Yamaha R-700 Service manual

Yamaha R-700 Service manual
YFM700RV
SERVICE MANUAL
LIT-11616-19-13
1S3-28197-10
EBS00001
YFM700RV
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First Edition, May 2005
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.
LIT-11616-19-13
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all 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:
Designs and specifications are subject to change without notice.
_
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
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.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
1
EBS00006
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Cooling system
6 Fuel injection system
7 Chassis
8 Electrical
9 Troubleshooting
ENG
5
6
FI
COOL
7
8
CHAS
ELEC
9
0
–
Symbols 0 to G indicate the following.
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data (Ω, V, A)
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
O
LT
New
H Apply engine oil
I Apply gear oil
J Apply molybdenum disulfide oil
K Apply wheel bearing grease
L Apply lithium-soap-based grease
M Apply molybdenum disulfide grease
Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
when to install a new part O.
N Apply the locking agent (LOCTITE®)
O Replace
EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
CHASSIS
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
FI
6
CHAS
7
–
ELECTRICAL
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION............................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
SELF-ADJUSTING PARKING BRAKE MECHANISM............................... 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 ..................................... 1-8
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 ............................................................................2-4
CHASSIS SPECIFICATIONS ........................................................................2-12
ELECTRICAL SPECIFICATIONS .................................................................2-14
TIGHTENING TORQUES .............................................................................. 2-16
ENGINE TIGHTENING TORQUES ........................................................ 2-16
CHASSIS TIGHTENING TORQUES ......................................................2-19
HOW TO USE THE CONVERSION TABLE.................................................. 2-22
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23
ENGINE................................................................................................... 2-23
COOLANT FLOW DIAGRAMS ..................................................................... 2-24
OIL FLOW DIAGRAMS ................................................................................. 2-28
CABLE ROUTING ......................................................................................... 2-33
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ......................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART............................ 3-2
SEAT, FENDERS AND FUEL TANK .............................................................. 3-3
REMOVING THE FUEL TANK ..................................................................3-9
REMOVING THE FUEL PUMP .................................................................3-9
INSTALLING THE FUEL PUMP..............................................................3-10
INSTALLING THE FUEL HOSE ..............................................................3-10
ENGINE .........................................................................................................3-11
ADJUSTING THE VALVE CLEARANCE ................................................ 3-11
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-13
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-14
ADJUSTING THE SPEED LIMITER........................................................ 3-15
CHECKING THE SPARK PLUG ............................................................. 3-16
CHECKING THE IGNITION TIMING.......................................................3-17
MEASURING THE COMPRESSION PRESSURE..................................3-18
CHECKING THE ENGINE OIL LEVEL....................................................3-20
CHANGING THE ENGINE OIL ...............................................................3-22
ADJUSTING THE CLUTCH CABLE........................................................ 3-25
CLEANING THE AIR FILTER ELEMENT................................................ 3-25
CHECKING THE THROTTLE BODY JOINT...........................................3-27
CHECKING THE FUEL HOSE ................................................................3-28
CHECKING THE BREATHER HOSES ...................................................3-28
CHECKING THE COOLANT LEVEL.......................................................3-29
CHANGING THE COOLANT................................................................... 3-29
CHECKING THE COOLING SYSTEM ....................................................3-32
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-33
CHECKING THE EXHAUST SYSTEM....................................................3-34
CLEANING THE SPARK ARRESTER ....................................................3-34
CHASSIS ....................................................................................................... 3-36
ADJUSTING THE FRONT BRAKE ......................................................... 3-36
ADJUSTING THE REAR BRAKE............................................................ 3-36
ADJUSTING THE PARKING BRAKE......................................................3-37
CHECKING THE BRAKE FLUID LEVEL................................................. 3-38
CHECKING THE FRONT BRAKE PADS ................................................ 3-39
CHECKING THE REAR BRAKE PADS .................................................. 3-39
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-40
CHECKING THE BRAKE HOSES........................................................... 3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-41
ADJUSTING THE SHIFT PEDAL............................................................ 3-43
ADJUSTING THE REVERSE CONTROL CABLE ..................................3-43
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-44
CHECKING THE STEERING SYSTEM .................................................. 3-46
ADJUSTING THE TOE-IN....................................................................... 3-46
CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-48
ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-48
ADJUSTING THE REAR SHOCK ABSORBER ...................................... 3-49
CHECKING THE TIRES..........................................................................3-52
CHECKING THE WHEELS ..................................................................... 3-54
CHECKING AND LUBRICATING THE CABLES .................................... 3-54
LUBRICATING THE LEVERS AND PEDALS .........................................3-55
ELECTRICAL SYSTEM................................................................................. 3-56
CHECKING AND CHARGING THE BATTERY....................................... 3-56
CHECKING THE FUSES ........................................................................3-62
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-64
REPLACING A HEADLIGHT BULB ........................................................ 3-64
CHAPTER 4
ENGINE
ENGINE REMOVAL ........................................................................................4-1
MUFFLER AND EXHAUST PIPES ........................................................... 4-1
INSTALLING THE EXHAUST PIPES AND MUFFLER ............................. 4-2
OIL TANK ..................................................................................................4-3
LEADS, CABLES AND HOSES ................................................................4-4
ENGINE MOUNTING BOLTS ...................................................................4-6
INSTALLING THE ENGINE....................................................................... 4-8
CYLINDER HEAD............................................................................................ 4-9
REMOVING THE CYLINDER HEAD.......................................................4-11
CHECKING THE CYLINDER HEAD .......................................................4-12
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER ................................................................................................... 4-13
CHECKING THE TIMING CHAIN TENSIONER...................................... 4-13
CHECKING THE CAMSHAFT SPROCKET............................................4-13
INSTALLING THE CYLINDER HEAD .....................................................4-13
ROCKER ARMS AND CAMSHAFT ..............................................................4-17
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-19
CHECKING THE CAMSHAFT.................................................................4-19
CHECKING THE DECOMPRESSION SYSTEM..................................... 4-20
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-22
VALVES AND VALVE SPRINGS.................................................................. 4-24
REMOVING THE VALVES AND VALVE SPRINGS ...............................4-25
CHECKING THE VALVES AND VALVE SPRINGS ................................4-26
INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31
CYLINDER AND PISTON.............................................................................. 4-33
REMOVING THE PISTON ...................................................................... 4-34
CHECKING THE CYLINDER AND PISTON ...........................................4-34
CHECKING THE PISTON RINGS........................................................... 4-36
CHECKING THE PISTON PIN ................................................................4-37
INSTALLING THE PISTON AND CYLINDER .........................................4-38
A.C. MAGNETO............................................................................................. 4-41
REMOVING THE A.C. MAGNETO ROTOR............................................4-43
CHECKING THE STATOR COIL
AND CRANKSHAFT POSITION SENSOR ............................................4-43
CHECKING THE STARTER CLUTCH ....................................................4-44
CHECKING THE TORQUE LIMITER......................................................4-45
INSTALLING THE A.C. MAGNETO ROTOR ..........................................4-45
CLUTCH ........................................................................................................4-47
REMOVING THE CLUTCH ..................................................................... 4-51
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR .......................................................... 4-52
CHECKING THE FRICTION PLATES.....................................................4-52
CHECKING THE CLUTCH PLATES .......................................................4-53
CHECKING THE CLUTCH SPRINGS.....................................................4-53
CHECKING THE CLUTCH HOUSING ....................................................4-54
CHECKING THE CLUTCH BOSS........................................................... 4-54
CHECKING THE PRESSURE PLATE ....................................................4-54
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................4-54
CHECKING THE PRIMARY DRIVE GEARS ..........................................4-55
CHECKING THE BALANCER DRIVE GEARS ....................................... 4-55
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEARS .......................................................4-55
INSTALLING THE CLUTCH.................................................................... 4-56
OIL PUMP...................................................................................................... 4-59
CHECKING THE OIL PUMP ................................................................... 4-61
ASSEMBLING THE OIL PUMP...............................................................4-62
SHIFT SHAFT................................................................................................4-63
CHECKING THE SHIFT SHAFT ............................................................. 4-65
CHECKING THE STOPPER LEVER ......................................................4-65
CHECKING THE SHIFT GUIDE..............................................................4-65
CHECKING THE SHIFT DRUM SEGMENT ...........................................4-65
INSTALLING THE SHIFT LEVER ........................................................... 4-65
INSTALLING THE SHIFT SHAFT ........................................................... 4-66
CRANKCASE ................................................................................................4-67
CRANKCASE BEARINGS....................................................................... 4-69
SEPARATING THE CRANKCASE.......................................................... 4-70
CHECKING THE OIL STRAINER ........................................................... 4-70
CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-71
CHECKING THE BEARINGS AND OIL SEALS...................................... 4-71
CHECKING THE CRANKCASE ..............................................................4-71
ASSEMBLING THE CRANKCASE.......................................................... 4-72
CRANKSHAFT ..............................................................................................4-74
CRANKSHAFT AND BALANCER ........................................................... 4-74
REMOVING THE CRANKSHAFT ........................................................... 4-75
CHECKING THE CRANKSHAFT ............................................................ 4-75
INSTALLING THE CRANKSHAFT .......................................................... 4-76
TRANSMISSION............................................................................................ 4-77
MAIN AXLE ............................................................................................. 4-79
DRIVE AXLE ........................................................................................... 4-80
COUNTER AXLE.....................................................................................4-82
CHECKING THE SHIFT FORKS............................................................. 4-83
CHECKING THE SHIFT DRUM ASSEMBLY..........................................4-83
CHECKING THE TRANSMISSION ......................................................... 4-83
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................4-84
INSTALLING THE TRANSMISSION .......................................................4-85
CHAPTER 5
COOLING SYSTEM
RADIATOR ...................................................................................................... 5-1
CHECKING THE RADIATOR.................................................................... 5-3
INSTALLING THE RADIATOR..................................................................5-4
THERMOSTAT ................................................................................................5-5
CHECKING THE THERMOSTAT.............................................................. 5-6
INSTALLING THE THERMOSTAT............................................................ 5-6
WATER PUMP.................................................................................................5-7
DISASSEMBLING THE WATER PUMP.................................................... 5-9
CHECKING THE WATER PUMP .............................................................. 5-9
ASSEMBLING THE WATER PUMP........................................................ 5-10
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................6-1
CIRCUIT DIAGRAM .................................................................................. 6-2
ECU’S SELF-DIAGNOSTIC FUNCTION................................................... 6-4
SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 6-5
TROUBLESHOOTING CHART .................................................................6-6
DIAGNOSTIC MODE ................................................................................ 6-7
TROUBLESHOOTING DETAILS ............................................................ 6-11
CHECKING THE SPEED SENSOR ........................................................ 6-25
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 6-26
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-27
THROTTLE BODY......................................................................................... 6-28
CHECKING THE INJECTOR .................................................................. 6-31
CHECKING THE THROTTLE BODY ......................................................6-31
INSTALLING THE THROTTLE BODY ASSEMBLY................................6-31
CHECKING THE FUEL PUMP
AND PRESSURE REGULATOR OPERATION...................................... 6-32
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ................................................................................................6-33
CHAPTER 7
CHASSIS
FRONT AND REAR WHEELS ........................................................................ 7-1
FRONT WHEELS ......................................................................................7-1
REAR WHEELS ........................................................................................7-3
CHECKING THE WHEELS ....................................................................... 7-4
CHECKING THE WHEEL HUBS............................................................... 7-4
CHECKING THE BRAKE DISCS .............................................................. 7-5
INSTALLING THE FRONT WHEEL HUB BEARINGS .............................. 7-6
INSTALLING THE FRONT BRAKE DISCS............................................... 7-6
INSTALLING THE FRONT WHEELS........................................................7-6
INSTALLING THE FRONT WHEEL HUBS ............................................... 7-7
INSTALLING THE REAR WHEEL HUBS.................................................. 7-7
REAR AXLE AND REAR AXLE HUB ............................................................. 7-8
REMOVING THE REAR BRAKE CALIPER ............................................7-10
REMOVING THE REAR AXLE................................................................7-10
CHECKING THE REAR AXLE ................................................................7-11
CHECKING THE DRIVEN SPROCKET .................................................. 7-11
CHECKING THE BRAKE DISC...............................................................7-12
INSTALLING THE DRIVEN SPROCKET ................................................ 7-12
INSTALLING THE REAR AXLE ..............................................................7-12
FRONT AND REAR BRAKES....................................................................... 7-14
FRONT BRAKE PADS ............................................................................7-14
REAR BRAKE PADS............................................................................... 7-15
REPLACING THE FRONT BRAKE PADS .............................................. 7-16
REPLACING THE REAR BRAKE PADS................................................. 7-18
FRONT BRAKE MASTER CYLINDER....................................................7-20
REAR BRAKE MASTER CYLINDER ......................................................7-22
REMOVING THE FRONT BRAKE LIGHT SWITCH ...............................7-25
CHECKING THE MASTER CYLINDERS................................................ 7-25
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 7-26
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................7-26
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................7-27
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 7-29
FRONT BRAKE CALIPERS .................................................................... 7-31
REAR BRAKE CALIPER .........................................................................7-33
REMOVING THE REAR BRAKE CALIPER ............................................7-36
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................7-36
DISASSEMBLING THE REAR BRAKE CALIPER ..................................7-37
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................7-37
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 7-38
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 7-39
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 7-40
INSTALLING THE REAR BRAKE CALIPER...........................................7-41
STEERING SYSTEM .....................................................................................7-44
HANDLEBAR........................................................................................... 7-44
REMOVING THE FRONT BRAKE LIGHT SWITCH
AND CLUTCH SWITCH .........................................................................7-46
REMOVING THE HANDLEBAR GRIPS.................................................. 7-46
CHECKING THE HANDLEBAR ..............................................................7-46
INSTALLING THE HANDLEBAR ............................................................ 7-47
INSTALLING THE HANDLEBAR GRIPS ................................................ 7-47
INSTALLING THE CLUTCH LEVER .......................................................7-48
INSTALLING THE BRAKE MASTER CYLINDER ................................... 7-48
STEERING STEM ...................................................................................7-49
REMOVING THE BEARING RETAINER ................................................ 7-51
CHECKING THE STEERING STEM .......................................................7-51
INSTALLING THE BEARING RETAINER ............................................... 7-51
INSTALLING THE LOCK WASHER........................................................ 7-51
INSTALLING THE PITMAN ARM............................................................ 7-52
TIE-RODS AND STEERING KNUCKLES ............................................... 7-53
REMOVING THE STEERING KNUCKLES ............................................. 7-54
CHECKING THE TIE-RODS ................................................................... 7-54
CHECKING THE STEERING KNUCKLES.............................................. 7-54
INSTALLING THE TIE-RODS .................................................................7-54
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 7-55
REMOVING THE FRONT ARMS ............................................................ 7-57
CHECKING THE FRONT ARMS............................................................. 7-57
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 7-57
CHECKING THE BALL JOINTS..............................................................7-58
INSTALLING THE FRONT ARMS........................................................... 7-59
REAR SHOCK ABSORBER AND RELAY ARM ..........................................7-60
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER.... 7-62
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER ............................................................................7-62
REMOVING THE REAR SHOCK ABSORBER ....................................... 7-63
CHECKING THE REAR SHOCK ABSORBER........................................ 7-63
CHECKING THE RELAY ARM AND CONNECTING ARM.....................7-63
INSTALLING THE RELAY ARM AND CONNECTING ARM................... 7-64
INSTALLING THE REAR SHOCK ABSORBER...................................... 7-64
SWINGARM AND DRIVE CHAIN.................................................................. 7-65
REMOVING THE SWINGARM................................................................7-67
CHECKING THE SWINGARM ................................................................7-67
CHECKING THE DRIVE CHAIN ............................................................. 7-68
INSTALLING THE SWINGARM ..............................................................7-70
INSTALLING THE DRIVE SPROCKET...................................................7-70
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................ 8-1
CHECKING SWITCH CONTINUITY................................................................8-2
CHECKING THE SWITCHES..........................................................................8-3
CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-5
TYPES OF BULBS .................................................................................... 8-5
CHECKING THE CONDITION OF THE BULBS ....................................... 8-5
CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7
IGNITION SYSTEM ......................................................................................... 8-8
CIRCUIT DIAGRAM .................................................................................. 8-8
TROUBLESHOOTING ..............................................................................8-9
ELECTRIC STARTING SYSTEM .................................................................. 8-14
CIRCUIT DIAGRAM ................................................................................ 8-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-15
TROUBLESHOOTING ............................................................................8-16
STARTER MOTOR........................................................................................ 8-20
CHECKING THE STARTER MOTOR .....................................................8-22
ASSEMBLING THE STARTER MOTOR................................................. 8-23
CHARGING SYSTEM....................................................................................8-25
CIRCUIT DIAGRAM ................................................................................ 8-25
TROUBLESHOOTING ............................................................................8-26
LIGHTING SYSTEM ......................................................................................8-28
CIRCUIT DIAGRAM ................................................................................ 8-28
TROUBLESHOOTING ............................................................................8-29
CHECKING THE LIGHTING SYSTEM....................................................8-30
SIGNALING SYSTEM ...................................................................................8-33
CIRCUIT DIAGRAM ................................................................................ 8-33
TROUBLESHOOTING ............................................................................8-34
CHECKING THE SIGNALING SYSTEM ................................................. 8-35
COOLING SYSTEM....................................................................................... 8-42
CIRCUIT DIAGRAM ................................................................................ 8-42
TROUBLESHOOTING ............................................................................8-43
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING .......................................................9-1
FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEM.............................................................................9-1
COMPRESSION SYSTEM........................................................................ 9-1
POOR IDLE SPEED PERFORMANCE ........................................................... 9-2
POOR IDLE SPEED PERFORMANCE.....................................................9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE..................................9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 9-2
FAULTY GEAR SHIFTING..............................................................................9-2
HARD SHIFTING.......................................................................................9-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 9-2
JUMPS OUT GEAR................................................................................... 9-2
CLUTCH SLIPPING/DRAGGING.................................................................... 9-3
CLUTCH SLIPPING .................................................................................. 9-3
CLUTCH DRAGGING ............................................................................... 9-3
OVERHEATING............................................................................................... 9-3
OVERHEATING ........................................................................................9-3
OVERCOOLING .............................................................................................. 9-3
COOLING SYSTEM .................................................................................. 9-3
FAULTY BRAKE ............................................................................................. 9-4
POOR BRAKING EFFECT........................................................................ 9-4
SHOCK ABSORBER MALFUNCTION ........................................................... 9-4
MALFUNCTION......................................................................................... 9-4
UNSTABLE HANDLING.................................................................................. 9-4
UNSTABLE HANDLING ............................................................................9-4
LIGHTING SYSTEM ........................................................................................9-5
HEADLIGHT DOES NOT COME ON ........................................................9-5
TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-5
HEADLIGHT BULB BURNT OUT.............................................................. 9-5
VEHICLE IDENTIFICATION
GEN
INFO
EBS00009
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1
stamped into the left side of the frame.
is
1
EBS00011
MODEL LABEL
The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.
1
1-1
GEN
INFO
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 with 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.
1 2
34 5 6 7890 A
H G F E
1 Engine trouble warning light
2 Ignition coil
3 Fuel tank
4 Fuel hose
5 Fuel pump
6 Intake air pressure sensor
7 Lean angle sensor
8 Battery
9 Intake air temperature sensor
B
D C
0 ECU (electronic control unit)
A Air filter case
B Relay unit (fuel pump relay)
C Speed sensor
D Throttle position sensor
E Crankshaft position sensor
F Fuel injector
G Coolant temperature sensor
H Spark plug
1-2
1
FEATURES
GEN
INFO
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 remains
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, intake air temperature sensor, coolant temperature sensor and speed 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.
B
Ê
1
4
2
È
3
A
0
É
9
8
7
5
6
1 Fuel pump
2 Fuel injector
3 Ignition coil
4 ECU (electronic control unit)
5 Coolant temperature sensor
6 Crankshaft position sensor
7 Intake air pressure sensor
8 Throttle body
9 Intake air temperature sensor
0 Air filter case
A Throttle position sensor
B Speed sensor
È Fuel system
É Air system
Ê Control system
1-3
FEATURES
GEN
INFO
SELF-ADJUSTING PARKING BRAKE MECHANISM
Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary
to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7
and the adjusting bolt 5.
This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake
mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking
performance when parking the vehicle.
1
2
3
7
6
5
4
1 Parking brake arm
2 Parking brake shaft
3 Adjusting bolt
4 Adjusting bolt sleeve
5 Adjusting bolt
6 Nut
7 Brake caliper piston
1-4
FEATURES
GEN
INFO
Parking Brake Operation
1
2
3
6
5
4
1 Parking brake arm
2 Parking brake shaft
3 Adjusting bolt
4 Adjusting bolt sleeve
5 Brake caliper piston
6 Brake pad
When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The
rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the
adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is
pushed and the brake pad 6 is pushed against the brake disc.
When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad
becomes larger and the force applied to the brake pad becomes weaker.
If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the
proper clearance.
1-5
FEATURES
GEN
INFO
Parking Brake Operation
1
È
2
É
4
3
Ê
1 Brake caliper piston
2 Nut
3 Adjusting bolt
4 Adjusting bolt sleeve
When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the
brake caliper piston 1 and the nut 2 are pushed.
When there is proper clearance between the brake caliper piston and the brake pad, no other parts
move because the movement of the brake caliper piston and the nut is absorbed by the backlash of
the threads of the nut and the adjusting bolt 3.
When the movement of the nut is greater than the backlash between the nut and the adjusting bolt,
the parking brake adjusts automatically.
The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes
no adjustment.
The adjustment operation is as follows.
1. When the brake pedal is operated, the brake fluid pressure increases and the brake caliper piston and the nut move.
2. When the movement of the brake caliper piston and the nut is greater than the backlash of the
threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt.
The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the
threads of the nut and the adjusting bolt.
3. At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will
decrease depending on the force required to pull the adjusting bolt.
When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance
between the brake caliper piston and the brake pad decreases by the movement of the threads of
the nut and the adjusting bolt.
1-6
IMPORTANT INFORMATION
GEN
INFO
EBS00013
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
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.
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.
EBS00014
REPLACEMENT PARTS
1. 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.
EBS00015
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.
1-7
IMPORTANT INFORMATION
GEN
INFO
EBS00016
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.
EBS00017
BEARINGS AND OIL SEALS
Install bearings and oil seals 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.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EBS00018
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.
4 Shaft
1-8
IMPORTANT INFORMATION
GEN
INFO
EBS00019
CHECKING THE CONNECTIONS
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.
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)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
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.
_
1-9
SPECIAL TOOLS
GEN
INFO
EBS00021
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN
P/N. 90890Tool No.
Tool name/Function
Slide hammer bolt
Slide hammer bolt (6 mm)
90890-01083
YU-01083-1
This tool is used to remove the rocker arm
shaft.
Weight
90890-01084
YU-01083-3
This tool is used to remove the rocker arm
shaft.
Crankcase separating tool
Crankcase separator
90890-01135
YU-01135-B
This tool is used to separate the crankcase.
Ring nut wrench
Spanner wrench
90890-01268
YU-01268
This tool is used to loosen or tighten the
rear shock absorber locknuts.
90890-01274
YU-90058
YU-90059
Crankshaft installer pot
Installer pot
Pot installer
This tool is used to install the crankshaft.
Crankshaft installer bolt
Bolt
90890-01275
YU-90060
This tool is used to install the crankshaft.
1 - 10
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Adapter (M16)
Adapter #13
90890-04130
YM-04059
This tool is used to install the crankshaft.
Spacer (crankshaft installer)
Pot spacer
90890-04081
YM-91044
This tool is used to install the crankshaft.
Piston pin puller set
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston pin.
Tappet adjusting tool
Valve adjuster (3 mm & 4 mm)
90890-01311
YM-08035-A
This tool is necessary for adjusting the
valve clearance.
Radiator cap tester
Radiator pressure tester
90890-01325
YU-24460-01
This tool is used to check the cooling system.
Radiator cap tester adapter
Radiator pressure tester adapter
90890-01352
YU-33984
This tool is used to check the cooling system.
Damper rod holder (30 mm)
90890-01327
YM-01327
This tool is needed to loosen and tighten
the steering stem bearing retainer.
Flywheel puller
90890-01404
YM-01404
This tool is used to remove the A.C.magneto rotor.
1 - 11
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Steering nut wrench
Spanner wrench
90890-01443
YU-33975
This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.
Ball joint remover
90890-01474
YM-01474
This tool is used to remove or install the
ball joints.
Ball joint remover attachment set
Ball joint adapter set
90890-01480
YM-01480
These tools are used to remove or install
the ball joints.
Rear axle nut wrench (46 mm)
Axle nut wrench (46 mm)
90890-01498
YM-37134
This tool is needed to loosen or tighten the
rear axle nut.
Sheave holder
Primary clutch holder
90890-01701
YS-01880-A
This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C. magneto rotor nut.
Thickness gauge
Narrow gauge set
90890-03079
YM-34483
This tool is used to measure the valve
clearance.
Compression gauge
Engine compression tester
90890-03081
YU-33223
This tool is used to measure engine compression.
Extension
90890-04082
This tool is used to measure engine compression.
1 - 12
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Pocket tester
Analog pocket tester
90890-03112
YU-03112-C
This instrument is needed for checking the
electrical system.
Timing light
Inductive clamp timing light
90890-03141
YU-03141
This tool is necessary for checking ignition
timing.
Pressure gauge
90890-03153
YU-03153
This tool is used to measure fuel pressure.
Fuel pressure adapter
90890-03176
YM-03176
This tool is used to measure fuel pressure.
Digital circuit tester
Model 88 Multimeter with tachometer
90890-03174
YU-A1927
This tool is used to check the electrical
system.
FI diagnostic tool
90890-03182
YU-03182
This tool is used to check the diagnosis.
Valve spring compressor
90890-04019
YM-04019
This tool is needed to remove and install
the valve assemblies.
Valve spring compressor attachment
Valve spring compressor adapter (26 mm)
90890-01243
YM-01253-1
This tool is needed to remove and install
the valve assemblies.
1 - 13
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Middle driven shaft bearing driver
Bearing driver (40 mm)
90890-04058
YM-04058
This tool is used to install the water pump
seal.
Mechanical seal installer
Water pump seal installer
90890-04132
YM-33221-A
This tool is used to install the water pump
seal.
Valve guide remover (ø6)
Valve guide remover (6.0 mm)
90890-04064
YM-4064-A
This tool is needed to remove and install
the valve guides.
Valve guide installer (ø6)
Valve guide installer (6.0 mm)
90890-04065
YM-4065-A
This tool is needed to install the valve
guides.
Valve guide reamer (ø6)
Valve guide reamer (6.0 mm)
90890-04066
YM-04066
This tool is needed to rebore the new
valve guides.
Universal clutch holder
90890-04086
YM-91042
This tool is needed to hold the clutch boss
when removing or installing the clutch
boss nut.
Ignition checker
Opama pet-4000 spark checker
90890-06754
YM-34487
This tool is used to check the ignition system components.
Digital tachometer
90890-06760
YU-39951-B
This tool is needed to observe engine rpm.
1 - 14
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Yamaha bond No. 1215
(Three bond No. 1215)
90890-85505
This bond is used on crankcase mating
surfaces, etc.
