malfunction, repair it
and connect it securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between relay unit coupler and
ECU coupler.
(Blue/Yellow–Blue/Yellow)
(Red/Blue–Red/Blue)
2
• Between relay unit coupler and
battery terminal.
(Red–Red)
• Between relay unit coupler and
engine stop switch coupler.
(Red/Black–Red/Black)
Malfunction or open circuit in fuel
• Execute the diagnostic mode.
pump relay
(Code No. 09)
• Replace if defective.
3
• If there is no malfunction with
the fuel pump relay, replace the
ECU.
Fault code No.
43
Symptom
An error is detected while reading or writing on EEPROM
(CO adjustment value).
Diagnostic code No.
60
EEPROM fault cylinder No.
Reinstatement
Orde
Item/components and probable
Check or maintenance job
method
r
cause
Malfunction in ECU
• Execute the diagnostic mode.
Turning the
(Code No. 60)
main switch to
1 Check the faulty cylinder. (If
“ON”.
multiple cylinders are defec1
tive, the number of the faulty
cylinders appears alternately
at 2-second intervals.)
• Replace ECU if defective.
Fault code No.
44
Symptom
8-67
FUEL INJECTION SYSTEM
Power supply to the fuel injection system relay is not normal.
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections.
• Check the coupler for any pins Starting the
• Main wire harness ECU coupler
that may be pulled out.
engine and
• Check the locking condition of operating it at
1
the coupler.
idle.
• If there is a malfunction, repair it
and connect the coupler
securely.
Faulty battery
• Replace or change the battery
Refer to "CHECKING AND
2
CHARGING THE BATTERY" on
page 8-85.
Malfunction in rectifier/regulator
• Replace if defective.
3
Refer to "CHARGING SYSTEM" on page 8-11.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between battery and main
switch
(Red–Red)
4
• Between main switch and ignition fuse
(Brown/Blue–Brown/Blue)
• Between ignition fuse and ECU
(Red/White–Red/White)
Fault code No.
46
Symptom
8-68
FUEL INJECTION SYSTEM
Fault code No.
47
Symptom
Sub-throttle position sensor:open or short circuit
detected.
Diagnostic monitor56
ing code No.
Item/components and probable
Order
cause
Installed state of sub-throttle position
sensor.
1
2
3
4
Sub-throttle servo motor
Check or maintenance job
• Check for looseness or pinching.
• Check that the sensor is
installed in the specified position.
Connections
• Check the couplers for any pins
• Sub-throttle position sensor coupler
that may be pulled out.
• Main wire harness ECU coupler
• Check the locking condition of
• Sub-wire harness coupler
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between sub-throttle position
sensor coupler and ECU coupler.
(Black/Blue–Black/Blue)
(Green/Yellow–Green/Yellow)
(Blue–Blue)
Defective sub-throttle position sensor. • Execute the diagnostic mode.
(Code No. 56)
• Replace if defective.
Refer to "CHECKING THE
SUB-THROTTLE POSITION
SENSOR" on page 8-97.
8-69
Reinstatement
method
Turning the
main switch to
“ON”.
FUEL INJECTION SYSTEM
Fault code No.
48 Symptom
Diagnostic code No.
56
Item/components and probable
Order
cause
Connections
• Sub-throttle servo motor coupler
• Main wire harness ECU coupler
1
•
•
•
Open or short circuit in wire harness.
•
•
2
Defective sub-throttle servo motor
•
•
3
Sub-throttle servo motor:stuck.
Sub-throttle servo motor
Reinstatement
Check or maintenance job
method
Check the couplers for any pins Turning the
that may be pulled out.
main switch to
Check the locking condition of “ON”.
the couplers.
If there is a malfunction, repair it
and connect the coupler
securely.
Repair or replace if there is an
open or short circuit.
Between sub-throttle servo
motor coupler and ECU coupler
(Yellow/Red–Yellow/Red)
(Yellow/White–Yellow/White)
Execute the diagnostic mode.
(Code No. 56)
Replace if defective.
Refer to "CHECKING THE
SUB-THROTTLE SERVO
MOTOR" on page 7-10.
Faulty ECU memory. (When this malfunction is detected
in the ECU, the fault code number might not appear on
the meter.)
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Malfunction in ECU.
Replace the ECU.
Turning the
main switch to
NOTE:
“ON”
Do not perform this procedure
1
with the main switch turned to
“ON”.
Fault code No.
50
Symptom
8-70
FUEL INJECTION SYSTEM
Fault code No. Er-1 Symptom
Diagnostic code No.
—
Item/components and probable
Order
cause
Connections
• Main wire harness ECU coupler
• Main wire harness meter assembly
1
coupler
• Sub-wire harness coupler
Open or short circuit in wire harness.
2
3
4
Malfunction in meter assembly.
Malfunction in ECU.
No signals are received from the ECU.
—
Reinstatement
Check or maintenance job
method
• Check the couplers for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of “ON”.
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
• Repair or replace if there is an
open or short circuit.
• Between meter assembly coupler and ECU coupler.