1 - 15
GEN
INFO
Illustration
GENERAL SPECIFICATIONS
SPEC
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Basic weight
With oil and full fuel tank
Engine
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Starting system
Lubrication system
Oil type or grade
Engine oil
0°
10°
30°
50°
70°
90°
110°
130°F
1S31
1,845 mm (72.6 in)
1,170 mm (46.1 in)
1,130 mm (44.5 in)
815 mm (32.1 in)
1,280 mm (50.4 in)
240 mm (9.45 in)
3,500 mm (137.8 in)
192 kg (423 lb)
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
686 cm3 (41.86 cu in)
102.0 × 84.0 mm (4.02 × 3.31 in)
9.20:1
450 kPa (4.5 kg/cm2, 64.0 psi)
Electric starter
Dry sump
API service SE, SF, SG type or higher
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20°
-10°
0°
10°
20°
30°
40°
50°C
2-1
2
GENERAL SPECIFICATIONS
Item
Oil capacity
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Radiator capacity (including all routes)
Air filter
Fuel
Type
Fuel tank capacity
Fuel reserve amount
Fuel injector
Type/quantity
Manufacturer
Spark plug
Type/manufacturer
Spark plug gap
Clutch type
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gear
Chassis
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread front (STD)
Tread rear (STD)
Toe-in (with tires touching the ground)
SPEC
Standard
1.75 L (1.54 Imp qt, 1.85 US qt)
1.85 L (1.63 Imp qt, 1.96 US qt)
2.30 L (2.02 Imp qt, 2.43 US qt)
1.61 L (1.42 Imp qt, 1.70 US qt)
Wet type element
Regular unleaded gasoline only (For CDN,
Europe)
Unleaded gasoline only (For Oceania)
11.0 L (2.42 Imp gal, 2.91 US gal)
2.6 L (0.57 Imp gal, 0.69 US gal)
297500-0390/1
DENSO
CR8E/NGK
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Wet, multiple disc
Spur gear
77/34 (2.265)
Chain drive
38/14 (2.714)
Constant mesh, 5-speed/forward, 1 speed/
reverse
Left foot operation
38/13 (2.923)
28/14 (2.000)
25/17 (1.471)
25/22 (1.136)
22/24 (0.917)
24/13 × 29/12 (4.462)
Aluminum die-cast and steel tube frame
5°
–1.0°
14.8°
2.8 mm (0.11 in)
21.0 mm (0.83 in)
940 mm (37.01 in)
900 mm (35.43 in)
2 ~ 12 mm (0.08 ~ 0.47 in)
2-2
GENERAL SPECIFICATIONS
Item
Tire
Type
Size
Manufacturer
Type
Tire pressure (cold tire)
Maximum load*
Off-road riding
SPEC
Standard
Tubeless
AT21 × 7-10
AT20 × 10-9
DUNLOP
DUNLOP
KT341 Radial
KT345 Radial
front
rear
front
rear
front
rear
front
rear
*Load is total weight of cargo, rider and
accessories
Brake
Front brake
type
operation
Rear brake
type
operation
Suspension
Front suspension
Rear suspension
Shock absorber
Front shock absorber
Rear shock absorber
Wheel travel
Front wheel travel
Rear wheel travel
Electrical system
Ignition system
Generator system
Battery type
Battery capacity
Bulb type
Bulb voltage/wattage × quantity
Headlight
Tail/brake light
Indicator light
Neutral indicator light
Fuel level warning light
Reverse indicator light
Coolant temperature warning light
Engine trouble warning light
100 kg (220 lb)
27.5 kPa (0.28 kg/cm2, 4.0 psi)
27.5 kPa (0.28 kg/cm2, 4.0 psi)
Dual disc brake
Right hand operation
Single disc brake
Right foot operation
Double wishbone
Swingarm (link suspension)
Coil spring/oil damper
Coil spring/gas-oil damper
230 mm (9.06 in)
256 mm (10.08 in)
Transistorized coil ignition (digital)
A.C. magneto
GT9B-4
12 V 8.0 Ah
Krypton bulb
12 V 30 W/30 W × 2
LED
LED
LED
LED
LED
LED
2-3
ENGINE SPECIFICATIONS
SPEC
EBS01002
ENGINE SPECIFICATIONS
Item
Standard
Cylinder head
Maximum warpage
----
Cylinder
Bore
Limit
0.03 mm
(0.0012 in)
102.000 ~ 102.010 mm (4.0157 ~ 4.0161 in) 102.080 mm
(4.0189 in)
50.0 mm (1.97 in)
----
Measuring point
Out of round
0.05 mm
(0.002 in)
Camshaft
Drive system
Camshaft lobe dimensions
Chain drive (left)
----
A
B
Intake measurement
“A”
“B”
Exhaust measurement
“A”
“B”
Maximum camshaft runout
Timing chain
Model/number of links
Tensioning system
43.300 ~ 43.400 mm (1.7047 ~ 1.7087 in) 43.200 mm
(1.7008 in)
37.026 ~ 37.126 mm (1.4577 ~ 1.4617 in) 36.926 mm
(1.4538 in)
43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 43.029 mm
(1.6941 in)
37.057 ~ 37.157 mm (1.4589 ~ 1.4629 in) 36.957 mm
(1.4550 in)
---0.03 mm
(0.0012 in)
98XRH2010/126
Automatic
2-4
-------
ENGINE SPECIFICATIONS
Item
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Shaft outside diameter
Arm-to-shaft clearance
Valve, valve seat, valve guide
Valve clearance–intake (cold)
Valve clearance–exhaust (cold)
Valve dimensions
SPEC
Standard
Limit
12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in)
11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in)
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
----------
0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in)
0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)
-------
B
C
D
A
Head Diameter
Face Width
Valve head diameter “A”
Intake
Exhaust
Valve face width “B”
Intake
Exhaust
Valve seat width “C”
Intake
Exhaust
Valve margin thickness “D”
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Seat Width
Margin Thickness
37.9 ~ 38.1 mm (1.4921 ~ 1.5000 in)
31.9 ~ 32.1 mm (1.2559 ~ 1.2638 in)
-------
2.26 mm (0.0890 in)
2.26 mm (0.0890 in)
-------
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)
0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)
5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
2-5
1.6 mm
(0.063 in)
1.6 mm
(0.063 in)
------5.945 mm
(0.2341 in)
5.930 mm
(0.2335 in)
6.050 mm
(0.2382 in)
6.050 mm
(0.2382 in)
0.080 mm
(0.0031 in)
0.100 mm
(0.0039 in)
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
Valve stem runout
----
0.01 mm
(0.0004 in)
Valve seat width
Intake
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
Exhaust
Valve spring
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
38.79 mm (1.53 in)
38.79 mm (1.53 in)
36.85 mm
(1.45 in)
36.85 mm
(1.45 in)
35.00 mm (1.38 in)
35.00 mm (1.38 in)
-------
169.0 ~ 199.0 N
(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)
169.0 ~ 199.0 N
(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)
-------
Spring tilt
Intake
----
Exhaust
----
Winding direction (top view)
Intake
Exhaust
2.5°/1.70 mm
(2.5°/0.067 in)
2.5°/1.70 mm
(2.5°/0.067 in)
Clockwise
Clockwise
2-6
-------
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Piston
Piston-to-cylinder clearance
0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in)
Diameter “D”
101.955 ~ 101.970 mm
(4.0140 ~ 4.0146 in)
Limit
0.13 mm
(0.0051 in)
----
H
D
Height “H”
Offset
Offset direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
10 mm (0.39 in)
---0.5 mm (0.0197 in)
---Intake side
---23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm
(0.9073 in)
22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) 22.971 mm
(0.9044 in)
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)
0.074 mm
(0.0029 in)
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Barrel
1.20 × 3.80 mm (0.05 × 0.15 in)
0.20 ~ 0.35 mm (0.008 ~ 0.014 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
------0.60 mm
(0.024 in)
0.12 mm
(0.0047 in)
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Taper
1.20 × 4.00 mm (0.05 × 0.16 in)
0.35 ~ 0.50 mm (0.014 ~ 0.020 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
2-7
------0.85 mm
(0.033 in)
0.13 mm
(0.0051 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
Crankshaft
2.50 × 3.40 mm (0.10 × 0.13 in)
0.20 ~ 0.70 mm (0.008 ~ 0.028 in)
0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in)
----------
F
C
C
E
D
A
Crank width “A”
Maximum runout “C”
74.95 ~ 75.00 mm (2.951 ~ 2.953 in)
----
Big end side clearance “D”
0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in)
Big end radial clearance “E”
Small end free play “F”
Balancer
Balancer drive method
Clutch
Friction plate 1 (inside dia.: 121 mm)
Thickness
Quantity
Friction plate 2 (inside dia.: 128 mm)
Thickness
0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in)
0.16 ~ 0.40 mm (0.0063 ~ 0.0157 in)
Gear
2.92 ~ 3.08 mm (0.115 ~ 0.121 in)
7
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
1
---0.03 mm
(0.0012 in)
1.00 mm
(0.040 in)
----------
2.82 mm
(0.111 in)
---2.80 mm
(0.110 in)
----
Quantity
Clutch plate
Thickness
Quantity
Maximum warpage
1.50 ~ 1.60 mm (0.059 ~ 0.063 in)
7
----
------0.20 mm
(0.0079 in)
Clutch spring
Free length
50.0 mm (1.97 in)
Quantity
Clutch release method
6
Outer pull, rack and pinion pull
48.0 mm
(1.89 in)
-------
2-8
ENGINE SPECIFICATIONS
Item
Standard
Transmission
Maximum main axle runout
----
Maximum drive axle runout
----
Shifting mechanism
Shift mechanism type
Decompression device
Device type
Air filter oil grade
Throttle body
Model/manufacturer × quantity
Engine idle speed
Intake vacuum
Fuel pump
Pump type
Model/manufacturer
Maximum consumption amperage
Output pressure
Oil filter type
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Bypass valve opening pressure
Oil pressure (hot)
Pressure check location
Cooling system
Radiator core
Width
Height
Depth
Radiator cap opening pressure
Coolant reservoir capacity
Up to the maximum level mark
From low to full level
Water pump
Water pump type
Reduction ratio
SPEC
Limit
0.08 mm
(0.0031 in)
0.08 mm
(0.0031 in)
Shift drum and guide bar
----
Auto decomp
Air-cooled 2-stroke engine oil
-------
44EHS/MIKUNI × 1
1,500 ~ 1,700 r/min
37.8 kPa (284 mmHg, 11.2 inHg)
----------
Electrical
1S3/DENSO
4.8 A
324 kPa (3.24 kg/cm2, 46.1 psi)
Paper
----------------
Trochoid
Less than 0.12 mm (0.0047 in)
0.09 ~ 0.15 mm (0.0035 ~ 0.0059 in)
40.0 ~ 80.0 kPa
(0.40 ~ 0.80 kg/cm2, 5.70 ~ 11.4 psi)
40.0 kPa at 1,600 r/min (0.40 kg/cm2 at
1,600 r/min, 5.70 psi at 1,600 r/min)
Element cover
---0.20 mm
(0.0079 in)
0.22 mm
(0.0087 in)
----------
197 mm (7.76 in)
300 mm (11.81 in)
22 mm (0.87 in)
93.3 ~ 122.7 kPa
(0.933 ~ 1.227 kg/cm2, 13.27 ~ 17.45 psi)
-------------
0.25 L (0.22 Imp qt, 0.26 US qt)
0.15 L (0.13 Imp qt, 0.16 US qt)
-------
Single-suction centrifugal pump
27/28 (0.964)
-------
2-9
SPEC
ENGINE SPECIFICATIONS
Lubrication chart
Cylinder head
Counter axle
Decompression
Camshaft
To oil tank
Main axle
Oil delivery pipe
Oil tank inlet pipe
Drive axle
A.C. magneto
cover
From oil tank
Oil filter
element
Left
crankcase
Right crankcase
Oil tank outlet
hose joint
Drain bolt
Right crankcase Clutch cover
Right
crankcase
Oil
strainer
Oil pump
Crankshaft
2 - 10
To clutch cover
ENGINE SPECIFICATIONS
Cylinder head tightening sequence
5
7
8
2
3
1
4
6
2 - 11
SPEC
CHASSIS SPECIFICATIONS
SPEC
EBS01003
CHASSIS SPECIFICATIONS
Item
Steering system
Steering bearing type
Front suspension
Shock absorber travel
Spring free length
Installed length
Spring rate (K1)
Spring rate (K2)
Optional spring available
Rear suspension
Shock absorber travel
Spring free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Swingarm
Free play limit (radial)
Free play limit (axial)
Front wheel
Type
Rim size
Rim material
Maximum radial wheel runout
Maximum lateral wheel runout
Rear wheel
Type
Rim size
Rim material
Maximum radial wheel runout
Maximum lateral wheel runout
Drive chain
Type/manufacturer
Link quantity
Drive chain slack
Standard
Limit
Ball and race bearing
----
115.0 mm (4.53 in)
269.0 mm (10.59 in)
260.5 mm (10.26 in)
21.60 N/mm (2.20 kg/mm, 123.33 lb/in)
29.40 N/mm (3.00 kg/mm, 167.87 lb/in)
No
-------------------
110.0 mm (4.33 in)
255.0 mm (10.04 in)
236.0 mm (9.29 in)
46.00 N/mm (4.69 kg/mm, 262.66 lb/in)
0 ~ 110.0 mm (0 ~ 4.33 in)
No
-------------------
----
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
----
Panel wheel
10 × 5.5 AT
Aluminum
-------
Panel wheel
9 × 8.5 AT
Aluminum
-------
520MXV/DAIDO
98
25 ~ 35 mm (0.98 ~ 1.38 in)
2 - 12
---------2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
---------2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
----------
CHASSIS SPECIFICATIONS
Item
Front disc brake
Type
Disc outside diameter × thickness
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake
Type
Disc outside diameter × thickness
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever and brake pedal
Brake pedal position
Parking brake cable end length
Clutch lever free play (lever end)
Throttle lever free play
Speed limiter length
Shift pedal height
Standard
Dual
161.0 × 3.5 mm (6.34 × 0.14 in)
4.3 mm (0.17 in)
4.3 mm (0.17 in)
12.70 mm (0.50 in)
25.40 mm (1.00 in)
DOT 4
Single
200.0 × 3.6 mm (7.87 × 0.14 in)
5.6 mm (0.22 in)
5.6 mm (0.22 in)
12.70 mm (0.50 in)
32.03 mm (1.26 in)
DOT 4
15.3 mm (0.60 in)
58 ~ 60 mm (2.28 ~ 2.36 in)
5 ~ 10 mm (0.20 ~ 0.39 in)
2 ~ 4 mm (0.08 ~ 0.16 in)
Less than 12 mm (0.47 in)
48 mm (1.89 in)
2 - 13
SPEC
Limit
------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
---------------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
----------------------------
ELECTRICAL SPECIFICATIONS
SPEC
EBS01004
ELECTRICAL SPECIFICATIONS
Item
Standard
System voltage
Ignition system
Ignition timing (B.T.D.C.)
Advancer type
Transistorized coil ignition
Crankshaft position sensor resistance/color
ECU
Model/manufacturer
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary winding resistance
Secondary winding resistance
Spark plug cap
Material
Resistance
A.C. magneto
Model/manufacturer
Standard output
Stator coil resistance/color
Rectifier/regulator
Type
Model/manufacturer
No load regulated voltage
Rectifier capacity
Withstand voltage
Electric starting system
Type
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Spring force
(DC)
Limit
12 V
----
9.0°/1,600 r/min
Digital type
-------
192 ~ 288 Ω at 20 °C (68 °F)/
blue/yellow-green/white
----
TBDF18/DENSO
----
JO267/DENSO
6.0 mm (0.24 in)
3.4 ~ 4.6 Ω at 20 °C (68 °F)
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
-------------
Resin
10.0 kΩ
-------
LMX58/DENSO
14 V 17.2 A at 5,000 r/min
0.248 ~ 0.372 Ω at 20 °C (68 °F)/
white-white
----------
Semiconductor, short-circuit type
SH650D-11/SHINDENGEN
14.1 ~ 14.9 V
18.0 A
200.0 V
----------------
Constant mesh type
----
SM-13/MITSUBA
0.80 kW
0.0250 ~ 0.0350 Ω at 20 °C (68 °F)
12.5 mm (0.49 in)
Commutator diameter
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)
28.0 mm (1.10 in)
Mica undercut
0.70 mm (0.03 in)
2 - 14
---------5.00 mm
(0.20 in)
---27.0 mm
(1.06 in)
----
ELECTRICAL SPECIFICATIONS
Item
Starter relay
Model/manufacturer
Amperage rating
Coil winding resistance
Circuit breaker
Circuit breaker type
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Fuel injection system fuse
Spare fuse
Standard
SPEC
Limit
2768106-A/JIDECO
180.0 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)
----------
Fuse
----
20 A
15 A
10 A
10 A
10 A
20 A
15 A
10 A
-------------------------
2 - 15
TIGHTENING TORQUES
SPEC
EBS01005
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Thread
Q’ty
size
Tightening torque
Part to be tightened
Part name
Cylinder head (exhaust pipe)
Cylinder head
Cylinder head
Cylinder head
Spark plug
Oil gallery bolt
Tappet cover
Camshaft sprocket cover
Camshaft sprocket
Decompressor assembly
Stud bolt
Bolt
Bolt
Bolt
—
Union bolt
Bolt
Bolt
Bolt
Bolt
M8
M9
M9
M6
M10
M8
M6
M6
M7
M7
4
4
2
2
1
1
8
2
2
2
15
35
38
10
13
10
10
10
20
20
1.5
3.5
3.8
1.0
1.3
1.0
1.0
1.0
2.0
2.0
11
25
27
7.2
9.4
7.2
7.2
7.2
14
14
Bolt
M10
4
50
5.0
36
Cylinder
Nm m · kg ft · lb
Remarks
M
E
See NOTE.
E
Cylinder
Cable guide
Water jacket joint
A.C. magneto rotor
A.C. magneto cover
Bolt
Bolt
Bolt
Nut
Bolt
M6
M6
M6
M16
M6
2
1
2
1
14
10
7
10
60
10
1.0
0.7
1.0
6.0
1.0
7.2
5.1
7.2
43
7.2
Balancer driven gear
Nut
M16
2
60
6.0
43
Breather plate
Bolt
M6
3
10
1.0
7.2
Primary drive gear
Nut
M20
1
110
11.0
80
E
Use a lock
washer.
Use a lock
washer.
M
Valve adjusting screw
Camshaft bearing retainer
Timing chain guide (intake side)
Timing chain tensioner cap bolt
Timing chain tensioner
Water pump outlet hose clamp
Water pump
Water pump housing cover
Thermostat cover
Radiator
Engine oil drain bolt (crankcase)
Engine oil drain bolt (oil tank)
Oil baffle plate 1
Oil baffle plate 2
Oil pump
Oil pump housing 2
Oil strainer
Nut
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
M6
M6
M6
M16
M6
M4
M6
M6
M6
M6
M14
M8
M5
M6
M6
M6
M6
2 - 16
4
2
2
1
2
2
3
3
2
2
1
1
2
2
1
1
2
14
10
10
20
10
2
10
11
10
7
23
19
4
10
10
7
10
1.4
1.0
1.0
2.0
1.0
0.2
1.0
1.1
1.0
0.7
2.3
1.9
0.4
1.0
1.0
0.7
1.0
10
7.2
7.2
14
7.2
1.4
7.2
8.0
7.2
5.1
17
13
2.9
7.2
7.2
5.1
7.2
LT
LT
LT
TIGHTENING TORQUES
Part to be tightened
Oil filter cover drain bolt
Oil filter cover
Check screw (oil filter cover)
Oil delivery pipe
Oil delivery pipe
Oil pipe joint
Oil tank inlet hose (oil tank side)
Oil tank inlet hose (engine side)
Oil tank outlet hose
Oil tank outlet hose
Intake manifold clamp
Air filter case joint clamp
ECU bracket
Exhaust pipe 2 and exhaust pipe 1
Spark arrester
Muffler and exhaust pipe 2
Muffler
Exhaust pipes
Muffler protector
Exhaust pipe protector
Oil seal retainer (clutch cover)
Timing mark accessing screw
Crankshaft end accessing screw
Crankcase bearing retainer
Crankcase bearing retainer
Crankcase
Engine oil filler bolt
Starter clutch
Clutch spring
Clutch boss
Clutch cover
Part name
Thread
Q’ty
size
SPEC
Tightening torque
Nm m · kg ft · lb
Bolt
Bolt
Screw
Union bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Screw
Bolt
Bolt
Screw
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
M6
M6
M5
M10
M6
M14
M6
M6
M16
M6
M4
M5
M6
M8
M6
M8
M8
M8
M6
M6
M6
M14
M36
M6
M6
M6
M20
M8
M6
M20
M6
1
2
1
2
1
1
1
1
1
2
2
1
2
1
1
1
2
4
2
4
2
1
1
2
2
17
1
3
6
1
14
10
10
5
20
10
50
10
10
35
10
3
4
7
16
8
18
38
20
8
8
10
6
10
10
10
10
12
30
8
95
10
1.0
1.0
0.5
2.0
1.0
5.0
1.0
1.0
3.5
1.0
0.3
0.4
0.7
1.6
0.8
1.8
3.8
2.0
0.8
0.8
1.0
0.6
1.0
1.0
1.0
1.0
1.2
3.0
0.8
9.5
1.0
7.2
7.2
3.6
14
7.2
36
7.2
7.2
25
7.2
2.2
2.9
5.1
11
5.8
13
27
14
5.8
5.8
7.2
4.3
7.2
7.2
7.2
7.2
8.7
22
5.8
68
7.2
Drive sprocket
Nut
M22
1
85
8.5
61
Oil seal retainer (left crankcase)
Shift drum segment
Shift guide
Reverse shift lever
Shift pedal
Stator coil
Crankshaft position sensor
A.C. magneto lead holder
Coolant temperature sensor
Starter motor
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
Bolt
M6
M8
M6
M6
M6
M6
M5
M5
M12
M6
2
1
2
1
1
3
2
1
1
2
10
30
10
13
16
7
7
7
18
10
1.0
3.0
1.0
1.3
1.6
0.7
0.7
0.7
1.8
1.0
7.2
22
7.2
9.4
11
5.1
5.1
5.1
13
7.2
2 - 17
Remarks
LT
LT
LT
LT
LT
LT
Stake
Use a lock
washer.
LT
LT
LT
LT
TIGHTENING TORQUES
Part to be tightened
Reverse switch
Neutral switch
Part name
—
—
Thread
Q’ty
size
M10
M10
1
1
SPEC
Tightening torque
Nm m · kg ft · lb
17
17
1.7
1.7
Remarks
12
12
NOTE:
Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb), and then tighten them to
50 Nm (5.0 m · kg, 36 ft · lb).
2 - 18
TIGHTENING TORQUES
SPEC
EBS01006
CHASSIS TIGHTENING TORQUES
Part to be tightened
Thread size
Tightening torque
Nm m · kg ft · lb
Remarks
Engine upper bracket
Engine mounting bolt (upper)
Engine lower bracket
Engine mounting bolt (middle)
Engine mounting bolt (lower)
Swingarm pivot shaft, engine, and frame
Middle frame and rear frame
Frame and oil tank
Frame and coolant reservoir
Rear shock absorber and frame
Relay arm and swingarm
Connecting arm and frame
Relay arm and rear shock absorber
Relay arm and connecting arm
Rear axle pinch bolt
Swingarm and guide pin
Swingarm skid plate and swingarm
Drive chain guide 1 and swingarm
Drive sprocket cover and engine
Upper front arm and frame
Lower front arm and frame
Front shock absorber and frame
Front shock absorber and lower front arm
Steering stem, pitman arm, and frame
M8
M10
M8
M10
M10
M16
M10
M6
M6
M12
M10
M12
M10
M10
M8
M12
M6
M6
M6
M10
M10
M10
M10
M14
33
40
41
66
66
100
54
7
7
55
43
55
43
43
21
55
7
7
10
38
55
48
48
180
3.3
4.0
4.1
6.6
6.6
10.0
5.4
0.7
0.7
5.5
4.3
5.5
4.3
4.3
2.1
5.5
0.7
0.7
1.0
3.8
5.5
4.8
4.8
18.0
24
29
30
48
48
72
39
5.1
5.1
40
31
40
31
31
15
40
5.1
5.1
7.2
27
40
35
35
130
Steering stem bushing and frame
M8
23
2.3
17
Steering stem and handlebar holder
Tie-rod end and locknut
Steering knuckle and front wheel hub
Steering knuckle and front arm (upper and lower)
Steering knuckle and tie-rod ball joint
Pitman arm and tie-rod ball joint
Frame and bearing retainer
Fuel tank and fuel pump
Fuel tank and frame
Front wheel and front wheel hub
Steering knuckle and front brake caliper bracket
Front brake disc and front wheel hub
Rear brake caliper and brake caliper bracket
Rear axle and rear wheel hub
Rear wheel and rear wheel hub
M8
M12
M14
M10
M10
M10
M42
M6
M6
M10
M8
M8
M8
M16
M10
23
18
70
25
25
25
65
7
7
45
28
28
34
200
45
2.3
1.8
7.0
2.5
2.5
2.5
6.5
0.7
0.7
4.5
2.8
2.8
3.4
20.0
4.5
17
13
50
18
18
18
47
5.1
5.1
32
20
LT
20
24
145 See NOTE.
32
2 - 19
LT
Use a lock
washer.
TIGHTENING TORQUES
Part to be tightened
Thread size
Driven sprocket and sprocket bracket
Front brake caliper and brake hose
Front brake pad retaining bolt
Brake caliper bleed screw
Front brake master cylinder and handlebar
Front brake master cylinder and brake lever
Front brake master cylinder and brake hose
Throttle lever assembly and handlebar
Clutch lever and handlebar
Parking brake lever and clutch lever
Front brake pipe nut
Brake hose joint and frame
Brake hose holder and front upper arm
Footrest and frame
Foot protector and footrest
Foot protector and footrest
Foot protector and bracket
Engine skid plate and frame
Rear axle ring nut
Rear axle ring nut set bolt
Rear brake pad retaining bolt
Rear brake caliper and brake hose
Parking brake case bracket and parking brake
case
Rear brake master cylinder and frame
Rear brake master cylinder and brake hose
Rear brake master cylinder adjusting bolt and
locknut
Parking brake adjusting bolt and locknut
Rear brake disc and brake disc bracket
Brake hose holder and swingarm
Front guard and frame
Front fender and frame
Headlight and frame
Rear fender and frame
Rear fender and bracket
Battery holding bracket and frame
Air filter case and frame
Rear guard and frame
Battery box and lean angle sensor
2 - 20
SPEC
Tightening torque
Nm m · kg ft · lb
M10
M10
M10
M8
M6
M6
M10
M5
M5
M6
M10
M6
M6
M10
M6
M8
M6
M6
M36
M6
M10
M10
72
27
17
6
7
6
27
4
4
7
19
10
7
78
13
16
12
7
240
7
17
30
7.2
2.7
1.7
0.6
0.7
0.6
2.7
0.4
0.4
0.7
1.9
1.0
0.7
7.8
1.3
1.6
1.2
0.7
24.0
0.7
1.7
3.0
52
19
12
4.3
5.1
4.3
19
2.9
2.9
5.1
13
7.2
5.1
56
9.4
11
8.7
5.1
175
5.1
12
22
M8
22
2.2
16
M6
M10
20
30
2.0
3.0
14
22
M8
17
1.7
12
M6
M8
M6
M8
M6
M6
M6
M6
M6
M6
M8
M4
10
33
7
12
7
7
7
7
7
7
32
2
1.0
3.3
0.7
1.2
0.7
0.7
0.7
0.7
0.7
0.7
3.2
0.2
7.2
24
5.1
8.7
5.1
5.1
5.1
5.1
5.1
5.1
23
1.4
Remarks
LT
LS
LT
LT
LT
LT
LT
TIGHTENING TORQUES
SPEC
NOTE:
1. Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel
hub surfaces that contact the rear axle washers.
2. Tighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb).
3. Loosen the rear axle nuts completely.
4. Retighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb). Do not loosen the axle nuts after
tightening them. If an axle nut slot is not aligned with the cotter pin hole on either side of the axle,
further tighten the axle nut until a slot is aligned with the hole.
2 - 21
HOW TO USE THE CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EBS00022
EBS00023
HOW TO USE THE CONVERSION
TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
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
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
m · kg
m · kg
cm · kg
cm · kg
7.233
86.794
0.0723
0.8679
ft · lb
in · lb
ft · lb
in · lb
Weight
kg
g
2.205
0.03527
lb
oz
10 mm
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu · in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit
(°F)
Torque
A
(nut)
2 - 22
B
(bolt)
General tightening
torques
Nm
m · kg
ft · lb
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EBS00024
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
LS
O-rings
LS
Bearings
E
Crankshaft pins
E
Timing chain sprocket inner surface
M
Connecting rod big end thrust surface
E
Piston pin
E
Piston surface
E
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
M
Rocker arm shaft
E
Camshaft lobes
M
Decompressor lever pin
E
Decompressor lever spring
E
Water pump impeller shaft
E
Oil pump rotors (inner rotor 2 and outer rotor 2) and pump
E
Oil pump rotors (inner rotor 1 and outer rotor 1) and pump
LS
Torque limiter
E
Starter idle gear and starter wheel gear inner surface
E
Primary driven gear
E
Clutch pull rod
LS
Transmission gears (wheel and pinion)
M
Shift drum
E
Shift forks
E
Shift lever assembly
E
Shift shaft
E
Reverse shift shaft
E
Crankcase mating surface
Yamaha bond
No. 1215
(Three bond
No. 1215)
A.C. magneto lead grommet (A.C. magneto cover)
Yamaha bond
No. 1215
(Three bond
No. 1215)
2 - 23
COOLANT FLOW DIAGRAMS
SPEC
EBS00025
COOLANT FLOW DIAGRAMS
È Install the radiator inlet hose onto the thermostat
cover pipe, making sure that it contacts the
cover and its yellow paint mark is facing outward.
É Fasten the fast idle plunger outlet hose and the
radiator inlet hose with the plastic band.
Ê Install the radiator inlet hose with its white paint
mark facing outward.
1 Thermostat cover
2 Fast idle plunger outlet hose
3 Radiator inlet hose
4 Radiator
5 Radiator outlet hose
6 Water pump breather hose
7 Water pump
Ë
4
È
3
2
É
Ê
A
A
Ë
1
Ì
Î
B
7
B
6
Í
5
Ð
Ï
A-A
B-B
2 - 24
COOLANT FLOW DIAGRAMS
SPEC
Ð Make sure that the end of the screw clamp does
not protrude past the side of the radiator outlet
hose.
Ë Position the screw clamp so that its screw can
be tightened from the right side of the vehicle.
Ì Install the radiator outlet hose with its white paint
mark facing outward.
Í Install the radiator outlet hose with its yellow
paint mark facing outward.
Î From fast idle plunger
Ï Make sure that the end of the screw clamp does
not protrude past the side of the radiator inlet
hose.
Ë
4
È
3
2
É
Ê
A
A
Ë
1
Ì
Î
B
7
B
6
Í
5
Ð
Ï
A-A
B-B
2 - 25
COOLANT FLOW DIAGRAMS
É Install the coolant reservoir hose onto the radiator pipe, making sure that it contacts the radiator.
Ê Pass the coolant reservoir hose and radiator fan
breather hose through the guide on the fuel tank
shield.
Ë 60 mm (2.36 in)
Ì Pass the clamp through the hole in the stay on
the frame, and then fasten the coolant reservoir
hose and drain hose with the clamp.
1 Radiator
2 Radiator fan breather hose
3 Fuel tank shield
4 Coolant reservoir breather hose
5 Coolant reservoir
6 Coolant reservoir hose
7 Drain hose
È Pass the radiator fan breather hose through the
guide.
É
6
SPEC
Ê
3
2
1
C
6
6
4
Ì
Ë
7
C
A
B
C-C
2
A
È
3
B
1
D
4
5
D
6
2 - 26
D-D
SPEC
COOLANT FLOW DIAGRAMS
È From radiator
É Install the water pump outlet hose onto the water
jacket inlet housing, making sure to align the yellow paint mark on the hose with the projection
on the water jacket inlet housing.
1 Water pump outlet hose
2 Water pump
3 Water pump breather hose
4 Water jacket inlet housing
A
1
È
B
4
B
2
É
1
3
A
2
È
B-B
2 - 27
OIL FLOW DIAGRAMS
SPEC
EBS00026
OIL FLOW DIAGRAMS
1 Oil tank breather hose
2 Oil tank outlet hose
3 Oil tank inlet hose
4 Oil tank
1
4
1
4
3
2
2 - 28
3
OIL FLOW DIAGRAMS
SPEC
1 Oil delivery pipe
2 Oil filter
3 Oil pump
2
A-A
1
A
2
A
3
2 - 29
OIL FLOW DIAGRAMS
SPEC
1 Oil filter
2 Oil pump driven gear
3 Oil pump rotor 1
4 Oil pump rotor 2
5 Oil pipe joint
6 Main axle
7 Counter axle
1
7
6
5
4
2 - 30
3
2
OIL FLOW DIAGRAMS
1 Oil strainer
2 Oil pump rotor 2
3 Oil pump rotor 1
4 Oil pump driven gear
È To oil tank
A
È
A
1
2
1
3
4
A-A
2 - 31
SPEC
OIL FLOW DIAGRAMS
SPEC
1 Balancer 1
2 Crankshaft
1
2
2 - 32
CABLE ROUTING
SPEC
EBS00028
CABLE ROUTING
1 Handlebar switch lead
2 Clutch switch lead
3 Parking brake cable
4 Clutch cable
5 Front brake hose
6 Front brake light switch lead
7 Throttle cable
8 Indicator light assembly lead
9 Radiator fan breather hose
0 Coolant reservoir breather hose
A Coolant reservoir hose
B Radiator fan motor lead
C Main switch lead
A
3
4
5
É
È
1
6
7
2
3
7
4
5
1
6
Ê
Û
2
È
Ë
C
Ú
Ì
Ù
8
9
Ø
0Í
×
Î
Ö
Ô
Ï
Ò
Õ
A
B
Ð
Ó
Ñ
A
2 - 33
CABLE ROUTING
Í Route the coolant reservoir breather hose under
the wire harness and over the handlebar switch
lead, clutch switch lead, front brake light switch
lead, main switch lead and indicator light assembly lead and then fasten the hose with the holder
on the fuel tank shield.
Î To resistor
Ï To left headlight
È Fasten the handlebar switch lead and clutch
switch lead with the plastic bands at the bends in
the handlebar.
É Fasten the front brake light switch lead with the
plastic band at the bend in the handlebar.
Ê To main switch
Ë Route the parking brake cable and clutch cable
in front of the front brake light switch and main
switch lead.
Ì To radiator
A
3
4
5
É
È
6
7
2
1
3
7
4
5
1
6
Ê
Û
2
È
Ë
C
Ú
Ì
Ù
8
9
Ø
0Í
×
Î
Ö
Ô
Ï
Ò
Õ
SPEC
A
B
Ð
Ó
Ñ
A
2 - 34
CABLE ROUTING
Ó Secure the plastic band by inserting the projection
on the band into the hole in the frame, and then
fasten the wire harness and radiator fan motor
lead with the band, making sure to face the end of
the band backward.
Ô To rectifier/regulator
Õ To ignition coil
Ö To right headlight
× Pass the clutch cable and parking brake cable
through the wire guide.
Ð Route the radiator fan breather hose and coolant
reservoir hose in front of the front brake light
switch lead, main switch lead, handlebar switch
lead, clutch switch lead and indicator light assembly lead.
Ñ Secure the plastic band by inserting the projection
on the band into the hole in the frame, and then
fasten the wire harness with the band, making
sure to face the end of the band backward.
Ò To radiator fan
A
3
4
5
É
È
6
7
2
1
3
7
4
5
1
6
Ê
Û
2
È
Ë
C
Ú
Ì
Ù
8
9
Ø
0Í
×
Î
Ö
Ô
Ï
Ò
Õ
SPEC
A
B
Ð
Ó
Ñ
A
2 - 35
CABLE ROUTING
Ú Pass the throttle cable, clutch cable, parking
brake cable, front brake light switch lead, main
switch lead, handlebar switch lead, clutch switch
lead, indicator light assembly lead and radiator
fan breather hose through the wire guide.
Û Route the front brake light switch lead behind
the front brake hose and throttle cable.
Ø Pass the radiator fan breather hose, coolant reservoir hose, front brake light switch lead, main
switch lead, handlebar switch lead, clutch switch
lead, and indicator light assembly lead through
the guide on the fuel tank shield, and then connect the leads below the guide.
Ù Route the throttle cable in front of the clutch
cable and parking brake cable.
A
3
4
5
É
È
6
7
2
1
3
7
4
5
1
6
Ê
Û
2
È
Ë
C
Ú
Ì
Ù
8
9
Ø
0Í
×
Î
Ö
Ô
Ï
Ò
Õ
SPEC
A
B
Ð
Ó
Ñ
A
2 - 36
SPEC
CABLE ROUTING
1 Coolant reservoir hose
2 Radiator fan breather hose
3 Throttle cable
4 Fuel tank breather hose
5 Fuel hose
6 Oil tank inlet hose
7 Reverse control cable
8 Oil tank outlet hose
9 Drain hose
0 Coolant reservoir breather hose
A Resistor lead
ÑA
B Resistor
C Headlight lead
D Main switch lead
E Handlebar switch lead
F Clutch switch lead
G Front brake light switch lead
H Wire harness
I Indicator assembly lead
J Fuel tank shield
K Fuel tank
L Rubber damper
B
4Ë
Ê3
5
Ì
É2
È1
CÒ
1
9
Í
Ð
0
B
E
D
9
D
A
E
F
F
A
F
F
E
F
3
K
2
0
C
B
1
×
0
H
L
J
C
I
6
Î 7
8 Ï
HÖ
G
D
Ó
1
HÔ
D-D
J
9
F-F
Õ5
H
J
C-C
K
2 - 37
E-E
SPEC
CABLE ROUTING
È Route the coolant reservoir hose in front of the
radiator fan breather hose, and then connect it to
the radiator.
É Pass the radiator fan breather hose through the
wire guide.
Ê Route the throttle cable on top of the fuel tank
shield.
Ë Pass the fuel tank breather hose through the
hole in the handlebar cover, and then insert the
end of the hose into the steering stem.
ÑA
Ì Route the wire harness to the inside of the
frame.
Í Connect the A.C. magneto lead, wire sub lead,
rear brake switch lead, and speed sensor lead,
and then fasten the leads with the plastic band.
Face the end of the plastic band inward.
Î Fasten the oil tank outlet hose and reverse control cable with the clamp, making sure that the
reverse control cable does not contact the edge
of the engine stay.
B
4Ë
Ê3
5
Ì
É2
È1
CÒ
1
9
Í
Ð
0
B
E
D
9
D
A
E
F
F
A
F
F
E
F
3
K
2
0
C
B
1
×
0
H
L
J
C
I
6
Î 7
8 Ï
HÖ
G
D
Ó
1
HÔ
D-D
J
9
F-F
Õ5
H
J
C-C
K
2 - 38
E-E
SPEC
CABLE ROUTING
Ï Route the reverse control cable under the oil
tank outlet hose.
Ð Pass the plastic band through the space
between the frame and the frame support, and
then fasten the wire harness to the frame with
the band, making sure to face the end of the
band inward.
ÑA
Ñ Route the resistor lead over the frame, making
sure that its coupler is positioned to the inside of
the frame.
Ò Route the headlight lead over the frame, connect the headlight coupler, and then insert the
projection on the coupler into the hole in the stay
on the front fender bracket.
B
4Ë
Ê3
5
Ì
É2
È1
CÒ
1
9
Í
Ð
0
B
E
D
9
D
A
E
F
F
A
F
F
E
F
3
K
2
0
C
B
1
×
0
H
L
J
C
I
6
Î 7
8 Ï
HÖ
G
D
Ó
1
HÔ
D-D
J
9
F-F
Õ5
H
J
C-C
K
2 - 39
E-E
SPEC
CABLE ROUTING
Ó Pass the radiator fan breather hose and coolant
reservoir hose, then the front brake light switch
lead, main switch lead, handlebar switch lead,
clutch switch lead, and indicator light assembly
lead through the guide on the fuel tank shield,
making sure to route the hoses in front of leads.
Do not pinch or crush the radiator fan breather
hose or coolant reservoir hose. Route the indicator light assembly lead to the left of the other
leads.
ÑA
Ô Pass the wire harness through the rubber
damper.
Õ Route the fuel hose to the outside of the wire
harness.
Ö Route the wire harness above the fuel tank
shield.
× Pass the clamp through the hole in the stay on
the frame, and then fasten the coolant reservoir
hose and drain hose with the clamp.
B
4Ë
Ê3
5
Ì
É2
È1
CÒ
1
9
Í
Ð
0
B
E
D
9
D
A
E
F
F
A
F
F
E
F
3
K
2
0
C
B
1
×
0
H
L
J
C
I
6
Î 7
8 Ï
HÖ
G
D
Ó
1
HÔ
D-D
J
9
F-F
Õ5
H
J
C-C
K
2 - 40
E-E
SPEC
CABLE ROUTING
1 A.C. magneto lead
2 Lean angle sensor lead
3 Negative battery lead
4 Crankcase breather hose
5 Starter relay lead
6 Relay unit
7 Self-diagnosis signal lead
8 Tail/brake light
9 Tail/brake light lead
0 ECU
A ECU lead
B Battery box
C Starter motor lead
D Speed sensor lead
E Rear brake light switch lead
F Wire sub lead
G Reverse switch lead
H Neutral switch lead
I Speed sensor
J Wire harness
Ù
3
Ø
E
F
1
D
×
E
J
F
C
A-A
D
C-C
I
B
3Ê
4
Ë
6
5
7
D
Ì
C
Î
É2
8
9Í
È
C
1
A
B
B
A
0Ñ
A
Ð Ï
CÓ Ò
D
E
Ö
F
Ô
F
H
E
F
F-F
G FÕ
9
8
Ú
E
9
D
E
8
2 - 41
E-E
SPEC
CABLE ROUTING
Ë Secure the plastic band by inserting the projection on the band into the hole in the frame, and
then fasten the wire harness at the center of its
positioning tape with the band, making sure that
the end of the band faces rearward and the
leads that branch off from the wire harness do
not contact the frame.