(Yellow/Blue–Yellow/Blue)
Replace the meter assembly.
Replace the ECU.
No signals are received from the ECU within the specified
duration.
Diagnostic code No.
—
—
Reinstatement
Item/components and probable
Check or maintenance job
Order
method
cause
Connections
• Check the couplers for any pins Turning the
• Main wire harness ECU coupler
that may be pulled out.
main switch to
• Main wire harness meter assembly • Check the locking condition of “ON”.
1
coupler
the couplers.
• Sub-wire harness coupler
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
2
• Between meter assembly coupler and ECU coupler.
(Yellow/Blue–Yellow/Blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
Fault code No.
Er-2 Symptom
8-71
FUEL INJECTION SYSTEM
Fault code No. Er-3 Symptom
Data from the ECU cannot be received correctly.
Diagnostic code No.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
• Main wire harness ECU coupler
that may be pulled out.
main switch to
• Main wire harness meter assembly • Check the locking condition of “ON”.
1
coupler
the couplers.
• Sub-wire harness coupler
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
2
• Between meter assembly coupler and ECU coupler.
(Yellow/Blue–Yellow/Blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
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.
—
—
Item/components and probable
Reinstatement
Order
Check or maintenance job
cause
method
Connections
• Check the couplers for any pins Turning the
main switch to
• Main wire harness ECU coupler
that may be pulled out.
• Main wire harness meter assembly • Check the locking condition of “ON”.
coupler
the couplers.
1
• Sub-wire harness coupler
• If there is a malfunction, repair it
and connect the coupler
securely.
Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
2
• Between meter assembly coupler and ECU coupler.
(Yellow/Blue–Yellow/Blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
8-72
B
L
L
R
78
80
L/Y L/B
L/B L/Y
R
B
L
Gy
L
Br/G
Br/L
Br/L
Br/L
B
79
77
R
76
75
74
81
R/W
R/Y
Br
2
R
B
W W W
B
R/W
R
Br/L
W
W
W
W
W
W
3
L/B
R/Y
Y/B
B
B/Y
B/L
73
B/L
B/Y
Y B/G B
72
Y
B/G
Y/B C Y/B
82
B
Br Y
R
R
B B
R
L
71
B
R
9
Y
8
7
R/W L/W
Y L/R B
Br B R/B
R/B B Br
56
R/W L/W G/Y
R
G/Y L/W R/W
52
6
B
B
B
B
L/R
R
Br
R
G/Y
L/B
L/Y
5
L/W
R/W
R
53
Br
R
R
R/W
Br/W R/Y
R/B
70
Y Dg
L/R C L/R
B/Y
Br B/Y B B/R Ch
R/Y Br/W
57
PUSH
FREE
55
Y D Y
Ch L/Y B B/Y Br
Dg Y
RUN
OFF
54
L/W G/R
B/G
B
B/Y Sb/W
R/B L/W R/L
B/W B/R L/W L/Y R/W L/B L/Y Sb
R
L/W
Br/L
R/G
B
69
58
L/W
R/W
ON
OFF
B
1
R/W
Gy
Br/L
Br/G
L
L
B
R
Br/G
Br/G
L
L
B
R/Y
B/L
R/Y C R/Y
L/B
Y/B
B/L
B/Y
10
59
LO
HI
11
B/Y
B/G
B
Sb
Br
Br/W
N
OFF
Br
Br/W
L
R
64
61
ON
60
13
12
HEADLIGHT SUB-WIRE HARNESS 1
L/Y
L/B B
B B
14
65
L
B
L/R Ch
B
Ch
ON
OFF
62
O/G R/B O Gy/R
63
R/L B
G/W B
66
B
L/R Dg
B
Dg L
15
WIRE HARNESS
R/W B/L
Gy/G L Br/R W/B
B
67
B
Ch
B
B/L R/W
W
51
W
W D W
B
Dg
B
Dg
68
Dg
Ch
G/W
W
R/G
R/W
39
SUB-WIRE HARNESS 2
Ch C Ch
Ch
Gy/R O R/B O/G
W/B Br/R L Gy/G
R/G C R/G
Sb/W Ch B Y/B R/W
Sb/W
Sb
4
L/Y
B/G