Ì Make sure that there is no slack in the wire harness in the area shown in the illustration.
È Route the leads that branch off from the wire
harness over the crankcase breather hose, then
towards the right side of the vehicle, making
sure that they do not contact the frame.
É Route the lean angle sensor lead to the outside
of the A.C. magneto lead, negative battery lead,
wire sub lead, rear brake light switch lead, and
speed sensor lead.
Ê Connect the negative battery lead to the negative battery terminal.
Ù
3
Ø
E
F
1
D
×
E
J
F
C
A-A
D
C-C
I
B
3Ê
4
Ë
6
5
7
D
Ì
C
Î
É2
8
9Í
È
C
1
A
B
B
A
0Ñ
A
Ð Ï
CÓ Ò
D
E
Ö
F
Ô
F
H
E
F
F-F
G FÕ
9
8
Ú
E
9
D
E
8
2 - 42
E-E
SPEC
CABLE ROUTING
Ð Fasten the radiator fan motor relay lead and tail/
brake light lead with the plastic band, making
sure to face the end of the band downward. Fasten the leads near the tail/brake light coupler and
after the split in the wire harness, making sure to
install the plastic band around the protective
sleeve of the tail/brake light lead, not the lead
itself.
Í When installing the tail/brake light cover and
rear fender, be sure not to pinch the tail/brake
light lead between the frame and the cover.
Î To fuse box
Ï Make sure that the tail/brake light lead is not
pulled taut when installing the rear fender.
Ù
3
Ø
E
F
1
D
×
E
J
F
C
A-A
D
C-C
I
B
3Ê
4
Ë
6
5
7
D
Ì
C
Î
É2
8
9Í
È
C
1
A
B
B
A
0Ñ
A
Ð Ï
CÓ Ò
D
E
Ö
F
Ô
F
H
E
F
F-F
G FÕ
9
8
Ú
E
9
D
E
8
2 - 43
E-E
SPEC
CABLE ROUTING
Õ Route the wire sub lead as shown in the illustration. The longer lead past the end of the protective sleeve is the neutral switch lead and the
shorter lead is the reverse switch lead.
Ö Route the A.C. magneto lead, negative battery
lead, wire sub lead, rear brake light switch lead,
and speed sensor lead between the crankcase
breather hose and the starter motor lead, and to
the rear of the leads that branch off from the wire
harness.
Ñ Secure the plastic band by inserting the projection on the band into the hole in the frame.
Ò Fasten the wire harness with the plastic band so
that the ECU lead is routed downward.
Ó Route the starter motor lead between the frame
and the battery box, then under the crankcase
breather hose.
Ô Make sure that there is not excessive slack in
the wire sub lead in the area shown in the illustration.
Ù
3
Ø
E
F
1
D
×
E
J
F
C
A-A
D
C-C
I
B
3Ê
4
Ë
6
5
7
D
Ì
C
Î
É2
8
9Í
È
C
1
A
B
B
A
0Ñ
A
Ð Ï
CÓ Ò
D
E
Ö
F
Ô
F
H
E
F
F-F
G FÕ
9
8
Ú
E
9
D
E
8
2 - 44
E-E
SPEC
CABLE ROUTING
Ù Secure the plastic band by inserting the projection on the band into the hole in the frame, and
then fasten the wire harness and starter motor
lead with the band, making sure to face the end
of the band upward and to fasten the wire harness between the sections where the starter
relay lead and ECU lead branch off from the wire
harness.
Ú Fasten the tail/brake light lead with the plastic
band.
× Fasten the speed sensor lead, rear brake light
switch lead, A.C. magneto lead, negative battery
lead and wire sub lead with the plastic band.
Face the end of the plastic band inward.
Ø Fasten the rear brake light switch lead and wire
sub lead with the holder.
Ù
3
Ø
E
F
1
D
×
E
J
F
C
A-A
D
C-C
I
B
3Ê
4
Ë
6
5
7
D
Ì
C
Î
É2
8
9Í
È
C
1
A
B
B
A
0Ñ
A
Ð Ï
CÓ Ò
D
E
Ö
F
Ô
F
H
E
F
F-F
G FÕ
9
8
Ú
E
9
D
E
8
2 - 45
E-E
CABLE ROUTING
1 Intake air pressure sensor lead
2 Fuel injector lead
3 Intake air pressure sensor
4 Throttle position sensor
5 Throttle position sensor lead
6 Intake air temperature sensor lead
7 Intake air temperature sensor
8 Crankcase breather hose
9 Negative battery lead
0 Lean angle sensor
A Fuel injector
SPEC
B Fuel pump
C Fuel hose
D Fuel pump lead
E Front brake light switch lead
F Radiator fan breather hose
G Indicator light assembly lead
H Clutch cable
I Parking brake cable
J Indicator light assembly
K Throttle cable
L Handlebar switch lead
H
G
I
Ò
Ñ
A-A
J
A
G
Ð
A
Ï
Ó
K
7
N M L
F
8
E
ÎD
C
8
B-B
1
È
B
2
A
Í
Ì
0
Ë9
B
B
3
4
5
6É
Ê8
7
2 - 46
CABLE ROUTING
SPEC
Ì Route the negative battery lead connector as
shown.
Í Connect the A.C. magneto lead, wire sub lead,
rear brake switch lead, and speed sensor lead in
front of the lean angle sensor.
Î Route the fuel pump lead under the fuel hose.
Ï 10 mm (0.39 in)
³ Pass the indicator light assembly lead through
the guide on the front fender.
Ñ Insert the projection on the indicator light assembly coupler into the hole in the front fender.
M Clutch switch lead
N Main switch lead
È To coolant temperature sensor
É Leave some slack in the intake air temperature
sensor lead in the area shown in the illustration.
Ê Route the crankcase breather hose between the
battery box and the air filter joint, and under the
wire harness.
Ë Route the negative battery lead between the
lean angle sensor and the wire harness.
H
G
I
Ò
Ñ
A-A
J
A
G
Ð
A
Ï
Ó
K
7
N M L
F
8
E
ÎD
C
8
B-B
1
È
B
2
A
Í
Ì
0
Ë9
B
B
3
4
5
6É
Ê8
7
2 - 47
CABLE ROUTING
SPEC
Ò Pass the indicator light assembly lead through
the guide on the radiator cover.
Ó Fasten the leads with the holder at the section
before the intake air temperature sensor lead
branches off from the other leads.
H
G
I
Ò
Ñ
A-A
J
A
G
Ð
A
Ï
Ó
K
7
N M L
F
8
E
ÎD
C
8
B-B
1
È
B
2
A
Í
Ì
0
Ë9
B
B
3
4
5
6É
Ê8
7
2 - 48
CABLE ROUTING
1 Radiator fan motor relay
2 Headlight relay
3 Fuse box
4 Relay unit
5 Relay unit lead
6 Self-diagnosis signal lead
7 Starter motor lead
8 Starter relay lead
9 Starter relay
0 Fuse box lead
A Headlight relay lead
B Radiator fan motor relay lead
SPEC
C Tail/brake light lead
È Route the starter motor lead under the starter
relay lead.
É Make sure that the self-diagnosis signal coupler
is positioned above the relay unit lead, fuse box
lead, headlight relay lead, and radiator fan motor
relay lead.
Ê Install the headlight relay, then the radiator fan
motor relay, onto the tab on the rear fender. The
headlight relay is identified by the presence of
white tape wrapped around its lead.
6É
4
5
0
A
B
C
A-A
9
8
È7
1
6
Ê
A
A
B
B
2
B
B-B
5
1
4
3
2 - 49
2
SPEC
CABLE ROUTING
1 Radiator inlet hose
2 Fast idle plunger outlet hose
3 Reverse control cable
4 Ignition coil lead (red/black)
5 Rectifier/regulator lead
6 Ignition coil lead (orange)
7 Radiator outlet hose
8 Brake pipe
9 Rear brake light switch holder
0 Rear brake light switch lead
A Rear brake light switch
B Throttle position sensor lead
C Coolant temperature sensor
D Hose (air-filter-joint-to-throttle-body-right-side)
E Coolant temperature sensor lead
F Intake air pressure sensor
G Fuel injector lead
H Intake air pressure sensor lead
I Parking brake cable
J Clutch cable
K Headlight lead
L Radiator fan motor lead
I
I
A
0
O
A-A
J
I
H
B
D
C
J
KÒ
4
Õ
3
I
I
J
F
O
M
3
5
ÑG
H
1
Ó
P
L
I
ÔN
E
L
5 K
6
G
6
4
I-I
H
7
2
F
È
E
3
Ð
Ö
J
ÏD
3É
C
B
F
4
5
Í
Î
6
E
C
D
J
ÌA
Ë0
G
B
A
A
Ê
9
2 - 50
7
8
SPEC
CABLE ROUTING
Ê Make sure that the rear brake light switch lead
does not contact the swingarm. There should be
no slack in the rear brake light switch lead
between the holder shown in the illustration and
the holder on the left side of the vehicle.
Ë Route the rear brake light switch lead behind the
spring.
Ì Route the rear brake light switch lead to the right
of the rear brake light switch holder.
M Wire harness
N Spark plug lead
O Rectifier/regulator
P Ignition coil
È Fasten the fast idle plunger outlet hose and radiator inlet hose with the plastic band, making sure
not to pinch or crush the hoses.
É Route the reverse control cable to the inside of
the frame.
I
I
A
0
O
A-A
J
I
H
B
D
C
J
KÒ
4
Õ
3
I
I
J
F
O
M
3
5
ÑG
H
1
Ó
P
L
I
ÔN
E
L
5 K
6
G
6
4
I-I
H
7
2
F
È
E
3
Ð
Ö
J
ÏD
3É
C
B
F
4
5
Í
Î
6
E
C
D
J
ÌA
Ë0
G
B
A
A
Ê
9
2 - 51
7
8
SPEC
CABLE ROUTING
Ð Route the leads that branch off from the wire
harness over the fast idle plunger outlet hose
and to the right of the hose (air filter joint to right
side of throttle body).
Ñ Route the fuel injector lead over the intake air
pressure sensor.
Ò Route the headlight lead over the frame, connect the headlight coupler, and then insert the
projection on the coupler into the hole in the stay
on the front fender bracket.
Í Secure the plastic band by inserting the projection on the band into the hole in the frame, and
then fasten the leads where the throttle position
sensor lead branches off from the other leads,
making sure to face the end of the band rearward.
Î From the left side of the vehicle
Ï Install the hose (air filter joint to right side of
throttle body) onto the pipe on the air filter joint.
‘
I
I
A
0
O
A-A
J
I
H
B
D
C
J
KÒ
4
Õ
3
I
I
J
F
O
M
3
5
ÑG
H
1
Ó
P
L
I
ÔN
E
L
5 K
6
G
6
4
I-I
H
7
2
F
È
E
3
Ð
Ö
J
ÏD
3É
C
B
F
4
5
Í
Î
6
E
C
D
J
ÌA
Ë0
G
B
A
A
Ê
9
2 - 52
7
8
SPEC
CABLE ROUTING
Ö Fasten the reverse control cable to the frame
with the plastic band, making sure to face the
end of the band downward.
Ó Fasten the rectifier/regulator lead with the plastic
band. Face the end of the plastic band downward.
Ô Route the spark plug lead to the right of the
clutch cable and parking brake cable, making
sure that the lead does not contact the cylinder
head.
Õ Route the reverse control cable in front of the
wire harness.
I
I
A
0
O
A-A
J
I
H
B
D
C
J
KÒ
4
Õ
3
I
I
J
F
O
M
3
5
ÑG
H
1
Ó
P
L
I
ÔN
E
L
5 K
6
G
6
4
I-I
H
7
2
F
È
E
3
Ð
Ö
J
ÏD
3É
C
B
F
4
5
Í
Î
6
E
C
D
J
ÌA
Ë0
G
B
A
A
Ê
9
2 - 53
7
8
INTRODUCTION/PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM
CHK
ADJ
EBS00029
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to machines already in service as well as to new machines that are being prepared for sale.
All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
NOTE:
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL
ITEM
ROUTINE
Whichever
comes first
Fuel line*
• Check fuel hose for cracks or damage.
• Replace if necessary.
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Valves*
• Check valve clearance.
• Adjust if necessary.
Fuel injection*
• Check and adjust engine idle speed.
Crankcase breather
system*
• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*
• Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary.
Spark arrester
• Clean.
3-1
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
ITEM
ROUTINE
Whichever
comes first
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
Every 20 ~ 40 hours
(more often in wet or dusty areas)
Air filter element
• Clean.
• Replace if necessary.
Clutch*
• Check operation.
• Adjust if necessary.
Front brake*
• Check free play/operation/fluid leakage/See NOTE.
• Correct if necessary.
Rear brake*
• Check operation/fluid leakage/See NOTE.
• Correct if necessary.
Wheels*
• Check balance/damage/runout.
• Replace if necessary.
Wheel bearings*
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
Rear arm pivots*
• Lubricate every 6 months with lithium-soap-based
grease.
Upper and lower arm
• Lubricate every 6 months with lithium-soap-based
pivot and steering
grease.
shaft*
Drive chain
• Check and adjust slack/alignment/clean/lube.
Fittings and fasteners*
• Check all chassis fittings and fasteners.
• Correct if necessary.
Front and rear suspension*
• Check operation.
• Correct if necessary.
Steering system*
•
•
•
•
Engine oil
• Replace (Warm engine before draining).
Engine oil filter element
• Replace.
Cooling system
• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Lights and switches*
• Check operation.
• Adjust headlight beams.
Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.
NOTE:
• Recommended brake fluid: DOT 4
• Brake fluid replacement:
• When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and add the fluid as required.
• On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
• Replace the brake hoses every four years, or if cracked or damaged.
_
WARNING
_
Indicates a potential hazard that could result in serious injury or death.
3-2
3
SEAT, FENDERS AND FUEL TANK
CHK
ADJ
EBS00033
SEAT, FENDERS AND FUEL TANK
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
1
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
2
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
4
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
3
5
(4)
R.
R.
1
Job/Part
Removing the seat, front panel, foot
protectors and engine skid plate
Seat
T.
T.
Order
LT
16 Nm (1.6 m • kg, 11 ft • Ib)
Q’ty
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
Pull back the seat lock lever, than pull up
on the rear of the seat.
_
2
3
4
5
Front panel
Left foot protector
Right foot protector
Engine skid plate
1
1
1
1
For installation, reverse the removal procedure.
3-3
SEAT, FENDERS AND FUEL TANK
CHK
ADJ
EBS00036
T.
R.
4
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
5
6
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
T.
R.
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
2
R.
R.
1
2
3
4
5
6
T.
T.
Order
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the headlights and front
fender
Seat/front panel
Headlight coupler
Left headlight
Right headlight
Fuel tank top panel
Indicator light assembly coupler
Front fender
Q’ty
2
1
1
1
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK”.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3-4
CHK
ADJ
SEAT, FENDERS AND FUEL TANK
EBS00039
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
2
T.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
R.
1
3
3
4
11
(4)
8
5
6
10
9
7
R.
R.
1
2
3
Job/Part
Removing the rear fender
Seat/front panel/fuel tank top panel/
front fender
Air filter case cover
Battery holding bracket
Battery lead
T.
T.
Order
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
1
1
2
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK”.
Disconnect.
CAUTION:
_
First disconnect the negative lead,
then disconnect the positive lead.
4
5
6
Battery
ECU
Intake air temperature sensor coupler
1
1
1
3-5
CHK
ADJ
SEAT, FENDERS AND FUEL TANK
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
2
T.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
R.
1
3
3
4
11
(4)
8
5
6
10
9
7
9
10
11
12
R.
R.
8
Job/Part
Hose (throttle-body-joint-to-throttlebody-left side)
Hose (throttle-body-joint-to-throttlebody-right side)
Crankcase breather hose
Clamp (throttle body joint)
Air filter case
Rear fender
T.
T.
Order
7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
1
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Remarks
1
1
1
1
1
Loosen
For installation, reverse the removal procedure.
3-6
SEAT, FENDERS AND FUEL TANK
CHK
ADJ
EBS00042
(6)
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
2
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New
3
4
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
5
Order
1
2
3
4
Job/Part
Removing the fuel tank
Seat/front panel/fuel tank top panel/
front fender
Fuel pump coupler
Fuel hose connector holder
Fuel hose
Fuel tank
Q’ty
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK”.
Disconnect.
Refer to “REMOVING THE FUEL TANK”
and “INSTALLING THE FUEL HOSE”.
NOTE:
When installing the fuel tank, pass the
fuel tank breather hose through the hole
in the handlebar cover, and then insert
the end of the hose into the steering
stem.
_
5
6
Drain hose
Fuel tank shield
1
1
3-7
SEAT, FENDERS AND FUEL TANK
(6)
CHK
ADJ
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
2
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New
3
4
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
5
Order
7
Job/Part
Fuel pump
Q’ty
Remarks
1
Refer to “REMOVING THE FUEL PUMP”
and “INSTALLING THE FUEL PUMP”.
For installation, reverse the removal procedure.
3-8
SEAT, FENDERS AND FUEL TANK
CHK
ADJ
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 holder
• fuel hose
1
1
CAUTION:
a
• 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 hose, since there may be fuel
remaining in it.
2
NOTE:
• When removing the fuel hose from the fuel
pump, remove the fuel hose connector
holder first, and next, insert a slotted head
screwdriver etc. in the slot part a of the fuel
hose connector cover 1, then slide the
screwdriver in the direction of the arrow, and
remove the fuel hose.
• To remove the fuel hose from the throttle
body, slide the fuel hose connector cover 2
on the end of the hose in direction of the
arrow shown, press the two buttons 3 on the
sides of the connector, and then remove the
hose.
• Before removing the hose, place a few rags
in the area under where it will be removed.
3
3. Remove:
• fuel tank
NOTE:
Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean
the fuel tank against a wall or like.
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump bracket
• fuel pump
• fuel pump gasket
3-9
SEAT, FENDERS AND FUEL TANK
CHK
ADJ
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
INSTALLING THE FUEL PUMP
1. Install:
• fuel pump gasket New
• fuel pump
7 Nm (0.7 m · kg, 5.1 ft · lb)
• fuel pump bracket
a
6
4
1
T.
R.
a
NOTE:
• 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 bracket by aligning the
projection a on the fuel pump with the projection on the fuel tank.
• Tighten the bolts to the specified torque in
the proper tightening sequence as shown.
• Install the fuel pump in the direction shown in
the illustration.
3
2
5
1
1
INSTALLING THE FUEL HOSE
1. Install:
• fuel hose
• fuel hose holder
• fuel pump coupler
CAUTION:
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
NOTE:
Install the fuel hose connector cover 1
securely onto the fuel tank until a distinct
“click” is heard, and then make sure that it
does not come loose.
3 - 10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00049
ENGINE
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.
2
1
1
2
1.
•
•
•
Remove:
seat
front fender
fuel tank
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.
•
•
•
Remove:
intake tappet cover
exhaust tappet cover 1
camshaft sprocket cover 2
3.
•
4.
•
Disconnect:
spark plug cap 1
Remove:
spark plug 2
5. Remove:
• timing mark accessing screw 1
• crankshaft end accessing screw 2
1
2
3 - 11
ADJUSTING THE VALVE CLEARANCE
a
CHK
ADJ
6. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.09 ~ 0.13 mm
(0.0035 ~ 0.0051 in)
Exhaust valve
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d
a. Turn the crankshaft counterclockwise.
b. When the piston is at the top dead center
(TDC) on the compression stroke, align the
“I” mark a on the A.C. magneto rotor with
the stationary pointer b on the A.C. magneto cover.
c
NOTE:
To position the piston at top dead center (TDC)
on the compression stroke, align the “I” mark
c on the camshaft sprocket with the stationary
pointer d on the cylinder head, as shown in
the illustration.
c. Measure the valve clearance with a thickness gauge 1.
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
1
Out of specification → Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust:
• valve clearance
3
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 with the tappet
adjusting tool 4 until the specified valve
clearance is obtained.
Tappet adjusting tool
90890-01311
Valve adjuster (3 mm & 4 mm)
YM-08035-A
4
3 - 12
ADJUSTING THE VALVE CLEARANCE/
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to the specified torque.
T.
Locknut
14 Nm (1.4 m · kg, 10 ft · lb)
R.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• timing mark accessing screw
T.
R.
6 Nm (0.6 m · kg, 4.3 ft · lb)
• crankshaft end accessing screw
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
9. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
10.Connect:
• spark plug cap
11.Install:
• O-ring New
• camshaft sprocket cover
R.
1
New
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• O-ring 1 New
• intake tappet cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• O-ring New
• exhaust tappet cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
12.Install:
• fuel tank
• front fender
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
EBS00051
ADJUSTING THE ENGINE IDLING SPEED
1. Start the engine and let it warm up for several minutes.
2. Attach:
• tachometer
(to the spark plug lead)
Digital tachometer
90890-06760, YU-39951-B
3 - 13
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE LEVER FREE PLAY
CHK
ADJ
3. Measure:
• idling speed
Out of specification → Adjust.
Engine idling speed
1,500 ~ 1,700 r/min
4. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the throttle stop screw 1 in direction
a or b until the specified idling speed is
obtained.
a
1
b
Direction a
Idling speed becomes
higher.
Direction b
Idling speed becomes
lower.
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5.
•
6.
•
Detach:
tachometer
Adjust:
throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.
Throttle lever free play
2 ~ 4 mm (0.08 ~ 0.16 in)
EBS00052
ADJUSTING THE THROTTLE LEVER FREE
PLAY
NOTE:
Engine idling speed should be adjusted properly before adjusting the throttle lever free
play.
_
a
1. Measure:
• throttle lever free play a
Out of specification → Adjust.
Throttle lever free play
2 ~ 4 mm (0.08 ~ 0.16 in)
3 - 14
ADJUSTING THE THROTTLE LEVER FREE PLAY/
ADJUSTING THE SPEED LIMITER
a
2
CHK
ADJ
2. Adjust:
• throttle lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
First step:
a. Slide back the rubber cover 1.
b. Loosen the locknut 2 on the throttle body
side.
c. Turn the adjusting nut 3 in direction a or
b until the correct free play is obtained.
b
3
Direction a
Free play is increased.
Direction b
Free play is decreased.
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
NOTE:
If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
_
Second step:
f. Slide back the rubber cover 4.
g. Loosen the locknut 5.
h. Turn the adjusting bolt 6 in direction c or
d until the correct free play is obtained.
d
c
4
6
5
Direction c
Free play is increased.
Direction d
Free play is decreased.
i. Tighten the locknut.
j. Slide the rubber cover to its original position.
WARNING
_
After adjusting the free play, turn the handlebar to the right and left to make sure
that the engine idling speed does not
increase.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00053
ADJUSTING THE SPEED LIMITER
The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum position. Screwing in the adjusting screw stops the
engine speed from increasing.
1. Measure:
• speed limiter length a
Out of specification → Adjust.
Speed limiter length
Less than 12 mm (0.47 in)
3 - 15
ADJUSTING THE SPEED LIMITER/
CHECKING THE SPARK PLUG
CHK
ADJ
2. Adjust:
• speed limiter length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting screw 2 in or out until
the specified speed limiter length is
obtained.
Turning in
Speed limiter length is
decreased.
Turning out
Speed limiter length is
increased.
c. Tighten the locknut.
WARNING
_
• Particularly for a beginner rider, the
speed limiter should be screwed in completely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
• For proper throttle lever operation do not
turn out the adjusting screw more than
12 mm (0.47 in). Also, always adjust the
throttle lever free play to 2 ~ 4 mm (0.08 ~
0.16 in).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00057
CHECKING THE SPARK PLUG
1. Remove:
• spark plug
2. Check:
• spark plug type
Incorrect → Change.
Standard spark plug
CR8E/NGK
3. Check:
• electrode 1
Wear/damage → Replace.
• insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
4. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
3 - 16
CHECKING THE SPARK PLUG/
CHECKING THE IGNITION TIMING
CHK
ADJ
5. Measure:
• spark plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
T.
R.
6. Tighten:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
_
EBS00058
CHECKING THE IGNITION TIMING
NOTE:
Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.
_
1. Attach:
• tachometer
• timing light
(to spark plug lead)
Digital tachometer
90890-06760, YU-39951-B
Timing light
90890-03141
Inductive clamp timing light
YU-03141
2. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Warm up the engine and keep it at the
specified speed.
Engine speed
1,500 ~ 1,700 r/min
3 - 17
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
1
CHK
ADJ
b. Remove the timing mark accessing screw
1.
c. Visually check the stationary pointer a to
verify it is within the required firing range b
indicated on the flywheel.
Incorrect firing range → Check the pulser
coil assembly.
NOTE:
When checking the ignition timing, make sure
that the timing light cord does not come in contact with the exhaust muffler.
d. Install the timing mark accessing screw.
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b
a
3. Detach:
• timing light
• tachometer
EBS00061
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
_
1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
CAUTION:
_
Before removing a spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it
from falling into the cylinder.
3 - 18
MEASURING THE COMPRESSION PRESSURE
1
CHK
ADJ
5. Attach:
• extension
• compression gauge 1
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
6. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
392 kPa (3.92 kg/cm2, 55.8 psi)
Standard
450 kPa (4.5 kg/cm2, 64.0 psi)
Maximum
504 kPa (5.04 kg/cm2, 71.7 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug
lead before cranking the engine.
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.
3 - 19
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston ring(s) wear
or damage →
Repair.
Same as without
oil
Piston rings,
valves, cylinder
head gasket or
piston possibly
defective → Repair.
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R.
Install:
spark plug
Connect:
spark plug cap
T.
7.
•
8.
•
13 Nm (1.3 m · kg, 9.4 ft · lb)
EBS01101
CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a level surface.
2. Start the engine, warm it up until the engine
oil has reached a normal temperature of
60 °C (140 °F), let it continue to idle for ten
seconds, and then turn the engine off.
NOTE:
To achieve the proper engine oil temperature
for an accurate oil level reading, the engine
must have first completely cooled down, and
then warmed up again for several minutes to
normal operating temperature.
_
3 - 20
CHECKING THE ENGINE OIL LEVEL
1
CHK
ADJ
3. Check:
• engine oil level
Oil level should be between the minimum
level mark a and the maximum level mark
b.
Low oil level → Add oil to the proper level.
1
b
NOTE:
• Wait a few minutes until the oil settles before
checking the oil level.
• Do not screw the dipstick 1 in when checking the oil level.
_
a
È
0°
10°
30°
50°
70°
90°
110°
130°F
Recommended oil
Follow the chart on the left.
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20°
-10°
NOTE:
Recommended oil classification:
API Service “SE”, “SF”, “SG” type or equivalent (e.g. “SF—SE—CC”, “SF—SE—SD” etc.)
_
0°
10°
20°
30°
40°
50°C
É
CAUTION:
_
É
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CONSERVING II” d or higher.
• Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
• Do not allow foreign material to enter the
crankcase.
È For CDN
É For Europe, Oceania
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
• engine oil level
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
_
3 - 21
CHANGING THE ENGINE OIL
CHK
ADJ
EBS00067
1
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 bolt 1
• dipstick 2
2
4. Remove:
• engine oil drain bolt (oil tank) 1
(along with the washer)
1
5. Remove:
• engine oil drain bolt (crankcase) 1
(along with the gasket)
1
1
6.
•
7.
•
Remove:
oil filter element drain bolt 1
Drain:
engine oil
(completely from the oil tank and the crankcase)
8. If the oil filter element is also to be replaced,
perform the following procedure.
1
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2
3
a. Remove the oil filter element cover 1 and
oil filter element 2.
b. Check the O-rings 3 and replace them if
they are cracked or damaged.
3
3 - 22
CHANGING THE ENGINE OIL
CHK
ADJ
c. Install the new oil filter element and the oil
filter element cover.
T.
Oil filter element cover bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
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9. Check:
• engine oil drain bolt gasket
Damage → Replace.
10.Install:
• engine oil drain bolt (crankcase)
(along with the gasket)
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
• engine oil drain bolt (oil tank)
(along with the washer)
T.
R.
19 Nm (1.9 m · kg, 13 ft · lb)
• oil filter element drain bolt
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
11.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
• crankcase
(with the specified amount of the recommended engine oil)
Overhaul
Total amount
2.30 L (2.02 Imp qt, 2.43 US qt)
Quantity in oil tank
1.30 L (1.14 Imp qt, 1.37 US qt)
Quantity in crankcase
1.00 L (0.88 Imp qt, 1.06 US qt)
Periodic oil replacement
Total amount
1.75 L (1.54 Imp qt, 1.85 US qt)
Quantity in oil tank
1.30 L (1.14 Imp qt, 1.37 US qt)
Quantity in crankcase
0.45 L (0.40 Imp qt, 0.48 US qt)
With oil filter element replacement
Total amount
1.85 L (1.63 Imp qt, 1.96 US qt)
Quantity in oil tank
1.30 L (1.14 Imp qt, 1.37 US qt)
Quantity in crankcase
0.55 L (0.48 Imp qt, 0.58 US qt)
3 - 23
CHANGING THE ENGINE OIL
CHK
ADJ
12.Install:
• dipstick
• engine oil filler bolt
T.
R.
12 Nm (1.2 m · kg, 8.7 ft · lb)
13.Start the engine, warm it up for several minutes, and then turn it off.
14.Check:
• engine
(for engine oil leaks)
15.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
1
16.Check:
• engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt 1.
b. Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
c. Check the engine oil passages, the oil filter
element and the oil pump for damage or
leakage. Refer to “OIL PUMP” in chapter 4.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
T.
Oil gallery bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
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3 - 24
ADJUSTING THE CLUTCH CABLE/
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
EBS00070
ADJUSTING THE CLUTCH CABLE
1. Check:
• clutch lever free play a
Out of specification → Adjust.
a
Clutch lever free play (at the
clutch lever end)
5 ~ 10 mm (0.20 ~ 0.39 in)
2. Adjust:
• clutch lever free play
1
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a. Pull the rubber cover 1 off.
b. Loosen the locknut 2 and finger tighten the
adjusting bolt 3.
c. Loosen the locknut 4.
d. Turn the adjusting nut 5 until the clutch
lever free play is within the specified limits.
2
3
Clutch lever free play (at the
clutch lever end)
5 ~ 10 mm (0.20 ~ 0.39 in)
e. Tighten the locknut 4.
5
NOTE:
If the specified clutch lever free play cannot be
obtained on it, use the adjusting bolt 3.
4
f. Turn the adjusting bolt 3 until the clutch
lever free play is within the specified limits.
g. Tighten the locknut 2.
h. Pull the rubber cover 1 in.
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EBS00073
CLEANING THE AIR FILTER ELEMENT
NOTE:
There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter element and air filter case.
_
1
3 - 25
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
1. Remove:
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Remove:
• air filter case cover 1
1
2
1
3.
•
•
•
Remove:
wing bolt 1
air filter element 2
air filter element frame 3
CAUTION:
_
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
4. Check:
• air filter element
Damage → Replace.
3
2
5. Clean:
• air filter element
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the element gently, but thoroughly in
solvent.
3 - 26
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINT
CHK
ADJ
WARNING
_
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
b. Squeeze the excess solvent out of the element and let it dry.
CAUTION:
_
Do not twist or wring out the element. This
could damage the foam material.
c. Apply Yamaha foam air filter oil or other
quality foam air filter oil to the element.
d. Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
_
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6.
•
7.
•
•
Install:
air filter element frame
Install:
air filter element
wing bolt
NOTE:
Make sure its sealing surface matches the
sealing surface of the case so there is no air
leak.
_
8.
•
9.
•
Install:
air filter case cover
Install:
seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
EAS00094
1
CHECKING THE THROTTLE BODY JOINT
1. Check:
• throttle body joint 1
Cracks/damage → Replace.
Refer to “FUEL INJECTION SYSTEM” in
chapter 6.
3 - 27
CHECKING THE FUEL HOSE/
CHECKING THE BREATHER HOSES
CHK
ADJ
EAS00096
CHECKING THE FUEL HOSE
1. Remove:
• seat
• front fender
• fuel tank
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Check:
• fuel hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• fuel tank
• front fender
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
1
EAS00098
3
1
2
CHECKING THE BREATHER HOSES
1. Check:
• crankcase breather hose 1
• hose (throttle-body-joint-to-throttle-body-left
side) 2
• hose
(throttle-body-joint-to-throttle-bodyright side) 3
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
Make sure the breather hoses are routed
correctly.
3 - 28
CHECKING THE COOLANT LEVEL/
CHANGING THE COOLANT
CHK
ADJ
EBS00076
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
2. Check:
• coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
b
a
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, soft
water may be used if distilled water is not
available.
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 the coolant has settled.
_
EBS00075
1
CHANGING THE COOLANT
1. Remove:
• coolant reservoir cap 1
2. Disconnect:
• coolant reservoir hose 2
2
3. Drain:
• coolant
(from the coolant reservoir)
4. Connect:
• coolant reservoir hose
3 - 29
CHANGING THE COOLANT
CHK
ADJ
5. Remove:
• radiator cap 1
1
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.
6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant
(from the engine and radiator)
1
8. Check:
• coolant drain bolt 1
Damage → Replace.
9. Install:
• copper washer 2 New
• coolant drain bolt
T.
R.
10.Remove:
• air bleed bolt 1
1
3 - 30
10 Nm (1.0 m · kg, 7.2 ft · lb)
CHANGING THE COOLANT
CHK
ADJ
11.Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.61 L (1.42 Imp qt, 1.70 US qt)
Coolant reservoir capacity
0.25 L (0.22 Imp qt, 0.26 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
_
• 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.
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.
R.
3 - 31
T.
12.Install:
• air bleed bolt
13.Install:
• radiator cap
10 Nm (1.0 m · kg, 7.2 ft · lb)
CHANGING THE COOLANT/
CHECKING THE COOLING SYSTEM
CHK
ADJ
14.Fill:
• coolant reservoir
(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”.
a
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
_
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
• seat
• front fender
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Check:
• radiator 1
• radiator outlet hose 2
• radiator inlet hose 3
• water pump assembly 4
• water jacket inlet housing 5
• water pump outlet hose 6
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 5.