L/W
R/Y
R/B
B/Y
R
Y
R
R/L
WIRE HARNESS
B/G
L/B
L/B
B
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
L/R
B
R/W C R/W
R/W Y/B B Ch Sb/W
B/Y
B
W
G/W Dg L/R R/G R/Y
Ch
Ch
R/L
B
C
L/R
G/W
B
B
L/Y
Br/W
L/R
B
Br
Dg C Dg
Dg
B
Y
Y
B
B/Y
R/Y R/G L/R Dg G/W
W
50
50
49
48
47
46
45
Y/L Sb/W
B/L
L W/B
B
Y/L
Sb/W
WIRE HARNESS
B/Y R/Y B Dg Ch
R/G R/W G/W
44
43
42
41
40
17
L
G/B R/B R/L
B/L
W L/Y
L B L
B/L P
B/L
G/W B/L
B/L
B/L
Gy/G B/L
P/B R/W
B/L
R/W
B B
20
38
L
B/L P/W L
35
B/L Y
37
21
W L
36
L Y/G B/L
Lg
19
B/L
Br/W B/L
L
W L/Y
B/L
B/L Gy
L W/Y
B/L B B/L
W/B W/B B W/B
B/L
P/W
L
L
Y
B/L
G/W
P/W A P/W
P/W
B/L
L
Y
G/W
Br/W
Gy/G
P/B
Y/G
P
W/Y
W/B
Gy
L/B
B/Y
L/Y
L/W
R/L
R/W
L/Y
B/Y
Y/R L/B
B/L A B/L
L A L
Y A Y
G/W A G/W
A
B/L
Y Y/G
W/B Gy P R/Y
L/W R/W
B/R B/L W/R P/W Y/L Gy/G R/L Br/W Br/Y O/Y G/Y G/R B
B/W L
Y/W Lg
Br/W
Gy
W/Y
L
B Gy
16
Br/W Br/W
Gy/G
P/B
B/L
Y/G
L
P
B/L
L
18
B/L
SUB-WIRE HARNESS 1
G/W P/W B/L
L O/B L/B Y/R
B/L P/W G/W
G/Y Br/W Y Y/W
A
Y/W Y Br/W G/Y
R/L R/B G/B
Y/R L/B O/B L
SbW C SbW
W
YL D YL
Y
B/Y
B
B C B
Ch
B
G/W C G/W
Dg
B
8-73
B D B
B Y/L
22
B
R/B
L/B
B/L
B/R
B/W
B/W
L
W/R
B/R
W/R
B/L
G/Y
L
Y/R
Y/W
Y/R A Y/R
G/Y A G/Y
Br/R
R/L O/B
O/B
R/L L/B
R/L G/B
G/B
R/L R/B
R/B
Gy/G
Y/W A Y/W
Br/R
R/B
O/G
G/Y
B
R/B
Gy/R
Y/W
Br/R
O/B A O/B
L/B A L/B
G/B A G/B
R/B A R/B
Gy/G B Gy/G
O/G B O/G
Gy/R B Gy/R
O B O
B
O
R/B
Y/R
Y/L
Y/B
Gy
Br/R
O/B
L/B
G/B
R/B
Gy/G
O/G
Gy/R
O
B
G/W
P/B
Y/B Br/R R/B O G/B Gy/R L/B O/G O/B Gy/G
Gy
R/B B R/B
W/Y
B
D
B
Y
B
W
B
Y/L B
33
Br Br/R
32
31
30
29
28
27
27
27
27
34
R/W
Gy/G R/B
O/G R/B
Gy/R R/B
O R/B
Br/R R/W
R/W
R/L
R/L
R/L
R/L
26
25
24
23
Y/W Y/R
R/W
R/L A R/L
B/W B/R
L W/R B/L
B/L G/Y L
B
FUEL PUMP SYSTEM
EAS27550
FUEL PUMP SYSTEM
EAS27560
CIRCUIT DIAGRAM
R/Y
Dg
L/W
FUEL PUMP SYSTEM
1. Main switch
5. Fuse (main)
6. Battery
7. Fuse (fuel injection)
12.Relay unit (fuel pump)
15.Fuel pump
22.ECU
44.Multi function meter
54.Engine stop switch
74.Fuse (ignition)
8-74
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
NOTE:
• Before troubleshooting, remove the following part(s):
1 Rider and passenger seat
2 Fuel tank
3 Air filter case
1 Check the fuses.
(Main, ignition and fuel injection
system)
Refer to "CHECKING THE FUSES"
on page 8-85.
NG→
Replace the fuse(s).
OK↓
2 Check the battery.
Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-85.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3 Check the main switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the main switch.
OK↓
4 Check the engine stop switch.
Refer to "CHECKING THE
SWITCHES" on page 8-81.
NG→
Replace the right handlebar switch.
OK↓
5 Check the relay unit (fuel pump
relay).
Refer to "CHECKING THE
RELAYS" on page 8-88.
NG→
Replace the relay unit.
OK↓
6 Check the fuel pump.
Refer to "CHECKING THE FUEL
PRESSURE" on page 7-8.
NG→
Replace the fuel pump.
OK↓
7 Check the entire fuel pump system’s wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-73.
NG→
Properly connect or repair the fuel
pump system’s wiring.
OK↓
Replace the ECU.
8-75
ELECTRICAL COMPONENTS
EAS27970
ELECTRICAL COMPONENTS
8-77
ELECTRICAL COMPONENTS
1. Main switch
2. Front brake light switch
3. Starter relay
4. Battery
5. Fuse box
6. Rear brake light switch
7. Neutral switch
8. Sidestand switch
9. Oil level switch
10.Radiator fan motor
11.Horn
12.Ignition coil
8-78
ELECTRICAL COMPONENTS
8-79
ELECTRICAL COMPONENTS
1. Coolant temperature sensor
2. Intake air temperature sensor
3. Intake air pressure sensor
4. Fuel pump
5. ECU
6. Lean angle sensor
7. Starting circuit cut-off relay
8. Headlight relay (on/off)
9. Headlight relay (dimmer)
10.Radiator fan motor relay
11.Turn signal relay
12.Recifier/regulator
13.Throttle position sensor
14.Sub-throttle position sensor
8-80
ELECTRICAL COMPONENTS
EAS27980
CHECKING THE SWITCHES
8-81
ELECTRICAL COMPONENTS
1. Main switch
2. Horn switch
3. Dimmer switch
4. Turn signal switch
5. Hazard switch
6. Clutch switch
7. Sidestand switch
8. Fuse box
9. Engine stop switch
10.Front brake light switch
11.Start switch
12.Oil level switch
13.O2 sensor
14.Neutral switch
15.Rear brake light switch
8-82
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes
from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in
the top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indication
by “
” There is continuity between red, brown/blue, and brown/red when the switch is set to
“ON” and between red and brown/red when the switch is set to “ ”.
8-83
ELECTRICAL COMPONENTS
hands away from the bulb until it has
cooled down.
EAS27990
CHECKING THE BULBS AND BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for continuity between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
ECA14380
CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight 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 it with a cloth
moistened with alcohol or lacquer thinner.
Types of bulbs
The bulbs used on this vehicle are shown in
the following illustration.
• Bulbs “a” and “b” are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by turning them counterclockwise.
• Bulbs “c” is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
2. Check:
• Bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “2”, and check the continuity.
b. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “3”, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
1. Remove:
• Bulb
EWA13320
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
Checking the condition of the bulb sockets
8-84
ELECTRICAL COMPONENTS
The following procedure applies to all of the
bulb sockets.
1. Check:
• Bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
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 electrical circuit.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Fuses
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
Main
Headlight
Signaling system
Fuel injection system
Ignition
Buckup
Radiator fan motor
Reserve
Reserve
Reserve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Q’ty
1
1
1
1
1
1
2
1
1
1
EWA13310
EAS28000
WARNING
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
ECA13680
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing a fuse.
1.
•
2.
•
Amperage
rating
50 A
20 A
10 A
15 A
15 A
10 A
10 A
10 A
15 A
20 A
Remove:
Rider and passenger seat
Check:
Fuse
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Rider and passenger seat
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS28030
a. Connect the pocket tester to the fuse and
check the continuity.
CHECKING AND CHARGING THE BATTERY
EWA13290
NOTE:
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
WARNING
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. If the pocket tester indicates “∞”, replace
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-85
ELECTRICAL COMPONENTS
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
3.
•
4.
•
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery terminals.
ECA13660
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal
CAUTION:
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown
in the charts and the following example.
NOTE:
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
1.
•
2.
•
Remove:
Battery
Check:
Battery charge
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method
illustration)
Remove:
Rider and passenger seat
Disconnect:
Battery leads
(from the battery terminals)
EWA13300
WARNING
Do not quick charge a battery.
ECA13640
CAUTION:
ECA13670
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
CAUTION:
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
8-86
ELECTRICAL COMPONENTS
•
•
•
•
•
•
•
c. Make sure that the current is higher than
the standard charging current written on
the battery.
into the battery quickly and can cause
battery overheating and battery plate
damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit voltage.
NOTE:
If the current is lower than the standard charging current written on the battery, set the
charging voltage adjust dial at 20–24 V and
monitor the amperage for 3–5 minutes to
check the battery.
• Reach the standard charging current
Battery is good.
• Does not reach the standard charging current
Replace the battery.
d. Adjust the voltage so that the current is at
the standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
f. If charging requires more than 5 hours, it is
advisable to check the charging current
after a lapse of 5 hours. If there is any
change in the amperage, readjust the voltage to obtain the standard charging current.
g. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to
charging.
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
NOTE:
NOTE:
Voltage should be measured 30 minutes after
the machine is stopped.
Voltage should be measured 30 minutes after
the machine is stopped.
b. Connect a charger and AMP meter to the
battery and start charging.
c. Make sure that the current is higher than
the standard charging current written on
the battery.
b. Connect a charged and AMP meter to the
battery and start charging.
NOTE:
Set the charging voltage at 16–17 V.If the setting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
8-87
ELECTRICAL COMPONENTS
EAS28040
NOTE:
CHECKING THE RELAYS
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, replace the relay.
If the current is lower than the standard charging current written on the battery, this type of
battery charger cannot charge the MF battery.
A variable voltage charger is recommended.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
d. Charge the battery until the battery’s charging voltage is 15 V.
NOTE:
Set the charging time at 20 hours (maximum).
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace.
e. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1.
•
2.
•
Install:
Battery
Connect:
Battery leads
(to the battery terminals)
1.
2.
3.
4.
ECA13630
CAUTION:
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Relay operation
Continuity/No continuity
(between “3” to “4”)
Relay unit (starting circuit cut-off relay)
3. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
4. Lubricate:
• Battery terminals
1.
2.
3.
4.