3. Install:
• front fender
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
3
1
2
4
5
6
3 - 32
CHECKING THE COOLANT TEMPERATURE WARNING
LIGHT
CHK
ADJ
EBS00077
1
CHECKING THE COOLANT TEMPERATURE
WARNING LIGHT
1 Coolant temperature warning light
Coolant temperature warning light checking method
Turn the main switch “ON” and the
engine stop switch to “RUN”.
Coolant temperature warning
light does not come on.
Coolant temperature warning
light comes on.
Push start switch with transmission
in “neutral”.
Coolant
temperature
warning light comes on
momentarily.
Coolant temperature and
electrical circuit are OK.
Go ahead with riding.
Coolant temperature warning
light does not come on.
Check the electrical circuit. Refer to
“SIGNALING SYSTEM” in chapter 8.
3 - 33
CHECKING THE EXHAUST SYSTEM/
CLEANING THE SPARK ARRESTER
CHK
ADJ
EAS00099
8
2
0
5
5
3 9
LT
5
A
1
LT
A
7
1
6
6
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipe gaskets.
1. Check:
• exhaust pipes 1
• muffler 2
• muffler protector 3
• exhaust pipe protector 4
Cracks/damage → Replace.
• gaskets 5
Exhaust gas leaks → Replace.
2. Check:
• tightening torques
LT
LT
A
LT
T.
4
R.
Exhaust pipe nut 6
20 Nm (2.0 m · kg, 14 ft · lb)
Exhaust pipe bolt 7
16 Nm (1.6m · kg, 11 ft · lb)
Muffler bolt 8
38 Nm (3.8 m · kg, 27 ft · lb)
Exhaust pipe and muffler bolt 9
18 Nm (1.8 m · kg, 13 ft · lb)
Muffler protector bolt 0
8 Nm (0.8 m · kg, 5.8 ft · lb)
Exhaust pipe protector bolt A
8 Nm (0.8 m · kg, 5.8ft · lb)
CLEANING THE SPARK ARRESTER
1. Clean:
• spark arrester
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WARNING
• Select a well-ventilated area free of combustible materials.
• Always let the exhaust system cool
before performing this operation.
• Do not start the engine when removing
the tailpipe from the muffler.
• Make sure that the transmission is in neutral.
3 - 34
CLEANING THE SPARK ARRESTER
CHK
ADJ
a. Remove the bolt 1.
b. Remove the tailpipe 2 by pulling it out of
the muffler.
c. Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush
to remove any carbon deposits from the
spark arrester portion of the tailpipe and
inside of the tail pipe housing.
d. Insert the tailpipe into the muffler and align
the bolt holes.
e. Insert the bolt 1 and tighten it.
2
1
T.
Bolt
8 Nm (0.8 m · kg, 5.8 ft · lb)
R.
f. Remove the purging bolt 3.
g. Start the engine and rev it up approximately
twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.
h. Stop the engine and allow the exhaust pipe
to cool.
i. Install the purging bolt 3 and tighten it.
T.
Purging bolt
27 Nm (2.7 m · kg, 19 ft · lb)
R.
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3
3 - 35
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EBS00080
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Measure:
• brake lever free play a
Out of specification → Bleed the front brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
Brake lever free play (at the end
of the brake lever)
0 mm (0 in)
EBS00085
ADJUSTING THE REAR BRAKE
1. Measure:
• brake pedal height a
Out of specification → Adjust.
a
Brake pedal height
15.3 mm (0.60 in)
2. Adjust:
• brake pedal height
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
1
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 until the brake
pedal height is within the specified limits.
c. Tighten the locknut.
T.
R.
3 - 36
Locknut
17 Nm (1.7 m · kg, 12 ft · lb)
ADJUSTING THE REAR BRAKE/
ADJUSTING THE PARKING BRAKE
CHK
ADJ
WARNING
_
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed, perform
the above steps again.
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ADJUSTING THE PARKING BRAKE
1. Check:
• parking brake cable end length a
Out of specification → Adjust.
a
Parking brake cable end length
58 ~ 60 mm (2.28 ~ 2.36 in)
2. Adjust:
• parking brake cable end length
a
1
b
3 2
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a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or
b until the specified brake cable end length
is obtained.
d. Tighten the locknut 2.
e. Slide the rubber cover to its original position.
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
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3 - 37
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
EBS00087
CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
NOTE:
When checking the brake fluid level, make
sure that the top of the brake master cylinder
reservoir top and the brake fluid reservoir top
is horizontal.
_
2. Check:
• brake fluid level
Below the minimum level mark 1 → Add
the recommended brake fluid to the proper
level.
È
Recommended brake fluid
DOT 4
È Front brake
É Rear brake
É
WARNING
_
1
• 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.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of the
brake master cylinder reservoir and the brake
fluid reservoir is horizontal.
_
3 - 38
CHECKING THE FRONT BRAKE PADS/
CHECKING THE REAR BRAKE PADS
CHK
ADJ
EBS00088
CHECKING THE FRONT BRAKE PADS
1. Remove:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 7.
2. Check:
• brake pads
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit a
1.0 mm (0.04 in)
3. Operate the brake lever.
4. Install:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 7.
EBS00089
CHECKING THE REAR BRAKE PADS
1. Check:
• brake pads
Wear indicator 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit a
1.0 mm (0.04 in)
2. Operate the brake pedal.
3 - 39
ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE BRAKE HOSES
CHK
ADJ
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.
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing
1
2
a
b
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a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper
time.
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
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EBS00092
1
1
1
2
CHECKING THE BRAKE HOSES
1. Remove:
• seat
• fuel tank top panel
• front fender
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Check:
• front brake hoses 1
• rear brake hose 2
Cracks/wear/damage → Replace.
3. Check:
• brake hose clamps
Loosen → Tighten.
4. Hold the vehicle in an upright position and
apply the front or rear brake.
3 - 40
CHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
5. Check:
• brake hoses
Apply the brake lever or brake pedal several times.
Fluid leakage → Replace the hoses.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
6. Install:
• front fender
• fuel tank top panel
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
EBS00094
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
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.
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.
_
3 - 41
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
1. Bleed:
• hydraulic brake system
È
2
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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).
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
1
È Front
É Rear
É
1
2
d. Place the other end of the hose into a container.
e. Slowly apply the brake lever or brake pedal
several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
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.
T.
Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
R.
k. Fill the brake master cylinder reservoir or
the brake fluid reservoir to the proper level
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,
check the brake operation.
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3 - 42
ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE REVERSE CONTROL CABLE
CHK
ADJ
EBS00098
ADJUSTING THE SHIFT PEDAL
1. Measure:
• shift pedal height a
Out of specification → Adjust.
Shift pedal height
48 mm (1.89 in)
a
2. Adjust:
• shift pedal position
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a.
b.
c.
d.
2
Loosen the bolt 1.
Remove the shift pedal 2.
Install the shift pedal at the correct height.
Tighten the bolt to specification.
1
T.
Shift pedal bolt
16 Nm (1.6 m · kg, 11 ft · lb)
R.
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EBS00096
ADJUSTING THE REVERSE CONTROL
CABLE
1. Check:
• reverse knob free play a
Out of specification → Adjust.
Reverse knob free play
0 mm (0 in)
3 - 43
ADJUSTING THE REVERSE CONTROL CABLE/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Adjust:
• reverse knob free play
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a. Pull the boots 1 and 2 off.
b. Loosen the locknut 3.
c. Turn the adjusting nut 4 until the reverse
control cable 5 is taut or the length a is
33 mm (1.30 in).
NOTE:
Be sure to hold the reverse shift lever 6 when
make this adjustment so that it does not move.
6
5
d. Tighten the locknut 3.
e. Pull the boots 1 and 2 in.
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a
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
Measure the drive chain slack halfway
between the drive axle and the rear axle.
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.
a
1. Measure:
• drive chain slack a
Out of specification → Adjust.
Drive chain slack
25 ~ 35 mm (0.98 ~ 1.38 in)
3 - 44
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Adjust:
• drive chain slack
3
5
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4
24
2
31
1 1
NOTE:
The drive chain slack is adjusted by the rotation of the rear axle hub.
a. Loosen the rear axle pinch bolts 1.
NOTE:
Loosen the rear axle pinch bolts in the proper
sequence as shown.
b. Insert an appropriate shaft 2 in the hole 4
of rear axle hub 3 so that the sprocket
bracket 5 does not move.
c. Shift the transmission into the neutral position.
d. To loosen the drive chain, push the vehicle
forward, and to tighten the drive chain, pull
the vehicle backward.
CAUTION:
Excessive chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.
e. If the chain slack cannot be adjusted,
replace the sprockets and drive chain as a
set.
f. Tighten the rear axle pinch bolts 1.
T.
Rear axle pinch bolt
21 Nm (2.1 m · kg, 15 ft · lb)
R.
31
24
1 1
NOTE:
• Tighten the rear axle pinch bolts 1 in the
proper sequence as shown.
• The chain should be cleaned and lubricated
after every use of the vehicle.
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3 - 45
CHECKING THE STEERING SYSTEM/
ADJUSTING THE TOE-IN
CHK
ADJ
EBS00106
CHECKING THE STEERING SYSTEM
1. Place the vehicle on a level surface.
2. Check:
• steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play → Replace the steering
stem bushings.
3. Check:
• tie-rod ends
Turn the handlebar to the left and right until
it stops completely, and then move the handlebar slightly in the opposite direction.
Tie-rod end(s) 1 have vertical play →
Replace the tie-rod end(s).
1
1
4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bearings.
EBS00108
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface.
2. Measure:
• toe-in
Out of specification → Adjust.
Toe-in
2 ~ 12 mm (0.08 ~ 0.47 in)
(with tires touching the ground)
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NOTE:
Before measuring the toe-in, make sure that
the tire pressure is correct.
_
a. Mark both front tire tread centers.
3 - 46
ADJUSTING THE TOE-IN
CHK
ADJ
b. Face the handlebar straight ahead.
c. Measure the width È between the marks.
d. Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width É between the marks.
f. Calculate the toe-in using the formula given
below.
Toe-in = É – È
g. If the toe-in is incorrect, adjust it.
Ê Forward
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3. Adjust:
• toe-in
WARNING
_
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
right or left even though the handlebar is
positioned straight. This may lead to mishandling and an accident.
• After setting the toe-in to specification,
run the vehicle slowly for some distance
with both hands lightly holding the handlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in specification.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
1
2
a. Mark both tie-rods ends.
This reference point will be needed during
adjustment.
b. Loosen the locknuts (tie-rod end) 1 of both
tie-rods.
c. The same number of turns should be given
to both the right and left tie-rods 2 until the
specified toe-in is obtained. This is to keep
the length of the rods the same.
d. Tighten the rod end locknuts of both tierods.
T.
Locknut (rod end)
18 Nm (1.8 m · kg, 13 ft · lb)
R.
NOTE:
Adjust the rod ends so that A and B are equal.
_
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3 - 47
CHECKING THE FRONT AND REAR SHOCK ABSORBERS/
ADJUSTING THE FRONT SHOCK ABSORBERS
È
É
CHK
ADJ
EBS00109
CHECKING THE FRONT AND REAR SHOCK
ABSORBERS
1. Place the vehicle on a level surface.
2. Check:
• damper rod
Bends/damage → Replace the rear shock
absorber assembly.
• oil leakage
Excessive oil leakage → Replace the front/
rear shock absorber assembly.
• gas cylinder
Damage/gas leaks → Replace the rear
shock absorber assembly.
• spring
Fatigue → Replace the front/rear shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR SHOCK ABSORBER AND RELAY
ARM” in chapter 7.
3. Check:
• operation
Pump the shock absorbers up and down for
several times.
Unsmooth operation → Replace the front/
rear shock absorber assembly.
Refer to “ADJUSTING THE FRONT
SHOCK ABSORBERS” and “ADJUSTING
THE REAR SHOCK ABSORBER”.
È Front shock absorber
É Rear shock absorber
EBS00110
ADJUSTING THE FRONT SHOCK
ABSORBERS
WARNING
Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.
3 - 48
ADJUSTING THE FRONT SHOCK ABSORBERS/
ADJUSTING THE REAR SHOCK ABSORBER
12
34
5
CHK
ADJ
1. Adjust:
• spring preload
Turn the adjuster 1 in direction a or b.
1
b
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
a
Standard position: 2
Minimum position: 1
Maximum position: 5
EBS00111
ADJUSTING THE REAR SHOCK
ABSORBER
1. Remove:
• seat
• air filter case
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the rear wheels by placing a suitable stand under the frame.
b. Loosen the locknut 2 with the ring nut
wrench 1.
b
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
a
1
2
c. Turn the adjusting ring 3 in direction a or
b.
3
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
c
Adjusting length c
Standard: 236 mm (9.29 in)
Minimum: 228 mm (8.98 in)
Maximum: 243 mm (9.57 in)
3 - 49
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
NOTE:
• Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
_
CAUTION:
_
Never attempt to turn the adjusting ring
beyond the maximum or minimum setting.
d. Tighten the locknut 2 with a steering nut
wrench 4.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01443
Spanner wrench
YU-33975
T.
Locknut
42 Nm (4.2 m · kg, 30 ft · lb)
R.
NOTE:
Always tighten the locknut against the adjusting ring, then torque it to specification.
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3. Install:
• air filter case with air intake duct
3 - 50
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
4. Adjust:
• rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
• Turn the adjusting screw 1 in direction a
or b.
a
1
Direction a
Rebound damping force
is increased.
Direction b
Rebound damping force
is decreased.
From the fully turned-in position
Standard: 12 clicks out
Minimum: 20 clicks out
Maximum: 3 clicks out
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
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5. Adjust:
• compression damping force
a
b
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Compression damping
force is increased.
Direction b
Compression damping
force is decreased.
From the fully turned-in position
Standard: 7 clicks out
Minimum: 12 clicks out
Maximum: 2 clicks out
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
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6. Install:
• air filter case
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
3 - 51
CHECKING THE TIRES
CHK
ADJ
EBS00114
CHECKING THE TIRES
WARNING
_
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.
• TIRE CHARACTERISTICS
1) Tire characteristics influence the handling of ATVs. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire combinations are used, they can adversely
affect your vehicle’s handling characteristics and are therefore not recommended.
Manufacturer
Size
Type
Front
DUNLOP
AT21 ×
7-10
KT341
Radial
Rear
DUNLOP
AT20 ×
10-9
KT345
Radial
• TIRE PRESSURE
1) Recommended tire pressure
Front 27.5 kPa (0.275 kg/cm2, 4.0 psi)
Rear 27.5 kPa (0.275 kg/cm2, 4.0 psi)
2) Tire pressure below the minimum specification could cause the tire to dislodge
from the rim under severe riding conditions.
The following are minimums:
Front 24.5 kPa (0.245 kg/cm2, 3.5 psi)
Rear 24.5 kPa (0.245 kg/cm2, 3.5 psi)
3) Use no more than
Front 250 kPa (2.5 kg/cm2, 36 psi)
Rear 250 kPa (2.5 kg/cm2, 36 psi)
when seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.
• MAXIMUM LOADING LIMIT
1) Vehicle load limits: 100 kg (220 lb)
*Total weight of the cargo, rider, and
accessories.
Be extra careful of the vehicle balance and
stability when towing a trailer.
3 - 52
CHECKING THE TIRES
CHK
ADJ
1. Measure:
• tire pressure
Out of specification → Adjust.
NOTE:
• The low-pressure tire gauge 1 is included
as standard equipment.
• If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.
_
Cold tire
pressure
Front
Rear
Standard
27.5 kPa
27.5 kPa
(0.275 kg/cm2, (0.275 kg/cm2,
4.0 psi)
4.0 psi)
Minimum
24.5 kPa
24.5 kPa
(0.245 kg/cm2, (0.245 kg/cm2,
3.5 psi)
3.5 psi)
Maximum
30.5 kPa
30.5 kPa
2
(0.305 kg/cm , (0.305 kg/cm2,
4.4 psi)
4.4 psi)
WARNING
_
Uneven or improper tire pressure may
adversely affect the handling of this vehicle
and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
2. Check:
• tire surfaces
Wear/damage → Replace.
Tire wear limit a
Front and rear: 3.0 mm (0.12 in)
WARNING
_
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.
3 - 53
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES
CHK
ADJ
EBS00116
CHECKING THE WHEELS
1. Check:
• wheel 1
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
_
WARNING
_
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.
EBS00117
CHECKING AND LUBRICATING THE
CABLES
WARNING
_
A damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result, so
replace a damaged cable as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Unsmooth operation
replace.
→
Lubricate
or
Recommended lubricant
Yamaha chain and cable lube or
engine oil
NOTE:
Hold the cable end up and apply several drops
of lubricant to the cable.
_
3. Apply:
• lithium-soap-based grease
(onto end of the cable)
3 - 54
LUBRICATING THE LEVERS AND PEDALS
CHK
ADJ
EBS00118
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
3 - 55
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EBS00120
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
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).
• 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.
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.
3 - 56
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
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. Remove:
• seat
• battery holding bracket
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
1
2
_
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3.
•
4.
•
Remove:
battery
Check:
battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
Open-circuit voltage (V)
Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
_
Charging time (hours)
These values vary with the temperature and the condition of the battery plates.
3 - 57
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Ambient temperature
20 °C (68 °F)
Open-circuit voltage (V)
Charging
5. Charge:
• battery
(refer to the appropriate charging method
illustration)
WARNING
_
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
_
Open-circuit voltage (V)
Ambient
temperature
20 °C (68 °F)
Charging condition of the battery (%)
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
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.
3 - 58
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
• 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.
3 - 59
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
NOTE:
Set the charging voltage to 16 ~
17 V. (If the charging voltage is
lower, charging will be insufficient,
if it is higher, the battery will be
over-charged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for
3 ~ 5 minutes. Is the standard
charging amperage exceeded?
NO
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the
charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3 - 60
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
YES
Is the amperage higher
than the standard charging amperage written on
the battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variable-voltage charger is recommended.
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Leave the battery unused for more than
30 minutes before measuring its open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3 - 61
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
6.
•
7.
•
2
1
CHK
ADJ
Install:
battery
Connect:
battery leads
(to the battery terminals)
CAUTION:
_
First, connect the positive battery lead 1,
and then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• battery holding bracket
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
EBS00121
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
_
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
3 - 62
CHECKING THE FUSES
CHK
ADJ
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
3 - 63
Items
Amperage
rating
Q’ty
Main fuse
20 A
1
Headlight fuse
15 A
1
Signaling system fuse
10 A
1
Ignition fuse
10 A
1
Fuel injection
system fuse
10 A
1
Spare fuse
20 A
15 A
10 A
1
1
1
CHECKING THE FUSES/ADJUSTING THE HEADLIGHT
BEAMS/REPLACING A HEADLIGHT BULB
CHK
ADJ
WARNING
_
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
EBS00122
a
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
• headlight beam (vertically)
b
a. Turn the adjusting bolt 1 in direction a or
b.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is
lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00124
REPLACING A HEADLIGHT BULB
1. Disconnect:
• headlight coupler 1
2. Remove:
• headlight bulb holder cover 2
1
2
3 - 64
REPLACING A HEADLIGHT BULB
CHK
ADJ
3. Remove:
• bulb holder 1
• bulb
NOTE:
Push the headlight bulb holder inward, turn it
counterclockwise and remove the defective
bulb.
_
1
WARNING
_
Keep flammable products and your hands
away from the bulb while it is on. since it
will be hot. Do not touch the bulb until it
cools down.
4. Install:
• bulb New
Secure the new bulb with the headlight unit.
CAUTION:
_
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lacquer thinner.
a
5. Install:
• bulb holder
• headlight bulb holder cover 1
NOTE:
After installing the bulb holder cover, make
sure that the “TOP” mark a is in the position
shown.
1
2
6. Connect:
• headlight lead coupler 2
3 - 65
ENG
ENGINE REMOVAL
EBS00198
ENGINE
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPES
T.
R.
38 Nm (3.8 m • kg, 27 ft • Ib)
1
New
New
3
New
2
8
8
5
LT
4
LT
7
6
LT
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
T.
R.
LT
Job/Part
Removing the muffler and exhaust
pipes
Seat/fuel tank top panel
Muffler
Muffler protector
Gasket
Exhaust pipe 1
Gasket
Exhaust pipe 2
Exhaust pipe protector
Gasket
R.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
T.
Order
1
2
3
4
5
6
7
8
20 Nm (2.0 m • kg, 14 ft • Ib)
8 Nm (0.8 m • kg, 5.8 ft • Ib)
Q’ty
16 Nm (1.6 m • kg, 11 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
1
1
1
1
1
1
1
2
Refer to “INSTALLING THE EXHAUST
PIPES AND MUFFLER”.
For installation, reverse the removal procedure.
4-1
4
ENGINE REMOVAL
c 1 New
ENG
INSTALLING THE EXHAUST PIPES AND
MUFFLER
1. Install:
• gasket 1 New
(to muffler)
b
a
NOTE:
Install the gasket with the chamfer a, located
on an inner rim of the gasket, and the chamfer
b, located on an outer rim of the gasket, as
shown.
Installed depth of gasket c
1.0 ~ 1.5 mm (0.04 ~ 0.06 in)
4-2
ENG
ENGINE REMOVAL
OIL TANK
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
1
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
New
4
T.
LS
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New
2
5
LS
T.
R.
T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
3
LS
T.
R.
Order
1
2
3
4
5
35 Nm (3.5 m • kg, 25 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the oil tank
Engine oil
Engine skid plate
Shift pedal
Oil tank inlet hose
Oil tank outlet hose
Oil tank breather hose
Oil tank
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
1
1
1
1
1
For installation, reverse the removal procedure.
4-3
ENGINE REMOVAL
ENG
EBS00204
LEADS, CABLES AND HOSES
Order
Job/Part
Removing the leads, cables and
hoses
Coolant
Right foot protector/air filter case/battery/fuel tank
Rear brake light switch/right footrest
Q’ty
Drain.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Refer to “REAR BRAKE MASTER CYLINDER” in chapter 7.
Refer to “THERMOSTAT” in chapter 5.
Refer to “WATER PUMP” in chapter 5.
Refer to “THROTTLE BODY” in chapter
6.
Refer to “SWINGARM AND DRIVE
CHAIN” in chapter 7.
Radiator inlet hose
Radiator outlet hose
Throttle body
Drive sprocket
1
2
Spark plug cap
Starter motor lead
Remarks
Remove the parts in the order listed.
1
1
4-4
ENGINE REMOVAL
Order
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Part
Coolant temperature sensor coupler
Plastic band
Wire sub lead coupler
Speed sensor coupler
A.C. magneto coupler
Crankshaft position sensor coupler
Rear brake light switch coupler
Rear brake light switch lead
Wire sub lead
Ground lead
Clutch cable
Parking brake cable
Reverse control cable
ENG
Q’ty
Remarks
1
Disconnect.
1
1
1
1
Disconnect.
1
Disconnect.
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
4-5
ENGINE REMOVAL
ENG
EBS00205
ENGINE MOUNTING BOLTS
1
T.
33 Nm (3.3 m • kg, 24 ft • Ib)
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
3
8
2
7
2
8
7
4
T.
R.
5
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
41 Nm (4.1 m • kg, 30 ft • Ib)
9
6
T.
6
R.
66 Nm (6.6 m • kg, 48 ft • Ib)
5
4
T.
R.
Order
1
2
3
4
5
6
7
8
41 Nm (4.1 m • kg, 30 ft • Ib)
Job/Part
Removing the engine mounting
bolts
Engine upper bracket bolt
Engine mounting bolt (upper)/nut
Engine upper bracket
Engine lower bracket bolt
Engine mounting bolt (middle)/nut
Engine lower bracket
Engine mounting bolt (lower)/nut
Pivot shaft/pivot shaft nut
Q’ty
2
1/1
1
4
1/1
2
1/1
1/1
4-6
Remarks
Remove the parts in the order listed.
CAUTION:
_
Install all of the bolts/nuts and then
tighten them to full torque specifications.
ENGINE REMOVAL
ENG
1
T.
33 Nm (3.3 m • kg, 24 ft • Ib)
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
3
8
2
7
2
8
7
T.
4
R.
5
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
41 Nm (4.1 m • kg, 30 ft • Ib)
9
6
T.
6
R.
66 Nm (6.6 m • kg, 48 ft • Ib)
5
4
T.
R.
Order
9
Job/Part
Engine assembly
41 Nm (4.1 m • kg, 30 ft • Ib)
Q’ty
Remarks
1
NOTE:
Remove the engine assembly from the
right side of the vehicle.
_
For installation, reverse the removal procedure.
4-7
ENGINE REMOVAL
ENG
EBS00206
2
INSTALLING THE ENGINE
1. Install:
• swingarm
• pivot shaft
• washer
• pivot shaft nut
1
3
NOTE:
Do not fully tighten the pivot shaft nut.
2.
•
•
•
•
•
•
•
•
4
7
6
Install:
engine mounting bolt (lower)/nut
engine lower bracket (left)
engine lower bracket (right)
engine lower bracket bolts
engine mounting bolt (middle)/nut
engine upper bracket
engine upper bracket bolts
engine mounting bolt (upper)/nut
NOTE:
Do not fully tighten the bolts and nuts.
5
_
3. Tighten:
• engine upper bracket bolt “1”
T.
R.
33 Nm (3.3 m · kg, 24 ft · lb)
• engine upper bracket bolt “2”
T.
R.
33 Nm (3.3 m · kg, 24 ft · lb)
• engine mounting bolt (upper)/nut “3”
T.
R.
40 Nm (4.0 m · kg, 29 ft · lb)
• pivot shaft nut “4”
T.
R.
100 Nm (10.0 m · kg, 72 ft · lb)
• engine mounting bolt (lower)/nut “5”
T.
R.
66 Nm (6.6 m · kg, 48 ft · lb)
• engine mounting bolt (middle)/nut “6”
T.
R.
66 Nm (6.6 m · kg, 48 ft · lb)
• engine lower bracket bolts “7”
T.
R.
41 Nm (4.1 m · kg, 30 ft · lb)
NOTE:
Tighten the bolts and nuts in the proper tightening sequence as shown.
]
4-8
CYLINDER HEAD
ENG
EBS00218
CYLINDER HEAD
T.
R.
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
33 Nm (3.3 m • kg, 24 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
40 Nm (4.0 m • kg, 29 ft • Ib)
R.
T.
35 Nm (3.5 m • kg, 25 ft • Ib)
R.
R.
2
T.
New
T.
M
R.
LS
(4)
6
7
4
E
10
9
11
4
8
New
LS
New
12
4
New
(4)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
4
New
5
20 Nm (2.0 m • kg, 14 ft • Ib)
New
3
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the cylinder head
Throttle body
Q’ty
Thermostat/coolant temperature sensor
Engine upper bracket
Spark plug
Camshaft sprocket cover/O-ring
Tappet cover/O-ring
Oil delivery pipe
Timing chain tensioner cap bolt
Timing chain tensioner/gasket
Camshaft sprocket
1
1
1/1
2/2
1
1
1/1
1
4-9
R.
R.
1
2
3
4
5
6
7
8
E
T.
T.
Order
LS
New
38 Nm (3.8 m • kg, 27 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “THROTTLE BODY” in chapter
6.
Refer to “THERMOSTAT” in chapter 5.
Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
CYLINDER HEAD
T.
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
ENG
R.
33 Nm (3.3 m • kg, 24 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
40 Nm (4.0 m • kg, 29 ft • Ib)
R.
T.
35 Nm (3.5 m • kg, 25 ft • Ib)
R.
R.
2
T.
New
T.
M
R.
LS
(4)
6
7
4
E
10
9
11
4
8
New
LS
New
12
4
New
(4)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
4
New
5
20 Nm (2.0 m • kg, 14 ft • Ib)
New
3
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
Cylinder head gasket
Dowel pin
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
1
1
R.
R.
11
12
Job/Part
Decompressor assembly
Cylinder head
E
T.
T.
Order
9
10
LS
New
38 Nm (3.8 m • kg, 27 ft • Ib)
Remarks
Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
1
2
For installation, reverse the removal procedure.
4 - 10
CYLINDER HEAD
ENG
EBS00220
a
b
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark a on the A.C. magneto rotor
(with the stationary pointer b on the A.C.
magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at top dead center (TDC)
on the compression stroke, align the “I”
mark c on the camshaft sprocket with the
stationary pointer d on the cylinder head.
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c
2. Loosen:
• camshaft sprocket bolts 1
1
NOTE:
While holding the A.C. magneto rotor nut with
a wrench, loosen the bolt.
3.
•
4.
•
Loosen:
timing chain tensioner cap bolt
Remove:
timing chain tensioner
(along with the gasket)
• camshaft sprocket
• timing chain
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
_
5. Remove:
• cylinder head
4
2
7
1
5
6
8
3
NOTE:
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
_
4 - 11
CYLINDER HEAD
ENG
EBS00230
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
_
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm (0.0012 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place 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.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 12
CYLINDER HEAD
ENG
EBS00227
2
1
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
1. Check:
• tappet covers 1
• camshaft sprocket cover 2
Damage/wear → Replace the defective
part(s).
EBS00229
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage → Replace.
2. Check:
• one-way cam operation
Rough movement → Replace the timing
chain tensioner.
3. Check:
• timing chain tensioner cap bolt
• copper washer New
• spring
• one-way cam
• gasket New
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
EBS00224
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• camshaft sprocket
Wear/damage → Replace the camshaft
sprocket and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Roller
2 Sprocket
EBS00232
INSTALLING THE CYLINDER HEAD
1. Install:
• dowel pins
• cylinder head gasket New
4 - 13
CYLINDER HEAD
ENG
2. Install:
• cylinder head
• cylinder head bolts
NOTE:
• Lubricate the cylinder head bolt 1 and 2
threads and mating surface with molybdenum disulfide grease.
• Lubricate the cylinder head bolts 3 threads
and mating surface with engine oil.
• Install the washers with their blunt surface
facing the bolt seat.
3
4
7
5
2
3. Tighten:
• cylinder head bolts 1:
3
1
T.
2
R.
8
T.
R.
4
35 Nm (3.5 m · kg, 25 ft · lb)
• cylinder head bolts 2:
1
4
6
= 135 mm (5.31 in)
= 145 mm (5.71 in)
35 Nm (3.5 m · kg, 25 ft · lb)
• cylinder head bolts 3
3
T.
R.
38 Nm (3.8 m · kg, 27 ft · lb)
• cylinder head bolts 4
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
_
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
a. Turn the primary pulley counterclockwise.
b. Align the “I” mark a on the A.C. magneto
rotor with the stationary pointer b on the
A.C. magneto cover.
c. Install the timing chain 1 onto the camshaft
sprocket 2, then the camshaft sprocket
onto the camshaft, and then finger tighten
the camshaft sprocket bolts.
d. Make sure the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
d
c
1
4. Install:
• camshaft sprocket
(onto the camshaft)
2
4 - 14
CYLINDER HEAD
ENG
NOTE:
• When installing the camshaft sprocket, be
sure to keep the timing chain as tight as possible at the exhaust end of the chain.
• Align the projection on the camshaft with the
slot in the camshaft sprocket.
_
CAUTION:
_
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• timing chain tensioner
6 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
2 New
1
a. Remove the timing chain tensioner cap bolt
1, copper washer 2 and spring 3.
b. Release the timing chain tensioner one-way
cam 4 and push the timing chain tensioner
rod 5 all the way into the timing chain tensioner housing.
c. Install the timing chain tensioner and gasket
6 onto the cylinder.
R.
5
T.
4
Timing chain tensioner bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Install the gasket with its beaded side facing
the timing chain tensioner end.
d. Install the spring and timing chain tensioner
cap bolt.
T.
Timing chain tensioner cap bolt
20 Nm (2.0 m · kg, 14 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Turn:
• crankshaft
(several turns counterclockwise)
4 - 15
CYLINDER HEAD
ENG
7. Check:
• “I” mark a
a
b
NOTE:
Check that the “I” mark on the A.C. magneto
rotor is aligned with the stationary pointer b
on the A.C. magneto cover.
• “I” mark c
d
c
NOTE:
Check that the “I” mark on the camshaft
sprocket is aligned with the stationary pointer
d on the cylinder head.
Out of alignment → Correct.
Repeat steps (4) to (7), if necessary.
8. Tighten:
• camshaft sprocket bolts
T.
R.
20 Nm (2.0 m · kg, 14 ft · lb)
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. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE
CLEARANCE” in chapter 3.
4 - 16
VALVE
ENG
ROCKER ARMS AND CAMSHAFT
EBS00235
ROCKER ARMS AND CAMSHAFT
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
R.
4
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
4
3
4
4
E
2
3
E
M
8
T.
7
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
1
E
M
2
6
E
E
Order
LT
1
2
3
4
5
Job/Part
Q’ty
Remarks
Removing the rocker arms and camRemove the parts in the order listed.
shaft
Cylinder head
Refer to “CYLINDER HEAD”.
Bearing retainer
1
Rocker arm shaft
2
Refer to “REMOVRocker arm
2
ING THE ROCKER
Locknut/valve adjuster
4/4
ARMS AND CAMCamshaft
1
CAUTION:
SHAFT” and
“INSTALLING
THE
Do not disassemble the cam- CAMSHAFT AND
ROCKER ARMS”.
shaft assembly.
6
Decompressor lever
1
4 - 17
ENG
ROCKER ARMS AND CAMSHAFT
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
R.
4
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
4
3
4
4
E
2
3
E
M
8
T.
7
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
1
E
M
2
6
E
E
Order
7
8
Job/Part
Decompressor lever pin
Bearing
Q’ty
1
1
4 - 18
LT
Remarks
Refer to “REMOVING THE ROCKER
ARMS AND CAMSHAFT” and
“INSTALLING THE CAMSHAFT AND
ROCKER ARMS”.
For installation, reverse the removal procedure.
ROCKER ARMS AND CAMSHAFT
ENG
EBS00238
1
2 1
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Loosen:
• locknuts
• adjusting screws
2. Remove:
• camshaft retainer 1
3.
•
•
•
•
Remove:
intake rocker arm shaft
exhaust rocker arm shaft
intake rocker arm
exhaust rocker arm
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.
_
Slide hammer bolt
90890-01083
Slide hammer bolt (6 mm)
YU-01083-1
Weight
90890-01084, YU-01083-3
4. Remove:
• camshaft
EAS00205
CHECKING THE CAMSHAFT
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft and camshaft
sprocket.
4 - 19
ROCKER ARMS AND CAMSHAFT
ENG
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Camshaft lobe dimensions
Intake
a 43.300 ~ 43.400 mm
(1.7047 ~ 1.7087 in)
<Limit>:
43.200 mm (1.7008 in)
b 37.026 ~ 37.126 mm
(1.4577 ~ 1.4617 in)
<Limit>:
36.926 mm (1.4538 in)
Exhaust
a 43.129 ~ 43.229 mm
(1.6980 ~ 1.7019 in)
<Limit>:
43.029 mm (1.6941 in)
b 37.057 ~ 37.157 mm
(1.4589 ~ 1.4629 in)
<Limit>:
36.957 mm (1.4550 in)
3. Measure:
• camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.030 mm (0.0012 in)
EBS00225
CHECKING THE DECOMPRESSION
SYSTEM
1. Check:
• decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
a. Check the decompression system with the
camshaft sprocket installed on and the
decompressor lever pin installed in the camshaft.
b. Check that the decompressor lever pin 1
projects from the camshaft.
c. Check that the decompressor cam 2
moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 20
ROCKER ARMS AND CAMSHAFT
ENG
EBS00239
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to both of the
rocker arms and rocker arm shafts.
1. Check:
• rocker arm
Damage/wear → Replace.
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication system.
3. Measure:
• rocker arm inside diameter
Out of specification → Replace.
Rocker arm inside diameter
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
4. Measure:
• rocker arm shaft outside diameter
Out of specification → Replace.
Rocker arm shaft outside diameter
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
4 - 21
ROCKER ARMS AND CAMSHAFT
ENG
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
_
Out of specification → Replace the defective part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
EAS00243
1
a
b
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Install:
• bearing 1
(onto the camshaft)
NOTE:
• Apply engine oil to the bearing.
• Install the bearing so that the seal is facing
a the camshaft.
Installed depth b
0 mm (0 in)
2.
•
•
•
Lubricate:
camshaft
decompressor lever pin
decompressor lever
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
4 - 22
ROCKER ARMS AND CAMSHAFT
ENG
3. Install:
• decompressor lever pin 1
• decompressor lever 2
1
2
NOTE:
Install the decompressor lever pin 1 and
decompressor lever 2 in the camshaft 3 as
shown in the illustration.
_
3
4. Install:
• camshaft 1
1
NOTE:
Install the camshaft so that its projection a
becomes horizontal.
5. Lubricate:
• rocker arm shafts
a
Recommended lubricant
Engine oil
1
2
3
6.
•
•
•
•
Install:
exhaust rocker arm 1
exhaust rocker arm shaft 2
intake rocker arm
intake rocker arm shaft
NOTE:
• Use a slide hammer bolt 3 to install the
rocker arm shaft.
• Make sure the rocker arm shafts (intake and
exhaust) are completely pushed into the cylinder head.
_
Slide hammer bolt
90890-01083
Slide hammer bolt (6 mm)
YU-01083-1
7. Install:
• camshaft retainer
• camshaft retainer bolts
LT
T.
R.
4 - 23
10 Nm (1.0 m · kg, 7.2 ft · lb)
ENG
VALVES AND VALVE SPRINGS
EBS00234
VALVES AND VALVE SPRINGS
1
3
3
2
1
2
2
2
6
3
M
6
M
7
6
7
New
7
M
7
3
6
New
M
New
5
4
4
5
M
Order
1
2
3
4
5
6
7
Job/Part
Removing the valves and valve
springs
Cylinder head
Rocker arms/rocker arm shafts/camshaft
Valve cotter
Valve spring retainer
Valve spring
Exhaust valve
Intake valve
Valve stem seal
Valve spring seat
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ROCKER ARMS AND CAMSHAFT”.
8
4
4
2
2
4
4
Refer to “REMOVING THE VALVES
AND VALVE SPRINGS” and “INSTALLING THE VALVES AND VALVE
SPRINGS”.
For installation, reverse the removal procedure.
4 - 24
VALVES AND VALVE SPRINGS
ENG
EAS00238
REMOVING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
_
1. Check:
• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVES AND
VALVE SPRINGS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valve seals properly.
There should be no leakage at the valve
seat 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• valve cotters
NOTE:
Attach a valve spring compressor 1 and
attachment 2 between the valve spring
retainer and the cylinder head to remove the
valve cotters.
_
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter
(26 mm)
YM-01253-1
4 - 25
VALVES AND VALVE SPRINGS
3.
•
•
•
•
•
ENG
Remove:
valve spring retainer 1
valve spring 2
valve stem seal 3
valve spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
_
EBS00240
CHECKING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Stem-to-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve
guide.
Stem-to-guide clearance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.08 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.10 mm (0.0039 in)
4 - 26
VALVES AND VALVE SPRINGS
ENG
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide remover 1 and valve guide installer
2.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper stem-to-guide clearance.
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
After replacing the valve guide, reface the
valve seat.
_
3. Check:
• valve face
Pitting/wear → Grind the face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace.
4. Measure:
• margin thickness a
Out of specification → Replace.
Margin thickness
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
4 - 27
VALVES AND VALVE SPRINGS
ENG
5. Measure:
• valve stem runout
Out of specification → Replace.
Valve stem runout
0.010 mm (0.0004 in)
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the valve stem seal.
_
6. Eliminate:
• carbon deposits
(from the valve face and valve seat)
7. Check:
• valve seat
Pitting/wear → Replace the valve seat.
8. Measure:
• valve seat width a
Out of specification → Replace the valve
seat.
Valve seat width
Intake
1.00 ~ 1.20 mm
(0.0394 ~ 0.0472 in)
<Limit>: 1.60 mm (0.0630 in)
Exhaust
1.00 ~ 1.20 mm
(0.0394 ~ 0.0472 in)
<Limit>: 1.60 mm (0.0630 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b to
the valve face.
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 pattern.
d. Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
e. If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 28
VALVES AND VALVE SPRINGS
ENG
9. Lap:
• valve face
• valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound to the
valve face.
CAUTION:
_
Do not let the compound enter the gap
between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil to 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 compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
_
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
After every lapping operation be sure to clean
off all of the compound from the valve face and
valve seat.
_
f. Apply Mechanic’s blueing dye (Dykem) to
the valve face.
g. Install the valve into the cylinder head.
h. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
i. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 29
VALVES AND VALVE SPRINGS
ENG
10.Measure:
• valve spring free length a
Out of specification → Replace.
Valve spring free length
Intake
38.79 mm (1.53 in)
<Limit>: 36.85 mm (1.45 in)
Exhaust
38.79 mm (1.53 in)
<Limit>: 36.85 mm (1.45 in)
11.Measure:
• compressed spring force a
Out of specification → Replace.
b Installed length
Compressed valve spring force
(installed)
Intake
169.0 ~ 199.0 N at 35.00 mm
(17.23 ~ 20.29 kg at 35.00 mm,
37.99 ~ 44.73 lb at 1.38 in)
Exhaust
169.0 ~ 199.0 N at 35.00 mm
(17.23 ~ 20.29 kg at 35.00 mm,
37.99 ~ 44.73 lb at 1.38 in)
12.Measure:
• valve spring tilt a
Out of specification → Replace.
Valve spring tilt limit
Intake
2.5°/1.70 mm (0.067 in)
Exhaust
2.5°/1.70 mm (0.067 in)
4 - 30
VALVES AND VALVE SPRINGS
ENG
EBS00241
INSTALLING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3.
•
•
•
•
•
Install:
valve 1
valve spring seat 2
valve stem seal 3
valve spring 4
valve spring retainer 5
(into the cylinder head)
NOTE:
• Install the valve spring with the larger pitch
a facing up.
• Install the valve spring with its painted end
facing up.
_
b Smaller pitch
4 - 31
VALVES AND VALVE SPRINGS
ENG
4. Install:
• valve cotters
NOTE:
Install the valve cotters while compressing the
valve spring with the valve spring compressor
1 and attachment 2.
_
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter
(26 mm)
YM-01253-1
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
_
Hitting the valve tip with excessive force
could damage the valve.
4 - 32
CYLINDER AND PISTON
ENG
EBS00245
CYLINDER AND PISTON
T.
1
R.
E
1st 15Nm (1.5 m • kg, 11 ft • lb)
2nd 50Nm (5.0m • kg, 5.1 ft • lb)
T.
R.
T.
R.
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
E
LS
3 New
2
10
11
12
9
5 New
6
7 New
6
T.
R.
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7 New
E
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the cylinder and piston
Cylinder head
Timing chain guide (exhaust)
Water jacket joint
O-ring
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
2nd ring
Oil ring
Q’ty
1
1
1
1
1
2
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “INSTALLING THE PISTON
AND CYLINDER”.
Refer to “REMOVING THE PISTON”
and “INSTALLING THE PISTON AND
CYLINDER”.
For installation, reverse the removal procedure.
4 - 33
CYLINDER AND PISTON
ENG
EBS00247
2
1
REMOVING THE PISTON
1. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
NOTE:
Before removing the piston pin, deburr the clip
groove and pin hole area. If the clip groove is
deburred and the piston pin is still difficult to
remove, use the piston pin puller 4.
_
3
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
CAUTION:
_
Do not use a hammer to drive the piston
pin out.
2. Remove:
• piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown, as shown in the illustration.
_
EBS00249
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.
4 - 34
CYLINDER AND PISTON
ENG
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the cylinder bore “C” with a cylinder bore gauge.
NOTE:
Measure the cylinder bore “C” in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
_
Cylinder bore
“C”
102.000 ~ 102.010 mm
(4.0157 ~ 4.0161 in)
Taper limit “T”
0.05 mm (0.002 in)
Out of round
“R”
0.05 mm (0.002 in)
“C” = Maximum D
“T” = (Maximum D1 or D2)
– (Maximum D5 or D6)
“R” = (Maximum D1, D3 or D5)
– (Minimum D2, D4 or D6)
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 10 mm (0.39 in) from the bottom edge of the piston
Piston size “P”
Standard
101.955 ~ 101.970 mm
(4.0140 ~ 4.0146 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.03 ~ 0.055 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.13 mm (0.051 in)
4 - 35
CYLINDER AND PISTON
ENG
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00250
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.
_
Piston ring side clearance
Top ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.12 mm (0.0047 in)
2nd ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.13 mm (0.0051 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
_
a 50.0 mm (1.97 in)
4 - 36
CYLINDER AND PISTON
ENG
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
_
Piston ring end gap
Top ring
0.20 ~ 0.35 mm
(0.008 ~ 0.014 in)
<Limit>: 0.60 mm (0.024 in)
2nd ring
0.35 ~ 0.50 mm
(0.014 ~ 0.020 in)
<Limit>: 0.85 mm (0.033 in)
Oil ring
0.20 ~ 0.70 mm
(0.008 ~ 0.028 in)
EBS00251
CHECKING THE PISTON PIN
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.
Piston pin outside diameter
22.991 ~ 23.000 mm
(0.9052 ~ 0.9055 in)
<Limit>: 22.971 mm (0.9044 in)
4 - 37
CYLINDER AND PISTON
ENG
3. Measure:
• piston pin bore inside diameter b
Out of specification → Replace the piston.
Piston pin bore inside diameter
23.004 ~ 23.015 mm
(0.9057 ~ 0.9061 in)
<Limit>: 23.045 mm (0.9073 in)
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter b –
Piston pin outside diameter a
Piston-pin-to-piston-pin-bore
clearance
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
EBS00252
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring 1
• 2nd ring 2
• oil ring expander 3
• lower oil ring rail 4
• upper oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
_
4 - 38
CYLINDER AND PISTON
2.
•
•
•
1
a
ENG
Install:
piston 1
piston pin 2
piston pin clips 3 New
NOTE:
• Apply engine oil to the piston pin.
• Make sure the punch mark a on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover
the crankcase opening with a clean rag to
prevent the clips from falling into the crankcase.
_
2
3 New
3.
•
•
4.
•
•
•
Install:
cylinder gasket New
dowel pins
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
120˚
e
120˚
a
120˚
f f
d
1
c
È
b
5. Offset:
• piston ring end gaps
a Top ring
b Upper oil ring rail
c Oil ring expander
d Lower oil ring rail
e 2nd ring
f 20 mm (0.79 in)
È Exhaust side
6. Install:
• cylinder 1
• timing chain guide (exhaust)
NOTE:
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
_
4 - 39
CYLINDER AND PISTON
7. Install:
• cylinder bolts
2
E
1
1
2
ENG
E
NOTE:
Lubricate the cylinder bolt 1 threads and mating surface with engine oil.
8. Tighten:
• cylinder bolts 1 (1st)
T.
R.
15 Nm (1.5 m · kg, 11 ft · lb)
• cylinder bolts 1 (2nd)
T.
R.
50 Nm (5.0 m · kg, 36 ft · lb)
• cylinder bolts (timing chain side) 2
T.
R.
4 - 40
10 Nm (1.0 m · kg, 7.2 ft · lb)
ENG
A.C. MAGNETO
EBS00256
A.C. MAGNETO
14
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
E
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
11
10
5
16
LT
1
2
LT
5
6
E
13
15
12
7
8
E
LT
LS
(3)
LT
LT
New
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(14)
3
T.
R.
Job/Part
Removing the A.C. magneto
Engine oil
Front fender
Q’ty
Oil tank inlet hose
Drive sprocket cover
1
2
3
4
5
6
7
8
A.C. magneto coupler
Crankshaft position sensor coupler
A.C. magneto cover
A.C. magneto cover gasket
Dowel pin
Lead holder
Crankshaft position sensor
Stator coil
1
1
1
1
2
1
1
1
4 - 41
R.
R.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
T.
Order
4
60 Nm (6.0 m • kg, 43 ft • Ib)
Remarks
Remove the parts in the order listed.
Drain.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Refer to “OIL TANK”.
Refer to “SWINGARM AND DRIVE
CHAIN” in chapter 7.
Disconnect.
Disconnect.
ENG
A.C. MAGNETO
14
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
E
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
11
10
5
16
LT
1
2
LT
5
6
E
13
15
12
7
8
E
LT
LS
(3)
LT
LT
New
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
Job/Part
Torque limiter
Starter idle gear
Starter idle gear shaft
A.C. magneto rotor
Starter clutch
Woodruff key
Starter wheel gear
Washer
New
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
13
14
15
16
(14)
3
T.
T.
Order
9
10
11
12
4
60 Nm (6.0 m • kg, 43 ft • Ib)
Q’ty
Remarks
1
1
1
1
Refer to “REMOVING THE A.C. MAGNETO ROTOR” and “INSTALLING THE
A.C. MAGNETO ROTOR”.
1
1
1
1
For installation, reverse the removal procedure.
4 - 42
A.C. MAGNETO
ENG
EBS00259
REMOVING THE A.C. MAGNETO ROTOR
1. Remove:
• A.C. magneto cover
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.
_
3
2. Remove:
• A.C. magneto rotor nut 1
• washer
NOTE:
While holding the A.C. magneto rotor 2 with
the sheave holder 3, loosen the A.C. magneto
rotor nut.
_
1
2
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
3. Remove:
• A.C. magneto rotor 1
1
NOTE:
Use the flywheel puller 2.
_
Flywheel puller
90890-01404
YM-01404
2
EBS00262
CHECKING THE STATOR COIL AND
CRANKSHAFT POSITION SENSOR
1. Check:
• stator coil
• crankshaft position sensor
Damage → Replace the crankshaft position
sensor/stator assembly.
4 - 43
A.C. MAGNETO
ENG
EBS00263
1
LT
CHECKING THE STARTER CLUTCH
1. Check:
• starter one-way clutch 1
Cracks/damage → Replace.
• bolts 2
Loose → Replace with a new one, and
clinch the end of the bolt.
2
T.
R.
Starter clutch bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
É
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
b. When turning the starter wheel gear
counter clockwise È, the starter clutch and
the wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.
c. When turning the starter wheel gear clockwise É, the starter wheel gear should turn
freely.
If not, the starter clutch is faulty. Replace it.
È
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• starter idle gear teeth 1
• starter wheel gear teeth 2
Burrs/clips/roughness/wear → Replace.
1
2
3. Check:
• starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.
4 - 44
A.C. MAGNETO
ENG
CHECKING THE TORQUE LIMITER
1. Check:
• torque limiter
Damage/wear → Replace.
NOTE:
Do not disassemble the torque limiter.
EBS00268
1
INSTALLING THE A.C. MAGNETO ROTOR
1. Install:
• stator coil 1
T.
LT
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
Align the projection a on the stator coil with
the slot b in the A.C. magneto cover.
a
_
b
1
2. Apply:
• Yamaha bond No. 1215 (Three bond No.
1215) 1
(into the slit)
Yamaha bond No. 1215
(Three bond No. 1215)
90890-85505
3. Install:
• woodruff key
• A.C. magneto rotor
NOTE:
• Before installing the rotor, clean the outside
of the crankshaft and the inside of the rotor.
• After installing the rotor, check that the rotor
rotates smoothly. If not, reinstall the key and
rotor.
_
4 - 45
A.C. MAGNETO
3
ENG
4. Tighten:
• A.C. magneto rotor nut 1
T.
R.
60 Nm (6.0 m · kg, 43 ft · lb)
NOTE:
While holding the A.C. magneto rotor 2 with
the sheave holder 3, tighten the A.C. magneto rotor nut.
_
1
2
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Install:
gasket New
A.C. magneto cover
10 Nm (1.0 m · kg, 7.2 ft · lb)
bolts
T.
R.
5.
•
•
•
NOTE:
Tighten the A.C. magneto cover bolts in
stages, using a crisscross pattern.
_
4 - 46
CLUTCH
ENG
EBS00293
CLUTCH
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
LS
2
1
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
6
5
New
7
LS
6
T.
R.
LS
3 New
LS
R.
1
2
3
4
5
6
7
LT
4
(14)
T.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the clutch cover
Engine oil
Front fender
Q’ty
Rear brake light switch/right foot rest/
brake pedal/spring
Oil delivery pipe
Oil filter cover/O-ring
Oil filter
O-ring
Clutch cover
Clutch cover gasket
Dowel pin
Oil seal retainer
1/1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Drain.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Refer to “CYLINDER HEAD”.
Refer to “REMOVING THE CLUTCH”
and “INSTALLING THE CLUTCH”.
For installation, reverse the removal procedure.
4 - 47
ENG
CLUTCH
EBS00294
4 New
5
7
8
3
6 New
2
E
LS
1 New
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the pull lever shaft
Circlip
Pull lever
Pull lever spring
Circlip
Pull lever shaft
Oil seal
Bearing
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
4 - 48
CLUTCH
ENG
EBS00291
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
LS
4
2
E
1
3
18
E
(6)
6
E
23
14
5
26
13
New
E
16
12
T.
R.
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
20
110 Nm (11.0 m • kg, 80 ft • lb)
21
22
25
Job/Part
Removing the clutch
Clutch spring
Pressure plate
Pull rod
Bearing
Friction plate 1
Clutch plate
Conical spring washer
Wire circlip
Friction plate 2
Clutch damper spring
Clutch damper spring seat
Clutch boss
Thrust washer
Clutch housing
M
19 New
E
R.
95 Nm (9.5 m • kg, 68 ft • Ib)
T.
R.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
24 New
E
9
60 Nm (6.0 m • kg, 43 ft • Ib)
T
R.
T.
Order
R.
8
7
New
6
15
11
T.
10
17
Q’ty
6
1
1
1
7
7
1
1
1
1
1
1
1
1
4 - 49
60 Nm (6.0 m • kg, 43 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE CLUTCH”.
Refer to “INSTALLING THE CLUTCH”.
Refer to “REMOVING THE CLUTCH”
and “INSTALLING THE CLUTCH”.
Refer to “INSTALLING THE CLUTCH”.
CLUTCH
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
LS
4
2
ENG
E
1
3
18
E
(6)
6
E
23
14
5
26
13
New
E
16
12
T.
R.
.
24 New
E
9
60 Nm (6.0 m • kg, 43 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
20
110 Nm (11.0 m • kg, 80 ft • lb)
21
22
25
T
R.
Job/Part
Breather plate
Lock washer
Balancer driven gear 1
Straight key
Lock washer
Water pump drive gear
Primary drive gear
Balancer drive gear
Straight key
Lock washer
Balancer driven gear 2
Straight key
M
19 New
E
R.
R.
95 Nm (9.5 m • kg, 68 ft • Ib)
T.
T.
Order
15
16
17
18
19
20
21
22
23
24
25
26
R.
8
7
New
6
15
11
T.
10
17
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
60 Nm (6.0 m • kg, 43 ft • Ib)
Remarks
Refer to “REMOVING THE PRIMARY
DRIVE GEAR AND BALANCER
DRIVEN GEAR” and “INSTALLING THE
PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEARS”.
For installation, reverse the removal procedure.
4 - 50
CLUTCH
ENG
EBS00297
REMOVING THE CLUTCH
1. Remove:
• clutch cover
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. Straighten the clutch boss nut staked point
a.
3. Loosen:
• clutch boss nut 1
1
2
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss
nut.
_
3
a
Universal clutch holder
90890-04086, YM-91042
3
1
2
4
4.
•
•
•
Remove:
clutch boss nut 1
conical spring washer 2
clutch boss assembly 3
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip 4 and disassemble the
built-in damper unless there is serious clutch
chattering.
4 - 51
CLUTCH
ENG
EBS00298
5
2
6
9
1
8
4
7
3
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR
1. Straighten the lock washer tabs.
2. Loosen:
• balancer driven gear 1 nut 1
• primary drive gear nut 2
• balancer driven gear 2 nut 3
NOTE:
• Place an aluminum plate 4 between the
teeth of the balancer driven gear 1 5 and
balancer drive gear 6, then loosen the nut
1.
• Place an aluminum plate 9 between the
teeth of the balancer driven gear 2 8 and
balancer drive gear 6, then loosen the nut
3.
• Place an aluminum plate 7 between the
teeth of the balancer drive gear 6 and balancer driven gear 2 8, then loosen the nut
2.
_
EBS00300
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
1. Check:
• friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
_
4 - 52
CLUTCH
ENG
Friction plate 1 thickness
2.92 ~ 3.08 mm (0.115 ~ 0.121 in)
<Limit>: 2.82 mm (0.111 in)
Friction plate 2 thickness
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
<Limit>: 2.8 mm (0.110 in)
EBS00301
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.
Maximum clutch plate warpage
0.2 mm (0.0079 in)
EBS00302
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.
Clutch spring free length
50.0 mm (1.97 in)
<Limit>: 48 mm (1.89 in)
4 - 53
CLUTCH
ENG
EBS00303
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.
_
EBS00304
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.
_
EBS00305
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate
Cracks/damage → Replace.
EBS00306
a
b
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
• pull lever shaft pinion gear teeth a
• pull rod teeth b
Damage/wear → Replace the pull lever
shaft and pull rod as a set.
2. Check:
• pull rod bearing
Damage/wear → Replace.
4 - 54
CLUTCH
ENG
EBS00307
2
1
CHECKING THE PRIMARY DRIVE GEARS
1. Check:
• primary drive gear 1
• primary driven gear 2
Damage/wear → Replace the primary drive
gear and clutch housing as a set.
Excessive noise during operation →
Replace the primary drive gear and clutch
housing as a set.
EBS00308
2
4
1
3
CHECKING THE BALANCER DRIVE GEARS
1. Check:
• balancer drive gear 1
• balancer driven gear 1 2
• balancer driven gear 2 3
• water pump drive gear 4
Damage/wear → Replace the balancer
drive gear and balancer driven gear as a
set.
Replace the water pump drive gear and
water pump driven gear as a set.
Excessive noise during operation →
Replace the balancer drive gear and balancer driven gear as a set.
Replace the water pump drive gear and
water pump driven gear as a set.
EBS00310
d
b
c
a
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEARS
1. Install:
• balancer drive gear
• primary drive gear
• water pump drive gear
• balancer driven gear 1
• balancer driven gear 2
NOTE:
• Align the punch mark a on the balancer
drive gear with the punch mark b on the balancer driven gear 2.
• Align the punch mark c on the balancer
drive gear with the punch mark d on the balancer driven gear 1.
_
4 - 55
CLUTCH
9
3
8
2
6
ENG
2. Tighten:
• balancer driven gear 2 nut 1
7
T.
R.
60 Nm (6.0 m · kg, 43 ft · lb)
• primary drive gear nut 2
T.
5
R.
110 Nm (11.0 m · kg, 80 ft · lb)
• balancer driven gear 1 nut 3
T.
R.
4
1
60 Nm (6.0 m · kg, 43 ft · lb)
NOTE:
• Apply the engine oil to the balancer threads.
• Apply the molybdenum disulfide grease to
the crankshaft and nut 2 threads.
• Place an aluminum plate 4 between the
teeth of the balancer driven gear 2 5 and
balancer drive gear 6, then tighten the nut
1.
• Place an aluminum plate 7 between the
teeth of the balancer driven gear 2 5 and
balancer drive gear 6, then tighten the nut
2.
• Place an aluminum plate 8 between the
teeth of the balancer drive gear 6 and balancer driven gear 1 9, then tighten the nut
3.
_
3. Bend the lock washer tabs along a flat side
of the nut.
EBS00311
1
INSTALLING THE CLUTCH
1. Install:
• clutch housing 1
NOTE:
• Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
• Make sure that the oil pump drive gear teeth
and oil pump driven gear teeth mesh correctly.
_
4 - 56
CLUTCH
ENG
2. Install:
• clutch boss assembly 1
1
NOTE:
• If the wire circlip 2 has been removed, carefully install a new one.
• Install the clutch damper spring 3 with the
“OUTSIDE” mark facing out.
3
2 New
1
3.
•
•
•
2
3
Install:
clutch boss 1
conical spring washer 2
clutch boss nut 3 New
OUT
T.
R.
a
95 Nm (9.5 m · kg, 68 ft · lb)
NOTE:
• Install the washer 2 with the “OUT” mark a
facing out.
• While holding the clutch boss 1 with the
clutch holding tool 4, tighten the clutch boss
nut.
• Stake the clutch boss nut 3 at a cutout b in
the main axle.
_
4
b
Universal clutch holder
90890-04086, YM-91042
4. Install:
• clutch springs
T.
R.
8 Nm (0.8 m · kg, 5.8 ft · lb)
NOTE:
Tighten the bolts in stages, using a crisscross
pattern.
_
T.
R.
5. Install:
• clutch cover
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• To install the clutch cover, position the pull
rod so that the teeth face towards the rear of
the vehicle.
• Tighten the clutch cover bolts in stages and
in a crisscross pattern.
_
4 - 57
CLUTCH
6.
•
•
•
•
1
a
b
2
c
a
b
Install:
pull lever spring 1
pull lever 2
washer
circlip New
NOTE:
• Install the pull lever with the “UP” mark facing
up.
• Align the mark a on the pull lever with the
stationary pointer b on the clutch cover.
• Install the pull lever spring 1 as shown.
_
7.
•
8.
•
1
ENG
Install:
clutch cable 1
Check:
clutch cable length a
Out of specification → Adjust.
NOTE:
• Push the pull lever in direction b and check
the cable length a.
• Bend the tab c on the pull lever to secure
the clutch cable.
Clutch cable length
67 ~ 76 mm (2.64 ~ 2.99 in)
9. Adjust:
• clutch cable length
NOTE:
Move the pull lever a notch until the cable
length is within specification.
10.Adjust:
• clutch cable free play
Refer to “ADJUSTING
CABLE” in chapter 3.
4 - 58
THE
CLUTCH
OIL PUMP
ENG
EBS00315
OIL PUMP
Order
1
2
3
4
5
6
7
Job/Part
Removing the oil pump
Clutch housing
Oil baffle plate 1
Circlip
Oil pump driven gear
Oil baffle plate 2
Oil pump
Oil pump gasket
O-ring
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CLUTCH”.
1
1
1
1
1
1
2
For installation, reverse the removal procedure.
4 - 59
OIL PUMP
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the oil pump
Oil pump housing 1/oil seal
Oil pump outer rotor 1
Dowel pin
Oil pump inner rotor 1
Oil pump housing cover/oil seal
Dowel pin
Oil pump shaft
Dowel pin
Oil pump inner rotor 2
Oil pump outer rotor 2
Oil pump housing 2
Q’ty
1/1
1
1
1
1/1
2
1
1
1
1
1
ENG
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE OIL
PUMP”.
For assembly, reverse the disassembly
procedure.
4 - 60
OIL PUMP
ENG
EBS00317
CHECKING THE OIL PUMP
1. Check:
• oil pump driven gear 1
• oil pump housing 1 2
• oil pump housing cover 3
• oil pump housing 2 4
Cracks/damage/wear → Replace.
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
Out of specification → Replace the oil
pump.
1 inner rotor
2 outer rotor
3 oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.12 mm (0.0047 in)
<Limit>: 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09 ~ 0.15 mm
(0.0035 ~ 0.0059 in)
<Limit>: 0.22 mm (0.0087 in)
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective parts.
4 - 61
OIL PUMP
ENG
EBS00318
ASSEMBLING THE OIL PUMP
1. Install:
• oil pump outer rotor 2 1
• oil pump inner rotor 2 2
(to the oil pump housing 2)
• oil pump housing
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
Align the match mark a on the inner rotor 2
with the match mark b on the outer rotor 2.
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
4 - 62
SHIFT SHAFT
ENG
SHIFT SHAFT
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the shift shaft
Clutch housing
Shift pedal
Shift shaft
Shift shaft spring
Stopper lever/washer
Stopper lever spring
Roller
Shift guide
Shift lever assembly
Pawl holder
Pawl
Pawl pin
Spring
Q’ty
1
1
1
1/1
1
1
1
1
1
2
2
2
4 - 63
Remarks
Remove the parts in the order listed.
Refer to “CLUTCH”.
Refer to “INSTALLING THE SHIFT
LEVER”.
Refer to “INSTALLING THE SHIFT
LEVER”.
SHIFT SHAFT
Order
13
Job/Part
Shift drum segment
ENG
Q’ty
Remarks
1
Refer to “INSTALLING THE SHIFT
LEVER”.
For installation, reverse the removal procedure.
4 - 64
SHIFT SHAFT
ENG
EBS01018
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
Bends/damage/wear → Replace.
• shift shaft spring 2
Damage/wear → Replace.
1
2
EBS01019
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• stopper lever spring 2
Damage/wear → Replace.
2
1
EBS00359
1
2
3
3
4
4
5
5
CHECKING THE SHIFT GUIDE
1. Check:
• shift guide 1
• pawl holder 2
• pawls 3
• pawl pins 4
• springs 5
Wear/cracks/damage → Replace.
CHECKING THE SHIFT DRUM SEGMENT
1. Check:
• shift drum segment
Damage/wear → Replace.
INSTALLING THE SHIFT LEVER
1. Install:
• shift drum segment 1
• shift drum segment bolt
1
a
T.
R.
b
30 Nm (3.0 m · kg, 22 ft · lb)
NOTE:
Align the notch a on the shift drum segment
with the pin b on the shift drum.
4 - 65
SHIFT SHAFT
4
3
3
2.
•
•
•
•
ENG
Install:
springs 1
pawl pins 2
pawls 3
shift guide 4
(to the pawl holder)
2
2
1
1
T.
3. Install:
• shift lever assembly 1
• shift guide 2
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
NOTE:
The shift lever assembly is installed at the
same time as the shift guide.
1
2
EBS00343
1
5
2
6
3
NOTE:
• Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss 5.
• Install the end of the shift shaft spring onto
the shift shaft spring stopper 6.
• Install the end of the shift shaft lever onto the
roller 4.
2. Install:
16 Nm (1.6 m · kg, 11 ft · lb)
• shift pedal
Refer to “ADJUSTING THE SHIFT PEDAL”
in chapter 3.
T.
R.
4
INSTALLING THE SHIFT SHAFT
1. Install:
• stopper lever 1
• stopper lever spring 2
• shift shaft 3
• roller 4
• shift shaft spring
4 - 66
CRANKCASE
ENG
EBS00320
CRANKCASE
Order
1
2
3
4
5
Job/Part
Separating the crankcase
Engine assembly
Piston
A.C. magneto
Balancer driven gears
Oil pump
Shift drum segment
Starter motor
Timing chain guide (intake side)
Timing chain
Neutral switch
Reverse switch
Oil pipe joint
Q’ty
1
1
1
1
1
4 - 67
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER AND PISTON”.
Refer to “A.C. MAGNETO”.
Refer to “CLUTCH”.
Refer to “OIL PUMP”.
Refer to “SHIFT SHAFT”.
Refer to “STARTER MOTOR” in
chapter 8.
CRANKCASE
Order
6
7
8
9
10
11
12
13
Job/Part
Reverse shift lever
Reverse shift lever spring
Circlip
Right crankcase
Left crankcase
Dowel pin
Dowel pin/O-ring
Oil strainer
Q’ty
1
1
1
1
1
2
1/1
1
ENG
Remarks
Refer to “SEPARATING THE CRANKCASE”.
For installation, reverse the removal procedure.
4 - 68
CRANKCASE
ENG
EBS00321
CRANKCASE BEARINGS
LS
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
LT
3
5
4 New
1
T.
3
R.
E
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
5
5
4 New
5
5
LS
E
LT
5
5
5
E
E
T.
R.
Order
1
2
3
4
5
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the crankcase bearings
Crankshaft
Transmission
Oil seal retainer
Bearing retainer
Bearing retainer
Oil seal
Bearing
Q’ty
E
5
Remarks
Remove the parts in the order listed.
Refer to “CRANKSHAFT”.
Refer to “TRANSMISSION”.
1
1
1
4
10
For installation, reverse the removal procedure.
4 - 69
CRANKCASE
ENG
EBS00332
1
SEPARATING THE CRANKCASE
1. Separate:
• right crankcase 1
• left crankcase 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
NOTE:
• Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
• Loosen the bolts in stages, using a crisscross pattern.
_
2
b. Remove the right crankcase.
NOTE:
Insert a screwdriver or pry bar into the pry
points in the crankcase and then carefully pry
apart the crankcase halves.
_
CAUTION:
_
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.
c. Remove the dowel pins and O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00325
CHECKING THE OIL STRAINER
1. Check:
• oil strainer
Damage → Replace.
Contaminants → Clean with engine oil.
4 - 70
CRANKCASE
ENG
EBS00335
CHECKING THE TIMING CHAIN AND GUIDE
1. Check:
• timing chain
Cracks/stiffness → Replace the timing
chain and camshaft as a set.
2. Check:
• timing chain guide (intake side)
Wear/damage → Replace.
EBS00339
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
• bearings
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.
2. Check:
• oil seals
Damage/wear → Replace.
EBS00338
CHECKING THE CRANKCASE
1. Thoroughly wash the case halves in a mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. Check:
• crankcase
Cracks/damage → Replace.
• oil delivery passages
Clogged → Blow out with compressed air.
4 - 71
CRANKCASE
ENG
EBS00342
È
ASSEMBLING THE CRANKCASE
1. Install:
• bearings New
• bearing retainers
• bearing retainer bolts 1
1
LT
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• bearing retainer screws 2
LT
T.
R.
É
2
a
b
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Install the bearing by pressing its outer race
evenly.