Recommended lubricant
Dielectric grease
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
5. Install:
• Rider and passenger seat
Relay unit (fuel pump relay)
8-88
ELECTRICAL COMPONENTS
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
(between “3” to “5”)
Radiator fan motor relay
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
Headlight relay (on/off)
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
ET2D1030
1.
2.
3.
4.
CHECKING THE TURN SIGNAL/HAZARD
RELAY
1. Check:
• Turn signal/hazard relay input voltage
Out of specification → The wiring circuit
from the main switch to the turn signal/hazard relay coupler is faulty and must be
repaired.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
Turn signal/hazard relay input
voltage
DC 12 V
Headlight relay (dimmer)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
8-89
ELECTRICAL COMPONENTS
EAS28050
• Positive tester probe →
Brown “1”
• Negative tester probe →
Ground
CHECKING THE RELAY UNIT (DIODE)
1. Check:
• Relay unit (diode)
Out of specification → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
The pocket tester and the analog pocket tester
readings are shown in the following table.
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Turn signal/hazard relay output voltage
Out of specification → Replace.
Turn signal/hazard relay output
voltage
DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
Brown/White “1”
• Negative tester probe →
Ground
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-90
ELECTRICAL COMPONENTS
a. Disconnect the relay unit coupler from the
wire harness.
b. Connect the pocket tester (Ω×1) to the
relay unit terminal as shown.
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continuity.
Continuity
Positive tester probe → Sky
blue “1”
Negative tester probe →
Black/Yellow “2”
No continuity
Positive tester probe → Black/
Yellow “2”
Negative tester probe → Sky
blue “1”
Continuity
Positive tester probe → Sky
blue “1”
Negative tester probe → Blue/
Yellow “3”
No continuity
Positive tester probe → Blue/
Yellow “3”
Negative tester probe → Sky
blue “1”
Continuity
Positive tester probe → Sky
blue “1”
Negative tester probe → Sky
blue/White “4”
No continuity
Positive tester probe → Sky
blue/White “4”
Negative tester probe → Sky
blue “1”
Continuity
Positive tester probe → Blue/
Black “5”
Negative tester probe → Blue/
Yellow “3”
No continuity
Positive tester probe → Blue/
Yellow “3”
Negative tester probe → Blue/
Black “5”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28100
CHECKING THE IGNITION COILS
The following procedure applies to all of the
ignition coils.
1. Check:
• Primary coil resistance
Out of specification → Replace.
Primary coil resistance
1.19–1.61 Ω at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil leads from the
wire harness.
b. Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Ignition coil terminal
• Negative tester probe
Ignition coil terminal
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Secondary coil resistance
Out of specification → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8-91
ELECTRICAL COMPONENTS
Secondary coil resistance
8.5–11.5 kΩ at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil leads from the
wire harness.
b. Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Spark plug cap
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
• Negative tester probe
Ignition coil terminal “1”
• Positive tester probe
Spark plug terminal “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28110
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crankshaft position sensor.
Crankshaft position sensor
resistance
336–504 Ω at 20°C (68°F)
c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Ignition spark gap “a”
Out of specification → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
Minimum ignition spark gap
6.0 mm (0.24 in)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker/dynamic
spark tester “2” as shown.
• Positive tester probe
Gray “1”
• Negative tester probe
Black “2”
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
8-92
ELECTRICAL COMPONENTS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1034
CHECKING THE STARTOR MOTOR OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting
with step5.
Refer to "TROUBLESHOOTING" on page
8-9.
b. Measure the crankshaft position sensor
resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
• Lean angle sensor
2. Check:
• Lean angle sensor out put voltage
Out of specification → Replace.
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
lead “3”.
EWA13810
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the battery, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
Lean angle sensor output voltage
Less than 65°: 0.4–1.4 V
More than 65°: 3.7–4.4 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
• Positive tester probe
Yellow/Green “1”
• Negative tester probe
Black/Blue “2”
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Startor coil resistance
Out of specification → Replace the startor
coil.
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
• Stator coil resistance
Out of specification → Replace the startor
coil.
c. When turn the lean angle sensor to 65°.
d. Measure the lean angle sensor output voltage.
Stator coil resistance
0.14–0.18 Ω at 20°C (68°F)
8-93
ELECTRICAL COMPONENTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
a. Connect the pocket tester (Ω × 1) to the
stator coil coupler as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Red “1”
• Negative tester probe
Black “2”
• Positive tester probe
White “1”
• Negative tester probe
White “2”
• Positive tester probe
White “1”
• Negative tester probe
White “3”
• Positive tester probe
White “2”
• Negative tester probe
White “3”
c. Start the engine and let it run at approximately 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28180
CHECKING THE HORN
1. Check:
• Horn resistance
Out of specification → Replace.
b. Measure the startor coil resistance.
Horn resistance
1.15–1.25 Ω at 20°C (68°F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltage
Out of specification → Replace the rectifier/
regulator.
a. Disconnect the horn leads from the horn
terminals.
b. Connect the pocket tester (Ω × 1) to the
horn terminals.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Charging voltage
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the ignition
coil of cylinder #1.
b. Connect the pocket tester (AC 20 V) to the
rectifier/regulator coupler as shown.