• To prevent the bearing retainer screws 2
from becoming loose, flatten the edge a of
each screw into the depression b using a
punch, etc. Be careful not to damage the
hole for the screwdriver in the screw heads.
È Right crankcase
É Left crankcase
2
2
2. Apply:
• Yamaha bond No. 1215 (Three bond No.
1215) 1
(to the mating surfaces of both case halves)
Yamaha bond No. 1215
(Three bond No. 1215)
90890-85505
1
New 3
2
3. Install:
• dowel pins 2
• O-ring 3 New
4 - 72
CRANKCASE
ENG
4. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft
hammer.
CAUTION:
_
Before installing and torquing the crankcase holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift
drum in both directions.
È
5. Install:
• crankcase bolts
È Left crankcase
É Right crankcase
6. Tighten:
• crankcase bolts
(follow the proper tightening sequence)
T.
R.
10 Nm (1.0m · kg, 7.2 ft · lb)
NOTE:
Tighten the bolts in stages, using a crisscross
pattern.
_
É
7. Apply:
• 4-stroke engine oil
(to the crankshaft pin, bearing and oil delivery hole)
8. Check:
• crankshaft and transmission operation
Unsmooth operation → Repair.
4 - 73
CRANKSHAFT
ENG
CRANKSHAFT
CRANKSHAFT AND BALANCER
1
2
3
Order
1
2
3
Job/Part
Removing the crankshaft and balancer
Crankcase
Balancer 1
Balancer 2
Crankshaft
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
4 - 74
Refer to “REMOVING THE CRANKSHAFT” and “INSTALLING THE CRANKSHAFT”.
For installation, reverse the removal procedure.
CRANKSHAFT
ENG
EBS00336
1
2
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
Use a crankcase separating tool 2.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
EBS00360
CHECKING THE CRANKSHAFT
1. Measure:
• crank width a
Out of specification → Replace the crankshaft.
d
Crank width
74.95 ~ 75.00 mm
(29.51 ~ 29.53 in)
c
c
2. Measure:
• side clearance d
Out of specification → Replace the crankshaft.
Big end side clearance
0.35 ~ 0.65 mm
(0.0138 ~ 0.0256 in)
<Limit>: 1.00 mm (0.040 in)
a
3. Measure:
• runout c
Out of specification → Replace the crankshaft.
Runout limit
0.03 mm (0.0012 in)
4 - 75
CRANKSHAFT
ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. The crankshaft 1 and the crankshaft pin 2
oil passages must be properly interconnected with a tolerance of less than 1 mm
(0.04 in).
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft 1
1
Crankshaft installer pot 2
90890-01274
Installer pot
YU-90058
Pot installer
YU-90059
Crankshaft installer bolt 3
90890-01275
Bolt
YU-90060
Adapter (M16) 4
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer) 5
90890-04081
Pot spacer
YM-91044
5
4 2
3
NOTE:
Hold the connecting rod at the Top Dead Center (TDC) with one hand while turning the nut
of the installing tool with the other. Operate the
installing tool until the crankshaft bottoms
against the bearing.
_
CAUTION:
_
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
4 - 76
TRANSMISSION
ENG
EAS00345
TRANSMISSION
New
6
11
1
4
2
LS
5
3
10
New
New
New
M
7
New
8
New
13
New
9
New
Order
1
2
3
4
5
Job/Part
Removing the transmission, shift
drum, and shift forks
Crankcase
Spacer
Circlip
Washer
Reverse wheel gear 2
Spacer
12
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
1
1
4 - 77
TRANSMISSION
ENG
New
6
11
1
4
2
LS
5
3
10
New
New
New
M
7
New
8
New
13
New
9
New
Order
6
7
8
9
10
11
12
13
Job/Part
Counter axle assembly
Shift drum
Shift fork “R”
Shift fork “C”
Shift fork “L”
Drive axle assembly
Main axle assembly
Reverse shift shaft
12
Q’ty
1
1
1
1
1
1
1
1
Remarks
Refer to “INSTALLING THE TRANSMISSION”.
For installation, reverse the removal procedure.
4 - 78
TRANSMISSION
ENG
EBS00347
MAIN AXLE
8
9
8
0
7
New
M
New
A
1
2
3
M
4
5
New
6
7
M
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the main axle
Circlip
2nd pinion gear
Toothed lock washer
Toothed washer retainer
4th pinion gear
Toothed spacer
Toothed washer
Circlip
3rd pinion gear
5th pinion gear
Main axle/1st pinion gear
Q’ty
1
1
1
1
1
1
2
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.
For assembly, reverse the disassembly
procedure.
4 - 79
TRANSMISSION
ENG
EBS00348
DRIVE AXLE
H
M
G
F
M
New 7
6
New
M
E
6
8
7
9
D
New
C
B
0
M
A
7
6
New
1
5
4
2
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D
Job/Part
Disassembling the drive axle
Circlip
Washer
Reverse wheel gear 2
Spacer
Dog clutch
Circlip
Toothed washer
1st wheel gear
Toothed spacer
5th wheel gear
Toothed lock washer
Toothed washer retainer
3rd wheel gear
Toothed spacer
M
M
3
Q’ty
1
1
1
1
1
3
3
1
1
1
1
1
1
1
4 - 80
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.
Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.
TRANSMISSION
ENG
H
M
G
F
M
New 7
6
New
M
E
8
6
7
9
D
New
C
B
0
M
A
7
6
New
1
5
4
2
Order
E
F
G
H
Job/Part
4th wheel gear
2nd wheel gear
Spacer
Drive axle
M
M
3
Q’ty
1
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
4 - 81
TRANSMISSION
ENG
COUNTER AXLE
1
2
5
New
4
3
2
1
M
New
Order
1
2
3
4
5
Job/Part
Disassembling the counter axle
Circlip
Washer
Spacer
Reverse wheel gear 1
Counter axle
Q’ty
Remarks
Remove the parts in the order listed.
2
2
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 82
TRANSMISSION
ENG
EBS00350
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. Check:
• shift fork movement
Rough movement → Replace the shift
forks.
2
1
EBS00351
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Scratches/wear/damage → Replace.
EBS00354
1
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the main
axle.
Main axle runout limit
0.08 mm (0.0031 in)
4 - 83
TRANSMISSION
ENG
2. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
3. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
4. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
5. Check:
• circlips
Bends/damage/looseness → Replace.
EBS00355
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
• toothed washer 1
• circlip 2 New
NOTE:
• Be sure the circlip shape-edged corner a is
positioned on the opposite side to the
toothed washer and gear.
• Install the circlip so that both ends b are
positioned in the center of two axle spline c.
_
4 - 84
TRANSMISSION
EBS00356
2
1
3
ENG
5
4
6
INSTALLING THE TRANSMISSION
1. Install:
• drive axle assembly 1
• main axle assembly 2
• shift fork “L” 3 (to drive axle)
• shift fork “C” 4 (to main axle)
• shift fork “R” 5 (to drive axle)
• shift drum 6
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”. Be
sure that the shift fork cam follower is properly
seated in the shift drum groove.
_
d
c
2. Install:
• counter axle assembly
NOTE:
• Engage the concave part a of the left crankcase and convex part b of the counter axle.
• Align the edge height of reverse wheel gear
1 c and main axle/1st pinion gear d.
_
b
a
3. Check:
• shift operation
Unsmooth operation → Repair.
NOTE:
• Apply engine oil to each gear and bearing
thoroughly.
• Before assembling the crankcase, make
sure that the transmission is in neutral and
that the gears turn freely.
_
4 - 85
COOL
RADIATOR
EBS00125
COOLING SYSTEM
RADIATOR
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
2
3
6
5
11
9
8
10
1
4
2
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the radiator
Front fender
Coolant
Radiator fan motor coupler
Coolant reservoir hose
Radiator fan breather hose
Radiator outlet hose
Radiator inlet hose
Fast idle plunger outlet hose
Radiator
Radiator fan
Coolant reservoir breather hose
Q’ty
1
1
1
1
1
1
1
1
1
5-1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Drain.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
COOL
RADIATOR
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
2
3
6
5
11
9
8
10
1
5
4
2
T.
R.
Order
10
11
Job/Part
Coolant reservoir
Coolant reservoir cap
Q’ty
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5-2
RADIATOR
COOL
EBS00127
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.
_
2. Check:
• radiator hoses
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
(0.933 ~ 1.227 kg/cm2,
13.27 ~ 17.45 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
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
5-3
RADIATOR
COOL
EBS00128
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-4
THERMOSTAT
COOL
EBS00129
THERMOSTAT
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
1
6 New
5
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
3 New
4
New
LS
Order
1
2
3
4
5
6
Job/Part
Removing the thermostat
Front fender
Coolant
Radiator inlet hose
Thermostat cover
O-ring
Thermostat
Coolant temperature sensor
Copper washer
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Drain.
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-5
THERMOSTAT
COOL
EBS00132
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 69 ~ 73 °C (156.2 ~
163.4 °F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Opening
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermostat
2 Thermometer
3 Water
4 Container
È Fully closed
É Fully open
Temperature
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
_
2. Check:
• thermostat cover
• thermostat housing (cylinder head)
Cracks/damage → Replace.
EBS00133
INSTALLING THE THERMOSTAT
1. Install:
• thermostat 1
• O-ring 2 New
• thermostat cover 3
a
NOTE:
Install the thermostat with its breather hole a
facing up.
1
3
2 New
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leak → Repair or replace any faulty part.
5-6
WATER PUMP
COOL
EBS00134
WATER PUMP
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
7 New
4 New
3
1
6
LS
2
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
Order
1
2
3
4
5
6
7
Job/Part
Removing the water pump
Coolant
Radiator outlet hose
Water pump outlet hose
Water pump
O-ring
Water pump breather hose
Water jacket inlet housing
O-ring
Q’ty
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
For installation, reverse the removal procedure.
5-7
WATER PUMP
COOL
EBS00135
T.
2 New
R.
11 Nm (1.1 m • kg, 8.0 ft • Ib)
1
A
9 New
8 New
New
LS
5
3 New
7
6
4
0
E
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the water pump
Water pump housing cover
Gasket
Circlip
Impeller shaft gear
Pin
Washer
Impeller shaft assembly
Water pump seal
Oil seal
Bearing
Water pump housing
Q’ty
1
1
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE WATER
PUMP”.
Refer to “DISASSEMBLING THE
WATER PUMP” and “ASSEMBLING
THE WATER PUMP”.
For assembly, reverse the disassembly
procedure.
5-8
WATER PUMP
COOL
EBS00138
DISASSEMBLING THE WATER PUMP
1. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
_
2
1
2 Water pump housing
2. Remove:
• bearing 1
• oil seal 2
1
3
2
NOTE:
Tap out the bearing and oil seal from the outside of the water pump housing.
_
3 Water pump housing
EBS00139
1
3
CHECKING THE WATER PUMP
1. Check:
• water pump housing 1
• impeller 2
• water pump housing cover 3
Cracks/damage/wear → Replace.
2. Check:
• bearing
Rough movement → Replace.
• impeller shaft gear
Pitting/wear → Replace.
2
5-9
WATER PUMP
COOL
EBS00140
3
0.5~1.0 mm
(0.02~0.04 in)
ASSEMBLING THE WATER PUMP
1. Install:
• oil seal 1 New
(into the water pump housing 2)
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its out surface.
• Install the oil seal with a socket 3 that
matches its outside diameter.
_
2
1 New
È
2. Install:
• water pump seal 1 New
(into the water pump housing 2)
4
3
1 New
CAUTION:
_
Never lubricate the water pump seal surface with oil or grease.
2
NOTE:
Install the water pump seal with the special
tools.
_
Mechanical seal installer 3
90890-04132
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
4
90890-04058
Bearing driver (40 mm)
YM-04058
È Push down.
3. Measure:
• impeller shaft tilt
CAUTION:
_
Make sure that the rubber damper and rubber damper holder are bottom with the
impeller.
Max. impeller shaft tilt
0.15 mm (0.006 in)
1 Straightedge
2 Impeller
5 - 10
FI
FUEL INJECTION SYSTEM
EAS00894
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 Engine trouble warning light
2 Ignition coil
3 Fuel tank
4 Fuel hose
5 Fuel pump
6 Intake air pressure sensor
7 Lean angle sensor
1
8 Battery
9 Intake air temperature sensor
0 ECU
A Air filter case
B Relay unit (fuel pump relay)
C Speed sensor
D Throttle position sensor
2
3 4
H
G
F
5
E
6-1
6
D
E Crankshaft position sensor
F Fuel injector
G Coolant temperature sensor
H Spark plug
7 8 9 0
C
A
B
W
W W
G/W L/Y
W
W W
L/Y B/L
B/L
2
1
L/Y
W
W
B R/L
W
W
W
W
L
Br
B
R/L
R/W
Y/R
W
W
W
i
6-2
B
g
R/L
R/L
Y/R
Br
R/W
R/W
R
3
(GRAY)
R
B
h
B
R
ON
OFF
R
Br/L
(BLACK)
Y Br/Y
Br/L
Br/L
a
B
L Y
Y
L Y
B
(BLACK)
B
Y
B
L
(BLACK)
B
(BLACK)
B
Y Br/Y
Br/R
Br/Y
Br
b
Br/Y
15A
10A
10A
Br/G
c
B
d
e
f
(GRAY)
Br/L
Br/L R
10A
Br
R
5
(GRAY)
4
R
G
L
Y
G
B
B
Y
9
B
B
R
R
]
(BLACK)
Y G
B
^
L
HI
OFF
LO
Z
B
Y G
Y Y
G B
L Y
B
X
8
B
7
R R
Br/R
B/Y B
Y
(BLACK)
Y
B
B
B
(BLACK)
Y
Br/Y
B
6
R
R
20A
R
R
B
Y
B
(BLACK)
G
OFF
PUSH
\
Br
L/B
B
B/Y
L/B
L/W
L/W R/B
(BLACK)
^
Br R/B
A
0
Y G
B
OFF
ON
[
Y G
B
B/Y
L/W
Br
(BLACK)
L/W Br
W/L G/L Sb
Br O/B G/Y
Lg G/L W/L
G/Y O/B Br
L/B Br
(BLACK)
Br
Br L/B
B R/B
Y L
Br/R
W
Sb
Sb
A
Sb
G/Y
E
C
(BLACK)
R/B B
Y
Y/R
L
Lg
Sb
B
L/R
R/L
Br/G
O/B
D
Br
B
B
G/L
G
Br O/G
O/G
J
B
B
R/L
B
O/G
R/B L/B R/L
Sb B/Y Lg
Br
U
B Br
Lg
Lg
H
A
Lg
L/Y
Br
B O/G
R/L
Sb
L/R
Y/R
G/L
W/L
L/W
O/B
Lg
G/Y
G/W
(GRAY)
R/L B
B
I
G/W
G/W
Lg
R
O
B
G/W
L/Y B/W G/Y L G/L Br O/B
Y B/L L/R Y/R W/L R/L R/B
L/W L/R Br
V
Br/G L/W
W/L
F
L/W Lg Y/G O/G W
Sb G/W Pu/R L/G P
B/W
K
B
L
B/L
B/L
P
Y/G
O/G
Y
S
R
L Y/G B/L
L Y/G B/L
T
P
B/L
L
Y
B/L
L W
B/L
L
P
O
W/R
(GRAY)
G/W Sb
Sb G/W
(GRAY)
Y B/L
L
(BLACK)
B/L P
(BLACK)
L
P O/R
B/W
Q
MAIN HARNESS WIRE SUB LEAD
W
B/L
N
M
L
L
Pu/R
(GREEN)
Pu/R B/L
L/G
(BLACK)
L/G B/L
R/B
(GLAY)
W/R R/B
O
R/B
W
B/L
Pu/R
L/G
R/B
O
A
FUEL INJECTION SYSTEM
FI
EAS27340
CIRCUIT DIAGRAM
6
FUEL INJECTION SYSTEM
1 Crankshaft position sensor
4 Main switch
5 Fuel injector system fuse
6 Battery
7 Main fuse
B Fuel pump relay
E Engine trouble warning light
H Neutral indicator light
J Self-diagnosis signal coupler
K ECU
L Ignition coil
M Spark plug
N Fuel injector
O Intake air temperature sensor
P Coolant temperature sensor
Q Speed sensor
R Throttle position sensor
S Intake air pressure sensor
T Lean angle sensor
U Fuel pump
W Neutral switch
[ Engine stop switch
f Ignition fuse
6-3
FI
FI
FUEL INJECTION SYSTEM
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control 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 correctly, 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
1
the self-diagnostic function, this mode provides an appropriate substitute characteristic
operation, and alerts the rider of the detected
malfunction by illuminating the engine trouble warning light.
1 Engine trouble warning light
• After the engine has been stopped, the lowest fault code number displays on the FI
diagnostic tool. This fault code remains
stored in the memory of the ECU until it is
deleted.
Engine trouble warning light fault code indication
Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF.
<Example> 42
Light ON
Light OFF
EAS00900
Engine trouble warning light indication and FI system operating condition
Engine condition
Operates
(cranking with electric starter)
Stopped
Warning light
indication
FI operation
Vehicle operation
Flashing
Operation stopped.
Unable
Remains ON
Operated with substitute characteristics in
accordance with the
description of the malfunction.
Able
Flashing
(indicate the fault
code)
—
—
6-4
FUEL INJECTION SYSTEM
FI
EAS27380
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.
Item
Symptom
Able / unable
to start
Able / unable
to drive
12
Crankshaft position sensor
No normal signals are received from the crankshaft
position sensor.
Unable
Unable
13
Intake air pressure sensor
(open or short circuit)
Intake air pressure sensor: open or short circuit
detected.
Able
Able
14
Intake air pressure sensor
(hose line)
Intake air pressure sensor: hose system malfunction
(clogged or detached hose).
Able
Able
15
Throttle position sensor (open
or short circuit)
Throttle position sensor: open or short circuit
detected.
Able
Able
16
Throttle position sensor
Stuck throttle position sensor detected.
Able
Able
21
Coolant temperature sensor
Coolant temperature sensor: open or short circuit
detected.
Able
Able
22
Intake air temperature sensor (open or short circuit)
Intake air temperature sensor: open or short circuit
detected.
Able
Able
30
Lean angle sensor (latch up
detected)
The vehicle has overturned.
Unable
Unable
33
Ignition coil (faulty ignition)
Malfunction detected in the primary wire of ignition
coil.
Unable
Unable
41
Lean angle sensor (open or
short circuit)
Lean angle sensor: open or short circuit detected.
Unable
Unable
Speed sensor
No normal signals are received from the speed sensor.
Able
Able
Neutral switch
Open or short circuit is detected in the neutral switch.
43
Fuel system voltage (monitoring voltage)
The ECU is unable to monitor the battery voltage (an
open or short circuit in the line to the ECU).
Able
Able
44
Error in writing the amount of
CO adjustment on EEPROM
Error is detected while reading or writing on EEPROM
(CO adjustment value).
Able
Able
46
Vehicle system power supply
(Monitoring voltage)
Power supply to the fuel injection system is not normal.
Able
Able
50
ECU internal malfunction
(memory check error)
Faulty ECU memory. (When this malfunction is
detected in the ECU, the fault code number might not
appear on the meter).
Unable
Unable
42
6-5
FI
FUEL INJECTION SYSTEM
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on.
The engine trouble warning light does not come on.
Check the fault code number displayed on the FI
diagnostic tool.
Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Sensor operation table” and “Actuator operation table”.
D01: Throttle position sensor (Throttle angle)
D30: Ignition coil
D36: Fuel injector
Identify the system with the malfunction. Refer to
“Self-Diagnostic Function table”.
Identify the probable cause of the malfunction. Refer
to “Diagnostic code table”.
OK
Check and repair the probable cause of malfunction.
Fault code No. YES
Fault code No. NO
Check and repair.
Refer to “TROUBLESHOOTING DETAILS”.
Monitor the operation of
the sensors and actuators in the diagnostic
mode. Refer to “Sensor operation table” and
“Actuator operation
table”.
Check and repair.
Refer to “Self-Diagnostic Function table”.
NG
Engine malfunction
Defective sensor or
actuator
Check and repair the
inner parts of engine.
Refer to Chapter 4.
Check and repair the
corresponding sensor or actuator.
OK
NG
OK
Check the engine condition.
Perform ECU reinstatement action. Refer to “Reinstatement method” in “TROUBLESHOOTING
DETAILS”.
Fault code number
displayed
OK
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number
is still displayed.
Fault code number not displayed
Repairs completed
Erasing the malfunction history:*
The malfunction history is stored even if the main switch is turned OFF.
The malfunction history must be erased in the diagnostic mode. Refer to “Sensor operation table” and “Actuator operation table” (Diagnostic code No.D62).
* Operated when the engine trouble warning light is on.
6-6
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators with the FI
diagnostic tool connected to the vehicle and
set to the normal mode or the diagnostic monitoring mode.
FI diagnostic tool
90890-03182, YU-03182
Setting the normal mode
NOTE:
The engine speed, engine temperature, and
fault code, if detected, can be displayed on the
LCD of the FI diagnostic tool when the tool is
connected to the vehicle and is set to the normal mode.
_
1
1. Turn the main switch to “OFF” and set the
engine stop switch to “RUN”.
2. Remove the self-diagnosis signal coupler
cap, and then connect the FI diagnostic tool
1 as shown.
3. Turn the main switch to “ON” and start the
engine.
FI Diagnostic Tool
1600rpm 35˚C
NOTE:
• Coolant temperature and engine revolution
appear on the LCD of the FI diagnostic tool.
• “POWER” LED (Green) comes on.
• If a malfunction is detected in the system,
“WARNING” LED (Orange) comes on.
_
4. Stop the engine.
FI Diagnostic Tool
0rpm 35˚C
S/D : 12
NOTE:
If a malfunction is detected in the system, the
fault code appears on the LCD of the FI diagnostic tool. And also, “WARNING” LED
(Orange) comes on.
_
5. Turn the main switch to “OFF” to cancel the
normal mode.
6. Disconnect the FI diagnostic tool and connect the self-diagnosis signal connector.
6-7
FUEL INJECTION SYSTEM
FI
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the
engine stop switch to “RUN”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Remove the self-diagnosis signal coupler
cap, and then connect the FI diagnostic tool
1 as shown.
4. While press the “MODE” button, turn the
main switch to “ON”.
1
NOTE:
• “DIAG” appears on the LCD of the FI diagnostic tool.
• “POWER” LED (Green) comes on.
_
5. Press the “UP” button to select the CO
adjustment mode “CO” or the diagnostic
mode “DIAG”.
6. After selecting “DIAG”, press the “MODE”
button.
7. Select the diagnostic code number corresponding to the fault code number by pressing the “UP” and “DOWN” buttons.
NOTE:
• The diagnostic code number appears on the
LCD (D01-D70).
• To decrease the selected diagnostic code
number, press the “DOWN” button. Press the
“DOWN” button for 1 second or longer to
automatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “UP” button. Press the
“UP” button for 1 second or longer to automatically increase the diagnostic code numbers.
FI Diagnostic Tool
D03 :
_
101
8. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appear on the LCD.
• Actuator operation
Set the engine stop switch to “OFF” and
then to “RUN”.
9. Turn the main switch to “OFF” to cancel the
diagnostic mode.
10.Disconnect the FI diagnostic tool and connect the self-diagnosis signal connector
cap.
11.Connect the wire harness coupler to the
fuel pump.
6-8
FUEL INJECTION SYSTEM
FI
Diagnostic code table
Fault
code No.
Symptom
Probable cause of malfunction
12
No normal signals are received from
the crankshaft position sensor.
•
•
•
•
•
13
Intake air pressure sensor: open or
short circuit detected.
• Open or short circuit in wire harness.
• Defective intake air pressure sensor.
• Malfunction in ECU.
D03
14
Intake air pressure sensor: hose system malfunction (clogged or detached
hose).
• Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction in ECU.
D03
15
Throttle position sensor: open or short
circuit detected.
•
•
•
•
•
D01
16
Stuck throttle position sensor
detected.
• Stuck throttle position sensor.
• Malfunction in ECU.
D01
21
Coolant temperature sensor: open or
short circuit detected.
•
•
•
•
Open or short circuit in wire harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed coolant temperature sensor.
D06
22
Intake air temperature sensor: open
or short circuit detected.
•
•
•
•
Open or short circuit in wire harness.
Defective intake air temperature sensor.
Malfunction in ECU.
Improperly installed intake air temperature sensor.
D05
30
The vehicle has overturned.
• Overturned.
• Malfunction in ECU.
•
•
•
•
Open or short circuit in wire harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
Diagnostic code No.
Open or short circuit in wire sub lead.
Open or short circuit in wire harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
Open or short circuit in wire harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
—
D08
D30
D32
33
Malfunction detected in the primary
lead of the ignition coil.
41
Lean angle sensor: open or short circuit detected.
• Open or short circuit in wire harness.
• Defective lean angle sensor.
• Malfunction in ECU.
D08
42
No normal signals are received from
the speed sensor.
Open circuit is detected in the neutral
switch.
•
•
•
•
•
•
D07
D21
43
The ECU is unable to monitor the battery voltage (an open or short circuit
in the line to the ECU).
• Open or short circuit in wire harness.
• Malfunction in ECU.
D09
44
Error is detected while reading or writing on EEPROM (CO adjustment
value).
• Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).
D60
46
Power supply to the fuel injection system is not normal.
• Malfunction in the charging system. Refer to “CHARGING SYSTEM” in chapter 8.
—
50
Faulty ECU memory. (When this malfunction is detected in the ECU, the
fault code number might not appear
on the LCD of the FI diagnostic tool.)
• Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
—
Open circuit in wire harness.
Defective speed sensor.
Malfunction in vehicle speed sensor detected.
Defective neutral switch.
Malfunction in the engine side of the neutral switch.
Malfunction in ECU.
6-9
FUEL INJECTION SYSTEM
FI
Sensor operation table
Diagnostic code
No.
Item
FI diagnostic tool display
Checking method
Throttle angle
D01
D03
• Fully closed position
15 ~ 20
• Fully opened position
95 ~ 100
Check with throttle fully closed.
Check with throttle fully open.
Pressure difference
(atmospheric pressure
and intake air pressure)
Displays the intake air pressure.
Set the engine stop switch to “RUN”,
then operate the throttle while pushing the start switch. (If the display
value changes, the performance is
OK.)
Intake air temperature
Displays the intake air temperature.
Compare the actually measured
intake air temperature with the FI
diagnostic tool.
Coolant temperature
Displays the coolant temperature.
Compare the actually measured coolant temperature with the FI diagnostic
tool.
Vehicle speed pulse
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.
D05
D06
D07
Lean angle sensor
D08
• Upright
0.4 ~ 1.4
• Overturned
3.7 ~ 4.4
Fuel system voltage
(battery voltage)
Approximately 12.0
Remove the lean angle sensor and
incline it more than 65 degrees.
Set the engine stop switch to “RUN”,
and then compare with the actually
measured battery voltage. (If the battery voltage is lower, perform recharging.)
D09
Neutral switch
D21
D60
Shift the transmission.
• Neutral
ON
• In gear
OFF
EEPROM fault code display
—
• No history
00
• History exists
01
Malfunction history code
display
—
• No history
00
• History exists
Fault codes 12-63
• (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.)
D61
Malfunction history code
erasure
D62
D70
• No history
0
—
• History exists
Up to 15 fault codes
To erase the history, set the engine
stop switch to “OFF” and then to
“RUN”.
Control number
00 ~ 255
—
6 - 10
FI
FUEL INJECTION SYSTEM
Actuator operation table
• Actuator operation
Set the engine stop switch to “OFF” and then to “RUN”.
Diagnostic code
No.
Item
Actuation
Checking method
D30
Ignition coil
Actuates the ignition coil for five times every second.
Illuminates the “WARNING” on the FI diagnostic tool
and engine trouble warning light.
Check the spark five times.
• Connect an ignition checker.
D36
Injector
Actuates the injector for five times every second.
Illuminates the “WARNING” on the FI diagnostic tool
and engine trouble warning light.
Check the operating sound of the
injector five times.
D50
Fuel pump relay
Actuates the fuel pump relay for five times every
second.
Illuminates the “WARNING” on the FI diagnostic tool
and 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).
Check the operating sound of the fuel
pump relay five times.
D51
Radiator fan motor relay
Actuates the radiator fan motor relay for five cycles
of five seconds. (ON 2 seconds, OFF 3 seconds)
Illuminates the engine trouble warning light.
Check the operating sound of the
radiator fan motor relay five times.
Communication error with the FI diagnostic tool
LCD Display
Symptom
Probable cause of malfunction
Waiting for connection....
No signals are received from the
ECU.
•
•
•
•
Improper connection in connecting lead.
The main switch is OFF position.
Malfunction in FI diagnostic tool.
Malfunction in ECU.
ERROR 4
Commands from the FI diagnostic
tool are not accepted by the ECU.
• Turn the main switch to “OFF” once, and then set the FI diagnostic tool to CO adjustment mode or diagnostic mode.
• Vehicle battery is insufficiently charged.
• Malfunction in FI diagnostic tool.
• Malfunction in ECU.
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the FI diagnostic
tool. 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 FI diagnostic
tool display according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the FI diagnostic tool when the engine failed to work normally.
Refer to “Diagnostic code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”.
6 - 11
FUEL INJECTION SYSTEM
Fault code No.
12
FI
Symptom No normal signals are received from the crankshaft position sensor.
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of crankshaft
position sensor.
Check for looseness or pinching.
Cranking the
engine.
2
Connections
• Crankshaft position sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• 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.
(blue/yellow–blue/yellow)
(black/blue–black/blue)
4
Defective crankshaft position sensor.
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 8.
6 - 12
FUEL INJECTION SYSTEM
Fault code No.
13
FI
Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No. D03
Intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Intake air pressure sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between intake air pressure sensor coupler and ECU coupler
(black/blue–black/blue)
(pink–pink)
(blue–blue)
3
Defective intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.D03)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE SENSOR”.
6 - 13
FUEL INJECTION SYSTEM
Fault code No.
14
FI
Symptom Intake air pressure sensor: hose system malfunction
(clogged or detached hose).
Diagnostic code No. D03
Intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Intake air pressure sensor hose
• Check the intake air pressure
sensor hose condition.
• Repair or replace the sensor
hose.
Starting the
engine and
operating it at
idle.
2
Intake air pressure sensor malfunction at intermediate electrical
potential.
• Check and repair the connection.
• Replace it if there is a malfunction.
3
Connections
• Intake air pressure sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
4
Defective intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.D03)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE SENSOR”.
6 - 14
FUEL INJECTION SYSTEM
Fault code No.
15
FI
Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No. D01
Throttle position sensor
Order Item/components and probable
cause
Check or maintenance job
1
Installed condition of throttle position sensor.
• Check for looseness or pinching. Turning the
• Check that the sensor is installed main switch to
in the specified position.
“ON”.
2
Connections
• Throttle position sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• 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 throttle position sensor
coupler and ECU coupler
(blue–blue)
(yellow–yellow)
(black/blue–black/blue)
4
Throttle position sensor lead wire
open circuit output voltage check.
• Check for open circuit and
replace the throttle position sensor.
(yellow–black/blue)
5
Defective throttle position sensor.
• Execute the diagnostic mode.
(Code No.D01)
• Replace if defective.
Refer to “CHECKING AND
ADJUSTING THE THROTTLE
POSITION SENSOR”.
6 - 15
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
16
FI
Symptom Stuck throttle position sensor detected.
Diagnostic code No. D01
Throttle position sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of throttle position sensor.
• Check the installed area for
looseness or pinching.
• Check that the throttle position
sensor is installed in the specified position.
Refer to “THROTTLE BODY”.
Reinstated by
starting the
engine, operating it at idle, and
then racing it.
2
Defective throttle position sensor.
• Execute the diagnostic monitoring mode.
(Code No.D01)
• Replace if defective.
Refer to “CHECKING AND
ADJUSTING THE THROTTLE
POSITION SENSOR”.
Fault code No.
21
Symptom Coolant temperature sensor: open or short circuit
detected.
Diagnostic code No. D06
Coolant temperature sensor
Order Item/components and probable
cause
Check or maintenance job
1
Installed condition of coolant temperature sensor.
2
Check the installed area for loose- Turning the
ness or pinching.
main switch to
“ON”.
• Check the coupler for any pins
Connections
• Coolant temperature sensor couthat may have pulled out.
pler
• Check the locking condition of
• Main wire harness ECU coupler
the coupler.
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 coolant temperature
sensor coupler and ECU coupler.
(black/blue–black/blue)
(black/yellow–black/yellow)
4
Defective coolant temperature
sensor.
• Execute the diagnostic mode.
(Code No.D06)
• Replace if defective.
Refer to “SIGNALING SYSTEM”
in chapter 8.
6 - 16
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
22
FI
Symptom Intake air temperature sensor: open or short circuit
detected.
Diagnostic code No. D05
Intake air temperature sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of air temperature sensor.
Check for looseness or pinching.
2
Connections
• Intake air temperature sensor
coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between air temperature sensor
coupler and ECU coupler
(brown/white–brown/white)
(black/white–black/blue)
4
Defective air temperature sensor.
• Execute the diagnostic mode.
(Code No.D05)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR TEMPERATURE
SENSOR”.
6 - 17
FUEL INJECTION SYSTEM
Fault code No.
30
FI
Symptom The vehicle has overturned.
Diagnostic code No. D08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
The vehicle has overturned.
Raise the vehicle upright.
2
Installed condition of the lean
angle sensor.
Check for looseness or pinching.
3
Connections
• Lean angle sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON” (however,
the engine cannot be restarted
unless the main
switch is first
turned “OFF”).
4
Defective lean angle sensor.
• Execute the diagnostic mode.
(Code No.D08)
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 8.
6 - 18
FUEL INJECTION SYSTEM
Fault code No.
33
FI
Symptom Malfunction detected in the primary lead of the ignition
coil.
Diagnostic code No. D30
Ignition coil
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Ignition coil connector (primary
coil side)
• Main wire harness ECU coupler
• Check the connector and coupler for any pins that may be
pulled out.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler or connector securely.
Starting the
engine and
operating it at
idle.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between ignition coil connector
and ECU coupler/main wire harness.
(red/black–red/black)
(orange–orange)
3
Defective ignition coil.
• Execute the diagnostic mode.
(Code No.D30)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 8.
6 - 19
FUEL INJECTION SYSTEM
Fault code No.
41
FI
Symptom Lean angle sensor: open or short circuit detected.
Diagnostic code No. D08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Lean angle sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
2
Open or short circuit in lead wire.
• Repair or replace if there is an
open or short circuit.
• Between lean angle sensor coupler and ECU coupler.