• Positive tester probe
Horn terminal “1”
• Negative tester probe
Horn terminal “2”
8-94
ELECTRICAL COMPONENTS
a. Connect the pocket tester (Ω × 10) to the
fuel sender terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Green/white “1”
• Negative tester probe
Black “2”
c. Measure the horn resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Horn sound
Faulty sound → Adjust or replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or
“b” until the specified horn sound is
obtained.
b. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
Out of specification → Replace.
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS28230
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
CHECKING THE FUEL SENDER
1. Remove:
• Fuel tank
2. Disconnect:
• Fuel pump coupler
• Fuel sender coupler
(from the wire harness)
3. Remove:
• Fuel pump
(from the fuel tank)
4. Check:
• Fuel sender resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
White/Yellow “1”
• Negative tester probe
Black/Blue “2”
Fuel sender resistance
Full position of the float
19–21Ω at 20°C (68°F)
Empty position of the float
139–141 Ω at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8-95
ELECTRICAL COMPONENTS
b. Set the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage (DC 5 V) of White/Yellow and Blue. With each full rotation of the
rear wheel, the voltage reading should
cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
Coolant temperature sensor
resistance
0°C (32°F) : 5.21–6.37 kΩ
80°C (176°F) : 0.29–0.35 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the
coolant temperature sensor “1” as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28250
CHECKING THE RADIATOR FAN MOTOR
1. Check:
• Radiator fan motor
Faulty/rough movement → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
• Positive tester probe
Coolant temperature sensor terminal
• Negative tester probe
Coolant temperature sensor terminal
• Positive tester probe
Blue “1”
• Negative tester probe
Black “2”
b. Immerse the coolant temperature sensor in
a container filled with coolant “2”.
NOTE:
Make sure the coolant temperature sensor terminals do not get wet.
c. Place a thermometer “3” in the coolant.
c. Measure the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28260
CHECKING THE COOLANT TEMPERATURE
SENSOR
1. Remove:
• Coolant temperature sensor
EWA14130
WARNING
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Out of specification → Replace.
8-96
ELECTRICAL COMPONENTS
d. While slowly opening the throttle, check
that the throttle position sensor resistance
is within the specified range.
The resistance does not change or it
changes abruptly → Replace the throttle
position sensor.
d. Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
e. Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Throttle position sensor resistance
0–6 kΩ at 20°C (68°F)
EAS28300
CHECKING THE THROTTLE POSITION
SENSOR
1. Remove:
• Throttle position sensor
(from the throttle body)
2. Check:
• Throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the
throttle position sensor as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Throttle position sensor
NOTE:
• Tester positive lead →
Blue “1”
• Tester negative lead →
Black/Blue “2”
When installing the throttle position sensor,
adjust its angle properly. Refer to "ADJUSTING THE THROTTLE POSITION SENSOR"
on page 7-8.
b. Check the throttle position sensor maximum resistance.
Out of specification → Replace the throttle
position sensor.
EAS2D1010
CHECKING THE SUB-THROTTLE POSITION
SENSOR
1. Remove:
• Sub-throttle position sensor
(from the throttle body)
2. Check:
• Sub-throttle position sensor
Maximum throttle position sensor resistance
4–6 kΩ at 20°C (68°F)
c. Connect the pocket tester (Ω × 1k) to the
throttle position sensor as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the sub-throttle motor coupler.
b. Disconnect the sub-throttle position sensor
coupler.
c. Remove the sub-throttle position sensor
from the sub-throttle servo motor.
d. Connect the pocket tester (Ω × 1k) to the
sub-throttle position sensor as shown.
• Tester positive lead →
Yellow “3”
• Tester negative lead →
Black/Blue “2”
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
8-97
ELECTRICAL COMPONENTS
• Tester positive lead →
Blue “1”
• Tester negative lead →
Black/Blue “2”
e. Check the throttle position sensor maximum resistance.
Out of specification → Replace the throttle
position sensor.
Maximum sub-throttle position
sensor resistance
4–6 kΩ at 20°C (68°F)
f.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Sub-throttle position sensor
Connect the pocket tester (Ω × 1k) to the
throttle position sensor as shown.
NOTE:
When installing the throttle position sensor,
adjust its angle properly. Refer to "ADJUSTING THE SUB-THROTTLE POSITION SENSOR" on page 7-9.
• Tester positive lead →
Green/Yellow “3”
• Tester negative lead →
Black/Blue “2”
EAS28370
CHECKING THE AIR INDUCTION SYSTEM
SOLENOID
1. Check:
• Air induction system solenoid resistance
Out of specification → Replace.
Air induction system solenoid
resistance
18–22 Ω at 20°C (68°F)
g. While slowly opening the sub-throttle worm
nut, check that the sub-throttle position
sensor resistance is within the specified
range.
The resistance does not change or it
changes abruptly → Replace the sub-throttle position sensor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the Air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (Ω × 1) to the Air
induction system solenoid terminal as
shown.
NOTE:
Check mainly that the resistance changes
gradually when turning the sub-throttle worm
nut, since the readings (from closed to wideopen sub-throttle) may differ slightly from those
specified.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Brown “1”
• Negative tester probe
Brown/Red “2”
Throttle position sensor resistance
0–6 kΩ at 20°C (68°F)
8-98
ELECTRICAL COMPONENTS
EAS28390
CHECKING THE CYLINDER IDENTIFICATION SENSOR
1. Check:
• Cylinder identification sensor output voltage
Out of specification → Replace.
Cylinder identification sensor
output voltage
When sensor is on
4.8 V or more
When sensor is off
0.8 V or less
c. Measure the Air induction system solenoid
resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28380
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE ATMOSPHERIC PRESSURE SENSOR
1. Check:
• Atmospheric pressure sensor output voltage
Out of specification → Replace.
a. Connect the pocket tester (DC 20 V) to the
cylinder identification sensor coupler (wire
harness side) as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Atmospheric pressure sensor
output voltage
3.75–4.25 V
• Positive tester probe
White/Black “1”
• Negative tester probe
Black/Blue “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
atmospheric pressure sensor coupler (wire
harness side) as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Pink “1”
• Negative tester probe
Black/Blue “2”
b. Set the main switch to “ON”.
c. Rotate the crankshaft.
d. Measure the voltage (DC 20 V) of White/
Black and Black/Blue. With each full rotation of the crankshaft, the voltage reading
should cycle from 0.8 V to 4.8 V to 0.8 V to
4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28410
CHECKING THE INTAKE AIR PRESSURE
SENSOR
1. Check:
• Intake air pressure sensor output voltage
Out of specification → Replace.
b. Set the main switch to “ON”.
c. Measure the atmospheric pressure sensor
output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-99
ELECTRICAL COMPONENTS
a. Connect the pocket tester (Ω × 100) to the
intake air temperature sensor terminal as
shown.
Intake air pressure sensor output voltage
3.75–4.25 V
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler (wire
harness side) as shown.
• Positive tester probe
Brown/White “1”
• Negative tester probe
Black/Blue “2”
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe
Pink/White “1”
• Negative tester probe
Black/Blue “2”
b. Measure the intake air temperature sensor
resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Set the main switch to “ON”.
c. Measure the intake air pressure sensor
output voltage.
3. Install:
• Intake air temperature sensor
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28420
CHECKING THE INTAKE AIR TEMPERATURE SENSOR
1. Remove:
• Intake air temperature sensor
(from the air filter case.)
EWA14110
WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
2. Check:
• Intake air temperature sensor resistance
Out of specification → Replace.
Intake air temperature sensor
resistance
2.21–2.69 kΩ at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8-100
Intake air temperature sensor
bolt
1.2 Nm (0.12 m·kg, 0.87 ft·lb)
TROUBLESHOOTING
• Sucked-in air
EAS28450
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
4. Ignition coil(s)
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
5. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
6. Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections
7. Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS28460
GENERAL INFORMATION
NOTE:
The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure in this manual for checks, adjustments,
and replacement of parts.
EAS28470
STARTING FAILURES
Engine
1. Cylinder(s) and cylinder head(s)
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston(s) and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
EAS28490
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder(s) and cylinder head(s)
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel filter
• Clogged fuel strainer
• Clogged fuel tank drain hose
• Clogged rollover valve hose
• Deteriorated or contaminated fuel
2. Fuel pump
• Faulty fuel pump
• Faulty fuel pump relay
3. Throttle body (-ies)
• Deteriorated or contaminated fuel
Fuel system
1. Throttle body (-ies)
• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improperly adjusted engine idling speed
(idle adjusting screw)
9-1
TROUBLESHOOTING
• Improperly assembled transmission
• Improper throttle cable free play
• Flooded throttle body
• Faulty air induction system
EAS28550
JUMPS OUT OF GEAR
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
3. Ignition coil(s)
• Broken or shorted primary or secondary
coils
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
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
EAS28560
FAULTY CLUTCH
Clutch slips
1. Clutch
• Improperly assembled clutch
• Improperly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS28510
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to "STARTING FAILURES" on page 9-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
Clutch drags
1. Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS28530
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to Clutch drags.
EAS28540
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
EAS28600
OVERHEATING
Engine
1. Clogged coolant passages
• Cylinder head(s) and piston(s)
• Heavy carbon buildup
Transmission
• Seized transmission gear
• Foreign object between transmission gears
9-2
9
TROUBLESHOOTING
2.
•
•
•
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
•
•
•
•
•
•
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
• Thermostat
• Thermostat stays closed
• Oil cooler
• Clogged or damaged oil cooler
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
EAS28660
FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
Malfunction
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
Fuel system
1. Throttle body (-ies)
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
EAS28670
Chassis
1. Brake(s)
• Dragging brake
UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly(-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire(s)
Electrical system
1. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
EAS28610
OVERCOOLING
Cooling system
1. Thermostat
• Thermostat stays open
EAS28620
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
9-3
TROUBLESHOOTING
•
•
•
7.
•
•
•
•
•
8.