(blue–blue)
(yellow/green–yellow/green)
(black/blue–black/blue)
3
Defective lean angle switch.
• Execute the diagnostic mode.
(Code No.D08)
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 8.
6 - 20
FUEL INJECTION SYSTEM
Fault code No.
42
FI
Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A
D07 Speed sensor
B
D21 Neutral switch
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
A-1
Connections
• Speed sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
A-2
Open or short circuit in speed sen- • Repair or replace if there is an
sor lead.
open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white–white)
(black/blue–black/blue)
Starting the
engine, and
activating the
vehicle speed
sensor by operating the vehicle at 20 to 30
km/h.
A-3
Gear for detecting vehicle speed
has broken.
• Replace if defective.
Refer to “TRANSMISSION” in
chapter 4.
A-4
Defective speed sensor.
• Execute the diagnostic mode.
(Code No.D07)
• Replace if defective.
Refer to “CHECKING THE
SPEED SENSOR”.
6 - 21
FUEL INJECTION SYSTEM
Fault code No.
42
FI
Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A
D07 Speed sensor
B
D21 Neutral switch
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
B-1
Connections
• Neutral switch coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
B-2
Open circuit in neutral switch lead. • Repair or replace if there is an
open circuit.
• Between neutral switch connector and relay unit coupler.
(sky blue–sky blue)
• Between relay unit coupler and
ECU coupler.
(light green–brown)
(black/yellow–sky blue)
Starting the
engine, and
activating the
vehicle speed
sensor by operating the vehicle at 20 to 30
km/h.
B-3
Faulty shift drum (neutral detection • Replace if defective.
area).
Refer to “TRANSMISSION” in
chapter 4.
B-4
Defective neutral switch.
• Execute the diagnostic mode.
(Code No.D21)
• Replace if defective.
Refer to “CHECKING THE
SWITCHES” in chapter 8.
6 - 22
FUEL INJECTION SYSTEM
Fault code No.
43
FI
Symptom The ECU is unable to monitor the battery voltage (an
open or short circuit in the line to the ECU).
Diagnostic code No. D09
Fuel system voltage
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Relay unit coupler (fuel pump
relay)
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Starting the
engine and
operating it at
idle.
2
Open or short circuit in the wire
harness.
• Repair or replace if there is an
open or short circuit.
• Between relay unit coupler and
ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
• Between relay unit coupler and
battery terminal.
(brown/green–red)
• Between relay unit coupler and
handlebar switch coupler.
(red/black–red/black)
3
Malfunction or open circuit in fuel
pump relay.
• Execute the diagnostic mode.
(Code No.D09)
• Replace if defective.
• If there is no malfunction with the
relay unit, replace the ECU.
Fault code No.
44
Symptom Error is detected while reading or writing on EEPROM
(CO adjustment value).
Diagnostic code No. D60
EEPROM improper cylinder indication
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
• Execute the diagnostic mode.
(Code No.D60)
1. Check the faulty cylinder.
• Replace ECU if defective.
Turning the
main switch to
“ON”.
Malfunction in ECU.
6 - 23
FUEL INJECTION SYSTEM
Fault code No.
46
FI
Symptom Power supply to the fuel injection system is not normal.
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Starting the
engine and
operating it at
idle.
2
Faulty battery.
• Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” in
chapter 3.
3
Malfunction in rectifier/regulator
• Replace if defective.
Refer to “CHARGING SYSTEM”
in chapter 8.
4
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)
• Between main switch and ignition fuse
(brown/blue–brown/blue)
• Between ignition fuse and ECU
(brown–brown)
Fault code No.
50
Symptom Faulty ECU memory. (When this malfunction is detected
in the ECU, the fault code number might not appear on
the meter.)
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
1
Replace the ECU.
Malfunction in ECU.
Reinstatement
method
Turning the
main switch to
NOTE:
Do not perform this procedure with “ON”.
the main switch turned to “ON”.
6 - 24
FUEL INJECTION SYSTEM
FI
EAS28240
1
P O/R
B/W
L
W
CHECKING THE SPEED SENSOR
1. Check:
• speed sensor output voltage
Out of specification → Replace.
B/L
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe → white 1
Negative tester probe → black/blue 2
b. Turn the main switch to “ON”.
c. Elevate the rear wheels and slowly rotate
them.
d. Measure the voltage of white and black/
blue. With each full rotation of the rear
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 25
FUEL INJECTION SYSTEM
FI
EAS28410
2
1
B/L P/L L
CHECKING THE INTAKE AIR PRESSURE
SENSOR
1. Check:
• intake air pressure sensor output voltage
Out of specification → Replace.
Intake pressure sensor output
voltage
3.00 ~ 4.00 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
pink/blue terminal 1
Negative tester probe →
black/blue terminal 2
b. Turn the main switch to “ON”.
c. Measure the intake air pressure sensor output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 26
FUEL INJECTION SYSTEM
FI
CHECKING THE INTAKE AIR
TEMPERATURE SENSOR
1. Remove:
• air temperature sensor
Br/W B/W
WARNING
_
2
1
• Handle the air temperature sensor with
special care.
• Never subject the air temperature sensor
to strong shocks. If the air temperature
sensor is dropped, replace it.
2. Check:
• air temperature sensor resistance
Out of specification → Replace.
Intake air temperature sensor
resistance
2.21 ~ 2.69 kΩ at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
air temperature sensor terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe → brown/white 1
Negative tester probe → black/white 2
b. Measure the air temperature sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 27
FI
THROTTLE BODY
EAS00909
THROTTLE BODY
T.
R.
3 Nm (0.3 m • kg, 2.2 ft • Ib)
13 14
6
3
12
2
11
8
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
1
4
5
9
7 10
15
Order
Job/Part
Removing the throttle body
Fuel tank shield
Q’ty
Coolant
1
2
3
4
5
6
7
8
Fuel hose
Fuel injector coupler
Intake air pressure sensor coupler
Throttle position sensor coupler
Throttle cable housing cover
Throttle cable
Hose (air-filter-joint-to-throttle-bodyleft-side)
Hose (air-filter-joint-to-throttle-bodyright-side)
1
1
1
1
1
1
1
1
6 - 28
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
FI
THROTTLE BODY
T.
R.
3 Nm (0.3 m • kg, 2.2 ft • Ib)
13 14
6
3
12
2
11
8
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
1
4
9
5
7 10
15
Order
9
10
11
12
13
14
15
Job/Part
Fast idle plunger inlet hose
Fast idle plunger outlet hose
Intake air pressure sensor hose
Intake air pressure sensor
Intake manifold clamp screw
Air filter case joint clamp screw
Throttle body assembly
Q’ty
Remarks
1
1
Disconnect.
1
1
1
Loosen.
1
Loosen.
1
For installation, reverse the removal procedure.
6 - 29
THROTTLE BODY
FI
EAS00910
2
3
1
5
4
Order
1
2
3
4
5
Job/Part
Removing the injector
Throttle position sensor
Fuel injection pipe
Fuel injector
Fast idle plunger unit
Throttle body
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
CAUTION:
_
The throttle body should not be disassembled.
For installation, reverse the removal procedure.
6 - 30
THROTTLE BODY
FI
EAS00912
CHECKING THE INJECTOR
1. Check:
• injector
Damage → Replace.
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
• throttle body
Cracks/damage → Replace the throttle
body.
2. Check:
• fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
b
INSTALLING THE THROTTLE BODY
ASSEMBLY
1. Install:
• throttle body assembly
NOTE:
Align the projection a on the throttle body
assembly with the slot b throttle body joint.
2.
•
3.
•
Install:
throttle cable
Adjust:
throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY” in chapter 3.
4. Adjust:
• engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.
6 - 31
THROTTLE BODY
FI
5. Check:
• throttle position sensor
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR”.
EAS00915
2
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
1
1
3
4
1
a. Remove the fuel tank top panel.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
b. Remove the fuel hose connector cover and
fuel hose retainer.
c. Disconnect the fuel hose 1 from the fuel
pump.
NOTE:
• When removing the fuel hose from the fuel
pump, remove the fuel hose connector
holder first, and next, insert a slotted head
screw driver etc. in the slot part a of the fuel
hose connector cover 2, then slide it in the
direction of the arrow, and remove the fuel
hose.
• Before removing the hose, place a few rags
in the area under where it will be removed.
d. Connect the pressure gauge 3 and adapter
4 to the fuel pump and fuel hose.
Pressure gauge
90890-03153, YU-03153
Fuel pressure adapter
90890-03176, YM-03176
e. Start the engine.
f. Measure the fuel pressure.
Fuel pressure
324 kPa (3.24 kg/cm2, 46.1 psi)
Out of specification → Replace the fuel
pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 32
THROTTLE BODY
FI
EAS00916
2 3 1
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor,
the engine idling speed should be properly
adjusted.
_
B/L Y L
1. Check:
• throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from
the throttle body.
c. Connect the pocket tester (Ω × 1k) to the
terminals of the throttle position sensor.
Positive tester probe → blue 1
Negative tester probe → black/blue 2
d. Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 kΩ at 20 °C (68 °F)
(blue-black/blue)
e. Connect the pocket tester (Ω × 1k) to the
terminals of the throttle position sensor.
Positive tester probe → yellow 3
Negative tester probe → black/blue 2
f. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
Resistance does not change or it changes
abruptly → Replace the throttle position
sensor.
6 - 33
THROTTLE BODY
FI
Slot is worn or broken → Replace the throttle position sensor.
NOTE:
Check mainly that the resistance changes
gradually when opening the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
_
1
2
B/L Y L
Throttle position sensor resistance
0 ~ 5 ± 1 kΩ at 20 °C (68 °F)
(yellow-black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
2. Adjust:
• throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the throttle position sensor coupler
to the wire harness.
b. Connect the digital circuit tester to the throttle position sensor.
Positive digital circuit tester probe →
yellow 1
Negative digital circuit tester probe →
black/blue 2
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
that the voltage is within the specified
range.
Throttle position sensor voltage
0.63 ~ 0.73 V (yellow-black/blue)
e. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws 3.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 34
FRONT AND REAR WHEELS
CHAS
EBS00378
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS
Order
Job/Part
Removing the front wheels
Q’ty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front wheels.
Place the vehicle on a level surface.
WARNING
_
Securely support the vehicle so there
is no danger of it falling over.
1
2
3
4
Front wheel
Brake disc guard (outer)
Cotter pin
Axle nut
1
1
1
1
7-1
Refer to “INSTALLING THE FRONT
WHEELS”.
Refer to “INSTALLING THE FRONT
WHEEL HUBS”.
FRONT AND REAR WHEELS
Order
5
Job/Part
Brake caliper assembly
CHAS
Q’ty
Remarks
1
NOTE:
Do not squeeze the brake lever when the
brake caliper is off of the brake discs as
the brake pads will be forced shut.
_
6
7
Wheel hub
Brake disc
1
1
For installation, reverse the removal procedure.
7-2
7
FRONT AND REAR WHEELS
CHAS
REAR WHEELS
Order
Job/Part
Removing the rear wheels
Q’ty
Remarks
Remove the parts in the order listed.
Place the vehicle on a level surface.
WARNING
_
Securely support the vehicle so there
is no danger of it falling over.
1
2
3
4
Rear wheel
Cotter pin
Axle nut
Wheel hub
2
2
2
2
Refer to “INSTALLING THE REAR
WHEEL HUBS”.
For installation, reverse the removal procedure.
7-3
FRONT AND REAR WHEELS
CHAS
EBS00383
CHECKING THE WHEELS
1. Check:
• wheels
2. Measure:
• wheel runout
Over the specified limit → Replace the
wheel or check the wheel bearing play 1.
Wheel runout limit
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
3. Check:
• wheel balance
Out of balance → Adjust.
WARNING
_
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in vehicle damage and possible
operator injury.
EBS00385
È
CHECKING THE WHEEL HUBS
1. Check:
• wheel hubs 1
Cracks/damage → Replace.
• splines (wheel hub) 2
Wear/damage → Replace the wheel hub.
È Front
É Rear
É
7-4
FRONT AND REAR WHEELS
CHAS
2. Check:
• wheel bearings
Wheel hub play/wheel turns roughly →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean wheel hub exterior.
b. Drive bearing out by pushing spacer aside
and tapping around perimeter of bearing
inner race. Use a soft metal drift punch and
a hammer. The spacer 1 “floats” between
bearings. Remove both bearings as
described.
1
WARNING
_
Eye protection is recommended when
using striking tools.
c. To install the wheel bearings, reverse the
above sequence. Use a socket that
matches outside diameter of bearing outer
race to drive in bearing.
CAUTION:
_
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00389
CHECKING THE BRAKE DISCS
1. Check:
• brake discs
Galling/damage → Replace.
2. Measure:
• brake disc deflection
Out of specification → Check the wheel
runout.
Brake disc maximum deflection
Front: 0.15 mm (0.006 in)
Rear: 0.15 mm (0.006 in)
• brake disc thickness a
Out of specification → Replace.
Brake disc minimum thickness
3 mm (0.12 in)
7-5
FRONT AND REAR WHEELS
CHAS
INSTALLING THE FRONT WHEEL HUB
BEARINGS
1. Install:
• bearings 1
NOTE:
Face the oil seal side of the bearing inward.
INSTALLING THE FRONT BRAKE DISCS
1. Install:
• brake discs
NOTE:
Install the brake discs with their spot-faced
side facing the bolt heads.
EBS00392
INSTALLING THE FRONT WHEELS
1. Install:
• brake disc guards (outer) 1
NOTE:
Install the brake disc guard (outer) with the
punched burrs 2 on the wheel hub side.
_
2. Install:
• wheels
NOTE:
The arrow mark 1 on the tire must point in the
direction of rotation È of the wheel.
_
7-6
FRONT AND REAR WHEELS
CHAS
EBS00390
INSTALLING THE FRONT WHEEL HUBS
1. Install:
• front axle nuts 1
T.
R.
70 Nm (7.0 m · kg, 50 ft · lb)
• cotter pins 2 New
NOTE:
Do not loosen the axle nut after torquing it. If
an axle nut slot is not aligned with the cotter
pin hole on either side of the axle, further
tighten the axle nut until a slot is aligned with
the hole.
_
INSTALLING THE REAR WHEEL HUBS
1. Install:
• rear axle washers 1 New
• rear axle nuts 2 New
• cotter pins 3 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a rust preventive lubricant to the
threads on both sides of the rear axle and to
the wheel hub surfaces that contact the rear
axle washers.
b. Tighten the rear axle nuts to specification.
T.
Rear axle nut
200 Nm (20.0 m · kg, 145 ft · lb)
R.
c. Loosen the rear axle nuts completely.
d. Retighten the rear axle nuts to specification.
T.
Rear axle nut
200 Nm (20.0 m · kg, 145 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
Do not loosen the axle nut after torquing it. If
an axle nut slot is not aligned with the cotter
pin hole on either side of the axle, further
tighten the axle nut until a slot is aligned with
the hole.
7-7
REAR AXLE AND REAR AXLE HUB
CHAS
EBS00382
REAR AXLE AND REAR AXLE HUB
Order
1
2
3
4
5
Job/Part
Removing the rear axle and rear axle
hub
Rear wheels/rear wheel hubs
Bolt
Nut
Conical spring washer
Rear axle pinch bolt
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT AND REAR WHEELS”.
2
1
1
4
1
Refer to “REMOVING THE REAR
AXLE” and “INSTALLING THE REAR
AXLE”.
NOTE:
Do not apply the brake pedal and do not
use the parking brake when the brake
caliper is off of the brake disc as the
brake pad will be force shut.
_
7-8
REAR AXLE AND REAR AXLE HUB
Order
6
7
8
9
10
11
12
13
14
15
16
17
Job/Part
Brake disc/brake disc bracket
Rear axle
Circlip
Driven sprocket/sprocket bracket
Circlip
Brake caliper bracket
Spacer
Rear axle hub
Oil seal
Bearing
Bearing
Spacer
CHAS
Q’ty
Remarks
1/1
Refer to “REMOVING THE REAR
1
AXLE”.
1
1/1 Refer to “INSTALLING THE DRIVEN
SPROCKET”.
1
1
1
1
2
2
2
1
For installation, reverse the removal procedure.
7-9
REAR AXLE AND REAR AXLE HUB
CHAS
REMOVING THE REAR BRAKE CALIPER
NOTE:
If the rear brake caliper cannot be removed
easily, first remove the brake pad, next remove
the caliper.
EBS00393
2
REMOVING THE REAR AXLE
1. Place the vehicle on a level surface.
2. Remove:
• bolts 1
3. Loosen:
• nut 2
NOTE:
• Apply the brake pedal so that the rear axle
does not turn, when loosening the nut.
• Use the rear axle nut wrench 46 mm 3.
1
_
3
Rear axle nut wrench (46 mm)
90890-01498
Axle nut wrench (46 mm)
YM-37134
2
4. Loosen:
• drive chain
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
5. Elevate the rear wheels by placing the suitable stand under the frame.
6. Remove:
• rear wheels
• wheel hubs
• nut 2
• conical spring washer
7 - 10
REAR AXLE AND REAR AXLE HUB
CHAS
7. Remove:
• rear axle 1
(with driven sprocket)
CAUTION:
_
1
• Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
• Attach a suitable socket 2 on the axle
end and tap it with a soft hammer, then
pull out the rear axle to the left.
8. Remove:
• circlip
• driven sprocket bracket
EBS00395
CHECKING THE REAR AXLE
1. Check:
• rear axle runout a
Out of specification → Replace.
WARNING
_
Do not attempt to straighten a bent axle.
Rear axle runout limit
1.5 mm (0.06 in)
CHECKING THE DRIVEN SPROCKET
1. Check:
• driven sprocket
Refer to “SWINGARM AND DRIVE
CHAIN”.
7 - 11
REAR AXLE AND REAR AXLE HUB
CHAS
CHECKING THE BRAKE DISC
1. Check:
• brake disc
Refer to “FRONT AND REAR WHEELS”.
a
INSTALLING THE DRIVEN SPROCKET
1. Install:
• driven sprocket
NOTE:
Make sure that the blunt-edged corner a of
the driven sprocket is facing outward.
EBS00397
1
INSTALLING THE REAR AXLE
1. Install:
• conical spring washer 1
• nut
NOTE:
Install the conical spring washer with the convex side of the washer facing outward as
shown.
2. Install:
• rear wheels
Refer to “FRONT AND REAR WHEELS”.
7 - 12
REAR AXLE AND REAR AXLE HUB
CHAS
3. Tighten:
• nut 1
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the nut with rear axle nut wrench
46 mm 2 to specification while holding the
rear axle.
Rear axle nut wrench (46 mm)
90890-01498
Axle nut wrench (46 mm)
YM-37134
3
1
T.
R.
Nut
240 Nm (24.0 m · kg, 170 ft · lb)
LOCTITE®
b. Tighten bolts 3.
T.
3
R.
Bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
LOCTITE®
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
7 - 13
CHAS
FRONT AND REAR BRAKES
EBS00400
FRONT AND REAR BRAKES
FRONT BRAKE PADS
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
2
4
LT
3
1
1
T.
R.
Order
1
2
3
4
28 Nm (2.8 m • kg, 20 ft Ib)
Job/Part
Removing the front brake pads
Front wheel
Brake caliper mounting bolt
Brake pad retaining bolt
Brake pad/pad shim
Brake pad spring
Q’ty
2
2
2/1
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “FRONT AND REAR WHEELS”.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
7 - 14
FRONT AND REAR BRAKES
CHAS
EBS00401
REAR BRAKE PADS
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
2
4
LT
3
1
T.
R.
Order
1
2
3
4
Job/Part
Removing the rear brake pads
Brake caliper mounting bolt
Brake pad retaining bolt
Brake pad/insulator/pad shim
Brake pad spring
34 Nm (3.4 m • kg, 24 ft • Ib)
Q’ty
2
2
2/1/1
1
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE REAR
BRAKE PADS”.
For installation, reverse the removal procedure.
7 - 15
FRONT AND REAR BRAKES
CHAS
EBS00402
CAUTION:
_
Disc brake components rarely require disassembly.
DO NOT:
• disassemble components unless absolutely necessary;
• use solvents on internal brake components;
• use spent brake fluid for cleaning; (use
only clean brake fluid)
• allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
• splash brake fluid onto painted surfaces
or plastic parts, as this may cause damage;
• disconnect any hydraulic connection, as
this would require the entire brake system to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
EBS00404
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both of the
front brake calipers.
NOTE:
It is not necessary to disassemble the brake
calipers and brake hoses to replace the brake
pads.
_
1. Remove:
• brake pads
a Wear limit
NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.
_
7 - 16
FRONT AND REAR BRAKES
CHAS
2. Install:
• brake pads
• brake pad spring
NOTE:
Always install new brake pads and brake pad
spring as a set.
_
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper pistons into
the brake caliper.
c. Tighten the brake caliper bleed screw.
T.
Brake caliper bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
R.
d. Install new brake pads and a new brake pad
spring.
e. Install the retaining bolts and brake caliper.
T.
R.
Brake pad retaining bolt
17 Nm (1.7 m · kg, 12 ft · lb)
Brake caliper mounting bolt
28 Nm (2.8 m · kg, 20 ft · lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 17
FRONT AND REAR BRAKES
CHAS
EBS00405
REPLACING THE REAR BRAKE PADS
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
_
1. Remove:
• brake pads
a wear limit
NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.
_
2. Install:
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.
_
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw, and
then turn the brake caliper piston 3 clockwise until section a of the brake caliper piston is level with the surface of the brake
caliper body.
2
NOTE:
Align the recesses b in the brake caliper piston with the brake caliper body as shown in the
illustration.
3
c. Tighten the brake caliper bleed screw.
T.
3
R.
a
b
7 - 18
Brake caliper bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
FRONT AND REAR BRAKES
CHAS
d. Install new brake pads, a new insulator, a
new pad shim, a new pad spring, and the
rear brake caliper.
NOTE:
Align the projection c on the piston side of the
brake pad with the lower recess in the brake
caliper piston.
c
e. Install the retaining bolts and brake caliper.
T.
R.
Brake pad retaining bolt
17 Nm (1.7 m · kg, 12 ft · lb)
Brake caliper mounting bolt
34 Nm (3.4 m · kg, 24 ft · lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4. Check:
• brake lever or brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 19
FRONT AND REAR BRAKES
CHAS
EBS00407
FRONT BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the front brake master
cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm
Front brake light switch
Brake lever
Union bolt
Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
2
1
1
1
Disconnect.
Refer to “INSTALLING
THE FRONT BRAKE
MASTER CYLINDER”.
For installation, reverse the removal procedure.
7 - 20
FRONT AND REAR BRAKES
CHAS
EBS00409
Order
1
2
3
Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Q’ty
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE FRONT
BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.
7 - 21
FRONT AND REAR BRAKES
CHAS
EBS00410
REAR BRAKE MASTER CYLINDER
T.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
R.
T.
2
7
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
3
4
5
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
8 New
9
10
1
6
11
New
LS
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
13
12
T.
R.
78 Nm (7.8 m • kg, 56 ft • lb)
T.
R.
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Right foot protector
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Brake fluid
Drain.
Brake fluid reservoir hose cover
1
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
7 - 22
FRONT AND REAR BRAKES
CHAS
T.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
R.
T.
2
7
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
3
4
5
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
8 New
9
10
1
6
11
New
LS
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
13
12
T.
R.
78 Nm (7.8 m • kg, 56 ft • lb)
T.
R.
Order
7
8
9
10
11
12
13
Job/Part
Union bolt
Copper washer
Brake hose
Brake master cylinder
Rear brake light switch
Right footrest
Brake pedal/spring
Q’ty
Remarks
1
Refer to “INSTALLING
2
THE REAR BRAKE MAS1
Disconnect.
TER CYLINDER”.
1
1
1
1/1
For installation, reverse the removal procedure.
7 - 23
FRONT AND REAR BRAKES
CHAS
EBS00411
Order
1
2
3
Job/Part
Disassembling the rear brake master cylinder
Hose joint
Brake master cylinder kit
Brake master cylinder
Q’ty
1
1
1
7 - 24
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE REAR
BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.
FRONT AND REAR BRAKES
CHAS
EBS00446
REMOVING THE FRONT BRAKE LIGHT
SWITCH
1. Remove:
• front brake light switch 1
NOTE:
Push the fastener when removing the front
brake light switch out of the brake master cylinder.
_
EBS00413
È
CHECKING THE MASTER CYLINDERS
1. Check:
• brake master cylinder 1
Wear/scratches → Replace the brake master cylinder assembly.
• brake master cylinder body
Cracks/damage → Replace.
• brake fluid delivery passage
(brake master cylinder body)
Blockage → Blow out with compressed air.
É
È
È Front
É Rear
É
2. Check:
• brake master cylinder kit
Scratches/wear/damage → Replace as a
set.
È Front
É Rear
3. Check:
• front brake master cylinder reservoir 1
• front brake master cylinder reservoir diaphragm 2
Cracks/damage → Replace.
7 - 25
FRONT AND REAR BRAKES
CHAS
4. Check:
• rear brake fluid reservoir 1
• rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
EBS00415
ASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Whenever a master cylinder is disassembled, replace the piston seals and dust
seals.
EBS00416
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Whenever a master cylinder is disassembled, replace the piston seals and dust
seals.
7 - 26
FRONT AND REAR BRAKES
CHAS
EBS00418
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• brake master cylinder 1
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• The “UP” mark on the brake master cylinder
bracket should face up.
• Install the brake master cylinder so that the
gaps between the brake master cylinder and
the brake master cylinder bracket are equal.
_
Install:
copper washers New
brake hose
27 Nm (2.7 m · kg, 19 ft · lb)
union bolt
T.
R.
2.
•
•
•
NOTE:
• Tighten the union bolt while holding the
brake hose as shown.
• Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
_
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
7 - 27
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake master cylinder reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful reaction and lead to poor brake performance.
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7 - 28
FRONT AND REAR BRAKES
EBS00419
a
1
2
CHAS
T.
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• copper washers New
• brake hose 1
30 Nm (3.0 m · kg, 22 ft · lb)
• union bolt 2
R.
b
CAUTION:
_
When installing the brake hose onto the
brake master cylinder, make sure the brake
hose is installed between the stoppers a
and b on brake master cylinder as shown.
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
2. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
7 - 29
FRONT AND REAR BRAKES
CHAS
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
• brake pedal height
Out of specification → Adjust.
Brake pedal height
15.3 mm (0.60 in)
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
7 - 30
FRONT AND REAR BRAKES
CHAS
EBS00421
FRONT BRAKE CALIPERS
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
LT
4
6
5
3
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
2 New
1
T.
R.
Order
1
2
3
4
5
6
27 Nm (2.7 m • kg, 19 ft • Ib)
Job/Part
Removing the front brake calipers
Brake fluid
Front wheel
Union bolt
Copper washer
Brake hose
Brake pad retaining bolt
Brake caliper mounting bolt
Brake caliper assembly
Q’ty
1
2
1
2
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Drain.
Refer to “FRONT AND REAR WHEELS”.
Disconnect.
Loosen.
Refer to “INSTALLING
THE FRONT BRAKE
CALIPERS”.
For installation, reverse the removal procedure.
7 - 31
CHAS
FRONT AND REAR BRAKES
EBS00423
3
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
1
2
8
New
7
6
5
4
LT
New
LS
Order
Job/Part
Disassembling the front brake calipers
Q’ty
1
2
3
4
5
6
7
Brake pad retaining bolt
Brake pad/pad shim
Brake pad spring
Caliper bracket
Caliper piston
Dust seal
Caliper piston seal
2
2/1
1
1
2
2
2
8
Bleed screw
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “DISASSEMBLING THE
FRONT BRAKE CALIPERS” and
“ASSEMBLING THE FRONT BRAKE
CALIPERS”.
1
For assembly, reverse the disassembly
procedure.
7 - 32
FRONT AND REAR BRAKES
CHAS
EBS00424
REAR BRAKE CALIPER
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
2
4
T.
R.
34 Nm (3.4 m • kg, 24 ft • Ib)
5
3 New
1
5
6
Order
1
2
3
4
5
6
Job/Part
Removing the rear brake caliper
Brake fluid
Parking brake cable
Union bolt
Copper washer
Brake hose
Brake caliper mounting bolt
Brake caliper assembly
Q’ty
1
1
2
1
2
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
Disconnect.
Refer to “INSTALLING
THE REAR BRAKE CALIPER”.
For installation, reverse the removal procedure.
7 - 33
FRONT AND REAR BRAKES
CHAS
EBS00425
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
Job/Part
Disassembling the rear brake caliper
Adjusting bolt
Locknut
Parking brake arm
Parking brake shaft
Rubber boot
Parking brake bracket mounting bolt
Parking brake case bracket
Parking brake case
Gasket
Brake pad retaining bolt
Brake pad/insulator/pad shim
Brake pad spring
Caliper bracket
Q’ty
1
1
1
1
1
1
1
1
1
2
2/1/1
1
1
7 - 34
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE REAR
BRAKE CALIPER”.
FRONT AND REAR BRAKES
Order
D
E
F
G
Job/Part
Brake caliper piston
Dust seal
Caliper piston seal
Bleed screw
Q’ty
1
1
1
1
CHAS
Remarks
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER” and “ASSEMBLING
THE REAR BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
7 - 35
FRONT AND REAR BRAKES
CHAS
REMOVING THE REAR BRAKE CALIPER
NOTE:
If the rear brake caliper cannot be removed
easily, first remove the brake pad, next remove
the caliper.
EBS00427
1
2
DISASSEMBLING THE FRONT BRAKE
CALIPERS
1. Remove:
• brake caliper pistons
• dust seals 1
• caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
WARNING
_
• Never try to pry out the caliper piston.
• Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the caliper cylinder.
b. Remove the dust seals and the caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 36
FRONT AND REAR BRAKES
1
CHAS
DISASSEMBLING THE REAR BRAKE
CALIPER
1. Remove:
• brake caliper piston 1
• dust seal 2
• caliper piston seal 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the brake caliper piston counterclockwise to remove it.
WARNING
Never try to pry out the caliper piston.
3
2
b. Remove the dust seal and caliper piston
seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00429
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
Brake pads
As required
Piston seals, dust
seals
Every two years
Brake hoses
Every four years
Brake fluid
Replace when
brakes are
disassembled.
WARNING
_
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
7 - 37
FRONT AND REAR BRAKES
È
2
1
2
3
1
É
1
CHAS
1. Check:
• brake caliper pistons 1
Scratches/rust/wear → Replace the brake
caliper assembly.
• brake caliper cylinders 2
Wear/scratches → Replace the brake caliper assembly.
• brake caliper body 3
Cracks/damage → Replace.
• brake fluid delivery passage
(brake caliper body)
Blockage → Blow out with compressed air.
WARNING
_
3
2
Replace the caliper piston seals and dust
seals whenever the brake caliper is disassembled.
È Front
É Rear
EBS00431
ASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
front brake calipers.
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
2 New
1 New
• Replace the caliper piston seals whenever a brake caliper is disassembled.
1. Install:
• caliper piston seals 1 New
• dust seals 2 New
2. Install:
• brake caliper pistons 1
1
7 - 38
FRONT AND REAR BRAKES
CHAS
EBS00432
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Replace the caliper piston seal and dust
seal whenever a brake caliper is disassembled.
1 New
2 New
1. Install:
• caliper piston seal 1 New
• dust seal 2 New
1
1
a
1
b
c
2. Install:
• brake caliper piston 1
Turn the brake caliper piston clockwise until
section a of the brake caliper piston is level
with the surface of the brake caliper body.
NOTE:
Align an end b of the groove in the brake caliper piston with the punch mark c on the brake
caliper body.
3. Install:
• parking brake shaft 1
a
NOTE:
When installing the parking brake shaft, the
punch mark a should be between the marks
b with the parking brake shaft fully turned in.
b
1
2
a
b
1
4. Install:
• rubber boot 1
• parking brake arm 2
NOTE:
When installing the parking brake arm, turn the
parking brake shaft clockwise and align the
punch mark a on the parking brake arm with
the punch mark b on the parking brake shaft.
7 - 39
FRONT AND REAR BRAKES
CHAS
EBS00434
1
a
b
2
3 New
4
1
INSTALLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
front brake calipers.
1. Install:
• brake caliper assembly
• brake caliper mounting bolts 1
T.
R.
28 Nm (2.8 m · kg, 20 ft · lb)
T.
• brake hose 2
• copper washers 3 New
27 Nm (2.7 m · kg, 19 ft · lb)
• union bolt 4
R.
CAUTION:
_
When installing the brake hose on the
brake caliper, make sure that the brake
pipe a touches the projection b on the
brake caliper.
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
2. Fill:
• brake master cylinder reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
7 - 40
FRONT AND REAR BRAKES
CHAS
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Brake fluid level is below the “LOWER”
level line → Add the recommended brake
fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
EBS00436
2
a
1
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• brake caliper assembly
• brake caliper mounting bolts 1
4
T.
3 New
R.
34 Nm (3.4 m · kg, 24 ft · lb)
• brake hose 2
• copper washers 3 New
30 Nm (3.0 m · kg, 22 ft · lb)
• union bolt 4
T.
1
R.
CAUTION:
_
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
7 - 41
FRONT AND REAR BRAKES
CHAS
2. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Brake fluid level is below the “LOWER”
level line → Add the recommended brake
fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7 - 42
FRONT AND REAR BRAKES
CHAS
5. Adjust:
• parking brake cable end length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a.
b.
c.
d.
1
2
Loosen the locknut 1 and adjusting bolt 2.
Slide back the rubber cover 3.
Loosen the locknut 4.
Turn the adjusting nut 5 in direction b or
c until the specified brake cable end length
a is obtained.
Parking brake cable end length
58 ~ 60 mm (2.28 ~ 2.36 in)
b
3
c
e. Tighten the locknut 4.
f. Slowly turn the adjusting bolt 2 clockwise
until resistance is felt.
g. Tighten the locknut 1.
5 4
T.
Locknut
9 Nm (0.9 m · kg, 6.5 ft · lb)
R.
h. Set the parking brake lever and wait more
than 5 minutes.
i. Release the parking brake lever.
j. Repeat step (a) to (g).
k. Slide the rubber cover to its original position.
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 43
CHAS
STEERING SYSTEM
EBS00444
STEERING SYSTEM
HANDLEBAR
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
8
1
9
4
3
7
9
5
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
11
12
12
10
2
13
4
5
2
T.
R.
T.
R.
Order
Q’ty
1
2
3
Job/Part
Removing the handlebar
Handlebar cover
Plastic band
Front brake light switch
4
5
6
7
Brake master cylinder/holder
Throttle lever assembly/holder
Spacer
Clutch switch
1/1
1/1
1
1
8
9
10
Parking brake lever
Clutch lever/bracket
Handlebar switch
1
1/1
1
1
3
1
7 - 44
6
11
4 Nm (0.4 m • kg, 2.9 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE FRONT
BRAKE LIGHT SWITCH AND CLUTCH
SWITCH”.