•
•
•
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
Uneven tire pressures (front and rear)
Incorrect tire pressure
Uneven tire wear
Wheel(s)
Incorrect wheel balance
Deformed cast wheel
Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Improperly installed bearing race
Turn signal blinks slowly
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
Turn signal remains lit
• Faulty turn signal relay
• Burnt-out turn signal bulb
Turn signal blinks quickly
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal bulb
EAS28710
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
Horn does not sound
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
Tail/brake light does not come on
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
Turn signal does not come on
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
9-4
FZS10V/FZS10VC WIRING DIAGRAM
FZS10V/FZS10VC WIRING DIAGRAM
D
C
HEADLIGHT
WIRE HARNESS SUB-WIRE HARNESS 2
WIRE HARNESS
B
HEADLIGHT SUB-WIRE HARNESS 1
A
WIRE HARNESS
SUB-WIRE HARNESS 2
WIRE HARNESS
SUB-WIRE HARNESS 1
4
5
23
27
1
24
ON
OFF
2
3
6
27
7
25
8
82
27
10
9
26
11
16
12
27
17
28
18
74
19
15
14
29
13
20
30
52
31
53
22
54
55
OFF
FREE
RUN
PUSH
21
32
39
75
40
38
41
76
42
57
37
43
56
59
B B
60
61
62
HI
ON
R
OFF
LO
OFF
N
ON
L
33
36
44
B
58
45
77
63
46
72
34
64
51
47
35
48
49
73
50
79
78
50
80
81
69
70
71
65
66
67
68
EAS28740
WIRING DIAGRAM
1. Main switch
2. Rectifier/regulator
3. A.C.magneto
4. Fuse (backup)
5. Fuse (main)
6. Battery
7. Fuse (fuel injection)
8. Starter relay
9. Starter motor
10. Starting circuit cut-off relay
11. Relay unit (diode)
12. Relay unit (fuel pump)
13. Neutral switch
14. Sidestand switch
15. Fuel pump
16. Crankshaft position sensor
17. Cylinder identification sensor
18. Speed sensor
19. Atmospheric pressure sensor
20. Lean angle sensor
21. O2 sensor
22. E.C.U.
23. Ignition coil #1
24. Ignition coil #2
25. Ignition coil #3
26. Ignition coil #4
27. Spark plug
28. Injector #1
29. Injector #2
30. Injector #3
31. Injector #4
32. Air induction system solenoid
33. Sub-throttle position sensor
34. EXUP servo motor
35. Intake air pressure sensor
36. Throttle position sensor
37. Coolant temperature sensor
38. Intake air temperature sensor
39. Meter assembly
40. Fuel level warning light
41. Oil level warning light
42. Neutral indicator light
43. Tacho meter
44. Multi function meter
45. Engine trouble warning light
46. Coolant temperature indicator
light
47. Hi beam indicator light
48. Turn signal indicator light (left)
49. Turn signal indicator light
(light)
50. Meter light
51. Oil level switch
52. Right handlebar switch
53. Front brake light switch
54. Engine stop switch
55. Start switch
56. Rear brake light switch
57. Left handlebar switch
58. Clutch switch
59. Dimmer switch
60. Hazard switch
61. Turn signal switch
62. Horn switch
63. Horn
64. Turn signal relay
65. Front turn signal/position light
(left)
66. Front turn signal/position light
(right)
67. Rear turn signal light (left)
68. Rear turn signal light (right)
69. Headlight
70. License plate light
71. Tail/brake light
72. Headlight relay (on/off)
73. Headlight relay (dimmer)
74. Fuse (ingition)
75. Fuse (signal)
76. Fuse (headlight)
77. Radiator fan motor relay
78. Fuse (radiator fan motor left)
79. Fuse (radiator fan motor right)
80. Radiator fan motor (left)
81. Radiator fan motor (right)
82. Ground
ET2D1023
COLOR CODE
B
Br
Ch
Dg
Gy
L
Lg
O
P
R
Sb
W
Y
B/G
B/L
B/R
B/W
B/Y
Br/G
Br/L
Br/R
Br/W
Br/Y
G/B
G/R
Black
Brown
Chocolate
Dark green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/Green
Black/Blue
Black/Red
Black/White
Black/Yellow
Brown/Green
Brown/Blue
Brown/Red
Brown/White
Brown/Yellow
Green/Black
Green/Red
G/W
G/Y
Gy/G
Gy/R
L/B
L/R
L/W
L/Y
O/B
O/G
O/Y
P/B
P/W
R/B
R/G
R/L
R/W
R/Y
Sb/W
W/B
W/R
W/Y
Y/B
Y/G
Y/L
Y/R
Y/W
Green/White
Green/Yellow
Gray/Green
Gray/Red
Blue/Black
Blue/Red
Blue/White
Blue/Yellow
Orange/Black
Orange/Green
Orange/Yellow
Pink/Black
Pink/White
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
Sky blue/White
White/Black
White/Red
White/Yellow
Yellow/Black
Yellow/Green
Yellow/Blue
Yellow/Red
Yellow/White