Refer to “INSTALLING THE BRAKE
MASTER CYLINDER”.
Refer to “REMOVING THE FRONT
BRAKE LIGHT SWITCH AND CLUTCH
SWITCH”.
Refer to “INSTALLING THE CLUTCH
LEVER”.
CHAS
STEERING SYSTEM
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
8
1
4
3
7
9
9
5
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
11
12
12
10
2
13
4
5
2
T.
R.
T.
R.
Order
11
12
13
Job/Part
Handlebar grip
Handlebar holder
Handlebar
6
11
4 Nm (0.4 m • kg, 2.9 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
Remarks
2
Refer to “REMOVING THE HANDLEBAR
GRIPS” and “INSTALLING THE HANDLEBAR GRIPS”.
2
Refer to “INSTALLING THE HANDLEBAR”.
1
For installation, reverse the removal procedure.
7 - 45
STEERING SYSTEM
CHAS
EBS00446
REMOVING THE FRONT BRAKE LIGHT
SWITCH AND CLUTCH SWITCH
1. Remove:
• front brake light switch 1
• clutch switch
NOTE:
• Push the fastener when removing the front
brake light switch out of the brake master cylinder.
• Push the fastener when removing the clutch
switch out of the clutch lever holder.
_
EBS00447
REMOVING THE HANDLEBAR GRIPS
1. Remove:
• handlebar grips 1
NOTE:
Blow compressed air between the handlebar
and handlebar grip, and gradually push the
grip off the handlebar.
_
EBS00448
CHECKING THE HANDLEBAR
1. Check:
• handlebar 1
Bends/cracks/damage → Replace.
WARNING
_
Do not attempt to straighten a bent handlebar as this may dangerously weaken the
handlebar.
7 - 46
STEERING SYSTEM
CHAS
EBS00449
INSTALLING THE HANDLEBAR
1. Install:
• handlebar
• handlebar holders
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
NOTE:
• Install the handlebar within 3.3° from the horizontal line shown in the illustration.
• The upper handlebar holders should be
installed with the punched mark 1 forward
2.
_
CAUTION:
_
First tighten the bolt 3 on the front side of
the handlebar holder, and then tighten the
bolt 4 on the rear side.
EBS00450
INSTALLING THE HANDLEBAR GRIPS
1. Install:
• handlebar grips 1
NOTE:
• Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
• Install the handlebar grips to the handlebar
so that the arrow marks faces straight
upward.
_
7 - 47
STEERING SYSTEM
CHAS
EBS00452
1
2
INSTALLING THE CLUTCH LEVER
1. Install:
• handlebar switch 1
• clutch lever
• clutch lever bracket 2
NOTE:
Install the clutch lever bracket as shown.
_
a
a 53 ~ 54 mm (2.09 ~ 2.13 in)
EBS00453
a
INSTALLING THE BRAKE MASTER
CYLINDER
1. Install:
• brake master cylinder
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
• spacer
• throttle lever assembly
b
T.
R.
4 Nm (0.4 m · kg, 2.9 ft · lb)
NOTE:
• The “UP” mark on the brake master cylinder
bracket should face up.
• Engage the indentations a in the spacer
with the lobes b on the throttle lever assembly and brake master cylinder.
_
7 - 48
STEERING SYSTEM
CHAS
EBS00454
STEERING STEM
Order
Job/Part
Removing the steering stem
Front fender/fuel tank
Q’ty
1
Pitman arm
1
2
Lock washer
1
3
4
5
6
7
8
Steering stem bushing
Spacer
Oil seal
Steering stem
Oil seal
Oil seal
2
2
2
1
1
1
7 - 49
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
Refer to “INSTALLING THE PITMAN
ARM”.
Refer to “INSTALLING THE LOCK
WASHER”.
STEERING SYSTEM
Order
9
10
Job/Part
Bearing retainer
Bearing
CHAS
Q’ty
Remarks
1
Refer to “REMOVING THE BEARING
RETAINER” and “INSTALLING THE
BEARING RETAINER”.
1
For installation, reverse the removal procedure.
7 - 50
STEERING SYSTEM
CHAS
EBS00455
REMOVING THE BEARING RETAINER
1. Remove:
• bearing retainer
Damper rod holder (30 mm)
90890-01327, YM-01327
EBS00456
CHECKING THE STEERING STEM
1. Check:
• steering stem 1
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2. Check:
• oil seals 1 New
• steering stem bushings 2
Wear/damage → Replace.
EBS00457
INSTALLING THE BEARING RETAINER
1. Install:
• bearing retainer
T.
R.
65 Nm (6.5 m · kg, 47 ft · lb)
Damper rod holder (30 mm)
90890-01327, YM-01327
EBS00459
T.
INSTALLING THE LOCK WASHER
1. Install:
• lock washer New
23 Nm (2.3 m · kg, 17 ft · lb)
• bolts
2. Bend the lock washer tab along a flat side of
the bolts.
R.
New
7 - 51
STEERING SYSTEM
CHAS
T.
INSTALLING THE PITMAN ARM
1. Install:
• pitman arm
• washer
180 Nm (18.0 m · kg, 130 ft · lb)
• nut
• clip
R.
NOTE:
Make sure that the threads of the steering
stem, washers, nuts, and the installation surfaces of the pitman arm are free of grease and
oil.
_
7 - 52
STEERING SYSTEM
CHAS
EBS00460
TIE-RODS AND STEERING KNUCKLES
Order
1
2
3
4
5
6
7
Job/Part
Removing the tie-rods and steering
knuckles
Front wheel/brake disc
Front brake caliper
Brake disc guard (inner)
Tie-rod
Pitman arm
Front guard
Lower front arm
Upper front arm
Steering knuckle
Q’ty
1
2
1
1
1
1
1
7 - 53
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the tie-rods and steering knuckles.
Refer to “FRONT AND REAR WHEELS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “INSTALLING THE TIE-RODS”.
Refer to “REMOVING THE STEERING
KNUCKLES”.
For installation, reverse the removal procedure.
STEERING SYSTEM
CHAS
EBS00461
REMOVING THE STEERING KNUCKLES
1. Remove:
• steering knuckles 1
NOTE:
Use a general puller to separate the ball joint
2 and steering knuckle.
_
EBS00462
CHECKING THE TIE-RODS
1. Check:
• tie-rod free play and movement
Free play → Replace the tie-rod end.
Turns roughly → Replace the tie-rod end.
2. Check:
• tie-rods
Bends/damage → Replace.
EBS00464
CHECKING THE STEERING KNUCKLES
1. Check:
• steering knuckles
Damage/pitting → Replace.
EBS00465
INSTALLING THE TIE-RODS
1. Install:
• tie-rods (left and right)
T.
R.
25 Nm (2.5 m · kg, 18 ft · lb)
NOTE:
The tie-rod side which must be installed on the
outside has grooves 1.
_
2. Adjust:
• toe-in
Refer to “ADJUSTING THE TOE-IN” in
chapter 3.
7 - 54
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00468
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the front arms and front
shock absorber assemblies
Front wheel/brake disc
Front brake caliper
Steering knuckle
Nut/washer/bolt
Nut/bolt
Lower front arm
Nut/bolt
Upper front arm
Nut/bolt
Front shock absorber
Dust cover
Q’ty
1/1/1
2/2
1
1/1
1
1/1
1
6
7 - 55
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front arms and front shock
absorber assemblies.
Refer to “FRONT AND REAR WHEELS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “STEERING SYSTEM”.
Refer to “REMOVING THE FRONT
ARMS” and “INSTALLING THE FRONT
ARMS”.
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
Order
9
10
11
12
13
14
Job/Part
Spacer
Spacer
Bushing
Circlip
Rubber boot/boot retaining ring
Ball joint
Q’ty
1
2
6
1
1/1
1
CHAS
Remarks
For installation, reverse the removal procedure.
7 - 56
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00469
REMOVING THE FRONT ARMS
1. Check:
• front arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play È by moving
it from side to side.
If side play is noticeable, check the bushings.
b. Check the front arm vertical movement É
by moving it up and down.
If the vertical movement is tight or rough, or
if there is binding, check the bushings.
È
È
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• front arm
É
É
EBS00470
2
2
1
1
CHECKING THE FRONT ARMS
1. Check:
• front arms 1
Bends/damage → Replace.
2. Check:
• bushings 2
Wear/damage → Replace.
EBS00488
CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
1. Check:
• shock absorber
Oil leaks → Replace the front shock
absorber assembly.
• spring
Fatigue → Replace the front shock
absorber assembly.
Move the spring up and down.
7 - 57
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00472
CHECKING THE BALL JOINTS
The following procedure applies to both of the
front arm ball joints.
1. Check:
• ball joint (upper front arm)
Damage/pitting → Replace the upper front
arm.
Free play → Replace the front arm.
Turns roughly → Replace the upper front
arm.
2. Check:
• ball joint (lower front arm)
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the lower front arm.
b. Remove the circlip 1, boot retaining ring 2
and rubber boot 3.
Use the ball joint remover and installer set.
Ball joint remover
90890-01474, YM-01474
Ball joint remover attachment set
90890-01480
Ball joint adapter set
YM-01480
4
Body
5
Long bolt
6
Base
90890-01480
YM-01480
7
Remover
attachment
90890-01474
YM-01474
8
Installer spacer
90890-01480
YM-01480
9
Installer washer
90890-01474
YM-01474
90890-01474
YM-01474
c. Install the body 4, long bolt 5, base 6 and
attachment 7 onto ball joint.
d. Hold the body 4 in place while turning in
the long bolt 5 to remove the ball joint 0
from the lower front arm A.
e. Remove the ball joint remover.
7 - 58
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
f. Attach the assembled ball joint remover/
installer, new ball joint (with rubber boot and
retaining ring) B, installer spacer 8 and
installer washer 9 to the lower front arm A.
NOTE:
• Do not tap or damage the top of the ball joint.
• Installer spacer 8 must be aligned with the
projection on the head of the ball joint B.
_
g. Remove the ball joint remover.
h. Install a new circlip.
NOTE:
Always use a new ball joint set.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00473
1
LS
INSTALLING THE FRONT ARMS
The following procedure applies to both of the
front arms.
1. Install:
• upper front arm 1
T.
R.
38 Nm (3.8 m · kg, 27 ft · lb)
• lower front arm 2
T.
2
R.
55 Nm (5.5 m · kg, 40 ft · lb)
NOTE:
• Be sure to position the bolts (upper and
lower) so that the bolt head faces forward.
• Apply lithium-soap-based grease to the
grease nipple.
_
7 - 59
CHAS
REAR SHOCK ABSORBER AND RELAY ARM
EBS00484
REAR SHOCK ABSORBER AND RELAY ARM
LS
6
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
LS
2
2
New
6
LS
1
1
2
5
New
7
3
LS
New
LS
7
LS
New
10
10
New
12
15
1
3
12
9
LS
15
13
11
LS
New
12
4
8
15
15
LS
12
8
LS
14
T.
R.
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)
43 Nm (4.3 m • kg, 31 ft • Ib)
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
Order
1
2
3
4
5
6
7
4
Job/Part
Removing the rear shock absorber
and relay arm
Rear wheels
Self-locking nut/bolt/spacer
Self-locking nut/bolt/spacer
Self-locking nut/bolt
Self-locking nut/bolt
Rear shock absorber
Spacer/oil seal/bearing
Spacer/oil seal/bearing
Q’ty
Remarks
Remove the parts in the order below.
Refer to “REAR WHEELS”.
1/1/1 Refer to “REMOVING THE REAR
1/1/1 SHOCK ABSORBER”.
1/1
1/1
1
1/2/1
1/2/1
7 - 60
CHAS
REAR SHOCK ABSORBER AND RELAY ARM
LS
6
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
LS
2
2
New
6
LS
1
1
2
5
New
7
3
LS
New
LS
7
LS
New
10
10
New
12
15
1
3
12
9
LS
15
13
11
LS
New
12
4
8
15
15
LS
12
4
8
LS
14
T.
R.
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)
43 Nm (4.3 m • kg, 31 ft • Ib)
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
Order
8
9
10
11
12
13
14
15
Job/Part
Self-locking nut/bolt
Relay arm
Spacer/oil seal/bushing
Connecting arm
Dust cover
Spacer
Spacer
Bushing
Q’ty
Remarks
1/1
1
1/2/2 Refer to “INSTALLING THE RELAY ARM
AND CONNECTING ARM”.
1
4
1
1
4 Refer to “INSTALLING THE RELAY ARM
AND CONNECTING ARM”.
For installation, reverse the removal procedure.
7 - 61
REAR SHOCK ABSORBER AND RELAY ARM
CHAS
EBS00485
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
_
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, 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 and gas cylinder.
• Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
• Do not subject the rear shock absorber or
gas cylinder 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 or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EBS00486
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before disposing of a rear shock absorber and gas cylinder.
To release the gas pressure, press on the gas
valve needle with a suitable tool as shown,
until all of the gas is released (the hissing has
stopped).
WARNING
_
Wear eye protection to prevent eye damage
from released gas or metal chips.
7 - 62
REAR SHOCK ABSORBER AND RELAY ARM
CHAS
EBS00487
REMOVING THE REAR SHOCK ABSORBER
1. Remove:
• relay arm-to-rear shock absorber lower bolt
• rear shock absorber upper bolt
NOTE:
While removing the relay arm-to-rear shock
absorber lower bolt, hold the swingarm so that
it does not drop down.
_
EBS00488
CHECKING THE REAR SHOCK ABSORBER
1. Check:
• shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
• shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• spring
Fatigue → Replace the rear shock absorber
assembly.
Move the spring up and down.
• gas cylinder
Damage/gas leaks → Replace the rear
shock absorber assembly.
EBS00489
CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
Damage/wear → Replace.
• bushings
• spacers
• oil seals
Damage/pitting/scratches → Replace.
7 - 63
REAR SHOCK ABSORBER AND RELAY ARM
CHAS
INSTALLING THE RELAY ARM AND
CONNECTING ARM
1. Install:
• bushings 1
(to connecting arm)
NOTE:
Apply lithium-soap-based grease on the bushings when installing.
Installed depth of bushing a
1.0 mm (0.04 in)
2. Install:
• bushings 1
• oil seals 2 New
(to relay arm)
NOTE:
Apply lithium-soap-based grease on the bushings when installing.
Installed depth of bushing a
6.5 mm (0.26 in)
INSTALLING THE REAR SHOCK ABSORBER
1. Install:
• connecting arm
• relay arm
• rear shock absorber
NOTE:
When installing the rear shock absorber, lift up
the swingarm.
7 - 64
SWINGARM AND DRIVE CHAIN
CHAS
EBS00492
SWINGARM AND DRIVE CHAIN
Order
Job/Part
Removing the swingarm and drive
chain
Rear axle hub
Q’ty
Refer to “REAR AXLE AND REAR AXLE
HUB”.
Refer to “REAR SHOCK ABSORBER
AND RELAY ARM”.
Rear shock absorber
1
2
3
4
5
6
7
8
9
Rear axle pinch bolt
Dust seal
Swingarm skid plate
Drive chain guide 1
Pivot shaft nut
Pivot shaft
Swingarm
Drive sprocket cover
Drive chain guide 2
Remarks
Remove the parts in the order below.
4
1
1
1
1
1
1
1
1
7 - 65
Refer to “REMOVING THE SWINGARM”.
SWINGARM AND DRIVE CHAIN
Order
10
11
12
13
14
15
16
17
18
Job/Part
Drive sprocket nut
Lock washer
Drive sprocket
Drive chain
Dust cover/washer
Spacer
Oil seal
Bushing
Bearing
Q’ty
1
1
1
1
2/2
2
2
2
2
7 - 66
CHAS
Remarks
Refer to “INSTALLING THE DRIVE
SPROCKET”.
Refer to “INSTALLING THE SWINGARM”.
For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN
CHAS
EBS00493
NOTE:
Before removing the drive chain and the
sprockets, measure the drive chain slack and
a 15-link section of the drive chain.
EBS00494
REMOVING THE SWINGARM
1. Check:
• swingarm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the tightening torque of the pivot
shaft nut.
T.
Pivot shaft nut
100 Nm (10.0 m · kg, 72 ft · lb)
R.
b. Check the swingarm side play È by moving
it from side to side.
If side play is noticeable, check the spacers,
bearings, bushings and frame pivot.
c. Check the swingarm vertical movement É
by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the spacers, bearings, bushings and frame pivot.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2.
•
•
•
•
Remove:
pivot shaft nut
washer
pivot shaft
swingarm
EBS00495
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
7 - 67
SWINGARM AND DRIVE CHAIN
CHAS
2. Check:
• pivot shaft
Roll the axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent pivot
shaft.
3.
•
•
•
•
Clean:
pivot shaft
spacers
bearings
bushings
Recommended cleaning solvent
Kerosene
4. Check:
• spacers
• oil seals
Damage/wear → Replace.
• bearings
• bushings
Damage/pitting → Replace.
EBS00496
CHECKING THE DRIVE CHAIN
1. Measure:
• Measure the length of 15 links on the inner
side a and outer side b of the pin and calculate the length between pin centers.
• Length 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, drive sprocket and rear wheel
sprocket as a set.
15-link drive chain section limit
(maximum)
239.3 mm (9.42 in)
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.
_
7 - 68
SWINGARM AND DRIVE CHAIN
CHAS
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
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.
CAUTION:
_
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 internal parts, 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.
Don’t soak the drive chain in kerosene for
more than ten minutes. Kerosene will damage the O-rings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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
Cracks/damage/wear → Replace the drive
chain.
5. Lubricate:
• drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
7 - 69
SWINGARM AND DRIVE CHAIN
CHAS
6. Check:
• drive sprocket
• driven 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
EBS00497
b
a
INSTALLING THE SWINGARM
1. Install:
• bearings 1
• bushings 2
(to swingarm)
NOTE:
Apply the lithium-soap-based grease on the
bushings when installing.
_
1
2
2
1
Installed depth of bearing a
5 mm (0.20 in)
Installed depth of bushing b
9 mm (0.35 in)
EBS00498
2 New
2 1
3
1
INSTALLING THE DRIVE SPROCKET
1. Install:
• drive sprocket 1
• lock washer 2 New
• drive sprocket nut 3
T.
R.
3
85 Nm (8.5 m · kg, 61 ft · lb)
2. Bend the lock washer tab along a flat side of
the nut.
7 - 70
ELECTRICAL COMPONENTS
ELEC
–
+
EBS00500
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Indicator light assembly
3 Front brake light
switch
4 Clutch switch
5 Handlebar switch
6 Lean angle sensor
7 Battery
8 Starter relay
9 Main fuse
0 Circuit breaker (fan)
A Fuse box
B Radiator fan motor
relay
C Headlight relay
D Relay unit
E Tail/brake light
F ECU
G Speed sensor
H Rear brake light
switch
I Neutral switch
J Reverse switch
8-1
K Coolant temperature
sensor
L Ignition coil
M Rectifier/regulator
N Resistor
O Radiator fan
P Headlight
CHECKING SWITCH CONTINUITY
ELEC
–
+
EBS01028
CHECKING SWITCH CONTINUITY
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.
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 terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
_
The example illustration on the left shows
that:
There is continuity between the switch terminals for the red and brown switch leads when
the switch is set to “ON”.
8-2
8
CHECKING THE SWITCHES
ELEC
–
+
EBS01029
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1
2
3
L
Br R/B
Y/R L Y
L/B B
OFF
OFF
OFF
LO
ON
PUSH
Y
Y/R
R/B B
HI
Br L/B
4
5
6
R Br
ON
OFF
B
R
B
B
7
B
Br
0
8
9
B
8-3
B
CHECKING THE SWITCHES
1 Light switch
2 Engine stop switch
3 Start switch
4 Main switch
5 Front brake light switch
6 Clutch switch
7 Fuses
8 Reverse switch
9 Neutral switch
0 Rear brake light switch
8-4
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EBS01030
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.
TYPES OF BULBS
The bulbs used on this vehicle are shown in
the illustration on the left.
• 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.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
8-5
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
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 clean it with
a cloth moistened with alcohol or lacquer
thinner.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-6
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-7
8-8
W W
G/W L/Y
W W
L/Y B/L
B/L
2
1
L/Y
W
W
B R/L
W
W
W
W
L
Br
B
R/L
R/W
Y/R
i
B
g
R/L
R/L
Y/R
Br
R/W
R/W
R
3
(GRAY)
R
W
W
B
W
h
B
R
ON
OFF
R
1 Crankshaft position sensor
4 Main switch
6 Battery
7 Main fuse
K ECU
L Ignition coil
M Spark plug
T Lean angle sensor
[ Engine stop switch
f Ignition fuse
W
W
Br/L
(BLACK)
Y Br/Y
Br/L
Br/L
a
B
L Y
Y
L Y
B
(BLACK)
B
Y
B
L
(BLACK)
B
(BLACK)
B
Y Br/Y
Br/R
Br/Y
Br
b
Br/Y
15A
10A
10A
Br/G
c
B
d
e
f
(GRAY)
Br/L
Br/L R
10A
Br
R
5
(GRAY)
4
R
G
L
Y
G
B
B
Y
9
B
B
]
(BLACK)
Y G
B
`
L
HI
OFF
LO
Z
B
Y G
Y Y
G B
L Y
B
X
8
B
7
R R
Br/R
B/Y B
Y
(BLACK)
Y
B
B
B
R
R
R
B
Y
B
(BLACK)
G
OFF
PUSH
\
Br
L/B
B
B/Y
L/B
L/W
L/W R/B
(BLACK)
`
Br R/B
A
0
Y G
B
OFF
RUN
[
Y G
B
B/Y
L/W
Br
(BLACK)
L/W Br
R
W/L G/L Sb
Br O/B G/Y
Lg G/L W/L
G/Y O/B Br
(BLACK)
Br L/B
R/B B
Y
Y/R
L
Lg
B R/B
L/B Br
(BLACK)
Br
G/Y
E
C
Y L
Br/R
W
Sb
Sb
A
Sb
Sb
B
L/R
R/L
Br/G
O/B
D
Br
B
B
G/L
G
Br O/G
O/G
L/W L/R Br
V
Br/G L/W
W/L
F
J
B
B
R/L
B
O/G
R/B L/B R/L
Sb B/Y Lg
Br
U
B Br
Lg
Lg
H
Lg
R
Lg
B O/G
L/R
R/L
Y/R
Sb
G/L
W/L
L/W
O/B
Lg
G/Y
G/W
L/Y
Br
(GRAY)
R/L B
B
I
G/W
G/W
A
G/W
O
B
B/W
K
B
P/L
Y/G
O/G
Y
W
B/L
L
B/Y
Br/W
R/B
O
B/Y
(GREEN)
B/Y B/L
Br/W
(BLACK)
Br/W B/W
R/B
(GLAY)
R/L R/B
O
R/B
N
P
O
R/L
L
S
R
L W
B/L
L Y/G B/L
(GRAY)
G/W Sb
A
Sb G/W
(GRAY)
Y B/L
(BLACK)
B/L P/L L
(BLACK)
L
P O/R
B/W
Q
MAIN HARNESS WIRE SUB LEAD
W
B/L
L Y/G B/L
T
P/L
B/L
L
Y
B/L
L
B/L
B/W
M
L
ELEC
(BLACK)
Y
Br/Y
B
6
R
R
20A
L/W Lg Y/G O/G W L/Y B/W G/Y L G/L Br O/B
Sb G/W B/Y Br/W P/L Y B/L L/R Y/R W/L R/L R/B
IGNITION SYSTEM
–
+
EBS00503
IGNITION SYSTEM
CIRCUIT DIAGRAM
ELEC
IGNITION SYSTEM
EBS01045
–
+
EBS01043
TROUBLESHOOTING
1. Main and ignition fuses
The ignition system fails to operate (no
spark or intermittent spark).
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
Check:
1. main and ignition fuses
2. battery
3. spark plug
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. main switch
8. engine stop switch
9. crankshaft position sensor resistance
10.lean angle sensor
11.wiring connections (of the entire ignition
system)
YES
NO
Replace the fuse(s).
EBS01044
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and light)
4. fuel tank
5. front fender
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
_
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
8-9
IGNITION SYSTEM
EBS01032
ELEC
–
+
EBS01034
3. Spark plug
4. Ignition spark gap
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
• Disconnect the ignition coil from the spark
plug.
• Connect the ignition checker 1 as shown.
2 Ignition coil
Standard spark plug
CR8E (NGK)
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
YES
NO
Re-gap or replace
the spark plug.
Minimum ignition spark gap
6 mm (0.24 in)
• Is there a spark and is the spark gap within
specification?
NO
YES
The ignition system
is OK.
8 - 10
EBS01036
–
ELEC
IGNITION SYSTEM
+
EBS01038
5. Spark plug cap resistance
6. Ignition coil resistance
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (“Ω × 1k” range)
to the spark plug cap as shown.
• Measure the spark plug cap resistance.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe →
red/black lead terminal 1
Negative tester probe →
orange lead terminal 2
Spark plug cap resistance
10 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?
• Measure the primary coil resistance.
NO
YES
Replace the
plug cap.
Primary coil resistance
3.4 ~ 4.6 Ω at 20 °C (68 °F)
spark
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Positive tester probe →
red/black lead terminal 1
Negative tester probe →
spark plug lead 2
• Measure the secondary coil resistance.
Secondary coil resistance
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES
NO
Replace the ignition
coil.
8 - 11
IGNITION SYSTEM
EBS01041
ELEC
–
+
EBS01040
9. Crankshaft position sensor resistance
7. Main switch
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
the
main
Positive tester probe → blue/yellow 1
Negative tester probe → green/white 2
EBS01042
8. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
G/W L/Y
2
1
• Measure the crankshaft position sensor
resistance.
Replace the handlebar switch.
Crankshaft position sensor resistance
192 ~ 288 Ω at 20 °C (68 °F)
• Is the crankshaft position sensor OK?
YES
NO
Replace the crankshaft position sensor/
stator assembly.
8 - 12
IGNITION SYSTEM
–
+
EBS01047
10.Lean angle sensor
• Remove the lean angle sensor.
• Connect the lean angle sensor terminals
and lean angle sensor coupler terminals
with jumper leads as shown.
• Connect the pocket tester (Ω × 100) to the
lean angle sensor terminals as shown.
Positive tester probe → blue 1
Negative tester probe → yellow/green 2
11.Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES
Replace the ECU.
• Set the main switch to “ON”.
• Measure the lean angle sensor voltage.
Lean angle sensor voltage
Less than 65° ± 10° a →
Approximately 1 V
More than 65° ± 10° b →
Approximately 4 V
• Is the lean angle sensor OK?
YES
ELEC
NO
Replace the
angle sensor.
lean
8 - 13
NO
Properly connect or
repair the ignition
system’s wiring.
W
W W
G/W L/Y
W
W W
L/Y B/L
B/L
2
1
L/Y
W
W
B R/L
W
W
W
W
L
Br
B
R/L
R/W
Y/R
i
8 - 14
B
g
R/L
R/L
Y/R
Br
R/W
R/W
R
3
(GRAY)
R
W
W
B
W
h
B
R
ON
OFF
R
Br/L
(BLACK)
Y Br/Y
Br/L
Br/L
a
B
L Y
Y
L Y
B
(BLACK)
B
Y
B
L
(BLACK)
B
(BLACK)
B
Y Br/Y
Br/R
Br/Y
Br
b
Br/Y
15A
10A
10A
Br/G
c
B
d
e
f
(GRAY)
Br/L
Br/L R
10A
Br
R
5
(GRAY)
4
R
G
L
Y
G
B
B
Y
9
B
B
]
(BLACK)
Y G
B
`
L
HI
OFF
LO
Z
B
Y G
Y Y
G B
L Y
B
X
8
B
7
R R
Br/R
B/Y B
Y
(BLACK)
Y
B
B
B
R
R
R
B
Y
B
(BLACK)
G
OFF
PUSH
\
Br
L/W
R/B
L/B
B
B/Y
L/B
L/W
(BLACK)
`
Br R/B
A
0
Y G
B
OFF
RUN
[
Y G
B
B/Y
L/W
Br
(BLACK)
L/W Br
R
W/L G/L Sb
Br O/B G/Y
Lg G/L W/L
G/Y O/B Br
(BLACK)
Br L/B
R/B B
Y
Y/R
L
Lg
B R/B
L/B Br
(BLACK)
Br
G/Y
E
C
Y L
Br/R
W
Sb
Sb
A
Sb
Sb
B
L/R
R/L
Br/G
O/B
D
Br
B
B
G/L
G
Br O/G
O/G
L/W L/R Br
V
Br/G L/W
W/L
F
J
B
B
R/L
B
O/G
R/B L/B R/L
Sb B/Y Lg
Br
U
B Br
Lg
Lg
H
Lg
R
Lg
B O/G
L/R
R/L
Y/R
Sb
G/L
W/L
L/W
O/B
Lg
G/Y
G/W
L/Y
Br
(GRAY)
R/L B
B
I
G/W
G/W
A
G/W
O
B
B/W
K
B
B/Y
(GREEN)
B/Y B/L
Br/W
(BLACK)
Br/W B/W
R/B
(GLAY)
R/L R/B
O
N
P
O
R/L
L
S
R
L W
B/L
L Y/G B/L
(GRAY)
G/W Sb
A
Sb G/W
(GRAY)
Y B/L
(BLACK)
B/L P/L L
(BLACK)
L
P O/R
B/W
Q
MAIN HARNESS WIRE SUB LEAD
W
B/L
L Y/G B/L
T
P/L
B/L
L
Y
B/L
L
B/L
B/W
M
L
4 Main switch
6 Battery
7 Main fuse
8 Starter relay
9 Starter motor
A Starting circuit cut-off relay
W Neutral switch
X Clutch switch
[ Engine stop switch
\ Start switch
f Ignition fuse
P/L
Y/G
O/G
Y
W
B/L
L
B/Y
Br/W
R/B
O
R/B
ELEC
(BLACK)
Y
Br/Y
B
6
R
R
20A
L/W Lg Y/G O/G W L/Y B/W G/Y L G/L Br O/B
Sb G/W B/Y Br/W P/L Y B/L L/R Y/R W/L R/L R/B
ELECTRIC STARTING SYSTEM
–
+
EBS00506
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EBS00508
9
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
The starting circuit on this model consists of
the starter motor, starter relay, clutch switch,
and neutral switch. If the main switch is on and
the engine stop switch is in the RUN position,
the starter motor can be operated only if:
2
• The transmission is in neutral (the neutral
switch is closed).
or
• You pull in the clutch lever (the clutch
switch is closed).
0
M
1
1 Battery
2 Main fuse
3 Main switch
4 Engine stop switch
5 Starting circuit cutoff relay
6 Clutch switch
7 Neutral switch
8 Start switch
9 Starter relay
0 Starter motor
A Ignition fuse
3
A
4
5
6
7
8
8 - 15
ELECTRIC STARTING SYSTEM
EBS01050
ELEC
–
+
EBS01044
TROUBLESHOOTING
2. Battery
The starter motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. relay unit (starting circuit cut-off relay)
5. relay unit (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.clutch switch
11.start switch
12.wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EBS01051
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
_
3. Starter motor
• Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EBS01043
WARNING
_
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
• A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
• Does the starter motor turn?
Replace the fuse(s).
YES
NO
Repair or replace the
starter motor.
8 - 16
ELECTRIC STARTING SYSTEM
EBS01052
–
ELEC
+
EBS01053
5. Relay unit (diode)
4. Relay unit (starting circuit cut-off relay)
• Remove the relay unit from the wire harness.
• Connect the pocket tester (Ω × 1) to the
relay unit as shown.
• Measure the relay unit for continuity as follows.
• Remove the relay unit from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit as shown.
Positive battery terminal → red/black 1
Negative battery terminal →
sky blue 2 or black/yellow 3
Positive tester probe → blue/white 4
Negative tester probe → blue/black 5
4
Br/G L/W
_
2
3
Positive tester probe →
sky blue 1
Continuity
Negative tester probe →
red/black 2
1
5
Positive tester probe →
red/black 2 No
continuity
Negative tester probe →
sky blue 1
R/B L/B R/L
L/W L/R Br
NOTE:
The pocket tester 90890-03112 and the analog pocket tester YU-03112-C readings are
shown in the following table.
Sb B/Y Lg
• Does the relay unit have continuity
between blue/white and blue/black?
1
NO
YES
Replace
unit.
the
relay
2
Br/G L/W
L/W L/R Br
R/B L/B R/L
Sb B/Y Lg
• Are the testing readings correct?
NO
YES
Replace
unit.
8 - 17
the
relay
ELECTRIC STARTING SYSTEM
EBS01054
ELEC
–
+
EBS01042
8. Engine stop switch
6. Starter relay
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Remove the starter relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay as shown.
Positive battery terminal → brown 1
Negative battery terminal → blue/white 2
YES
Positive tester probe → red 3
Negative tester probe → black 4
NO
Replace the handlebar switch.
3
EBS01046
R
R
9. Neutral switch
R
L/W Br
B
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
1 2
4
YES
• Does the starter relay have continuity
between red and black?
Replace the neutral
switch.
NO
YES
NO
EBS01056
Replace the starter
relay.
10.Clutch switch
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
EBS01041
7. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
Replace the clutch
switch.
NO
YES
NO
EBS01057
Replace
switch.
the
main
11.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the handlebar switch.
8 - 18
ELECTRIC STARTING SYSTEM
EBS01059
12.Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
YES
The starting system
circuit is OK.
NO
Properly connect or
repair the starting
system’s wiring.
8 - 19
ELEC
–
+
STARTER MOTOR
ELEC
–
+
EBS01061
STARTER MOTOR
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5 Nm (0.5 m • kg, 3.6 ft • Ib)
1
2
3
Order
1
2
3
Job/Part
Removing the starter motor
Exhaust pipe
Starter motor lead
Parking brake cable
Starter motor
Q’ty
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL” in
chapter 4.
Disconnect.
For installation, reverse the removal procedure.
8 - 20
STARTER MOTOR
ELEC
–
+
EBS01062
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the starter motor
O-ring
Front bracket
Square ring
Lock washer
Shim
Armature assembly
Starter motor yoke
Brush holder assembly
Square ring
Shim
Rear bracket
Q’ty
1
1
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly
procedure.
8 - 21
STARTER MOTOR
ELEC
–
+
EBS01064
a
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.
Commutator wear limit
27 mm (1.06 in)
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
0.7 mm (0.03 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
_
4. Measure:
• armature assembly resistances
(commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance 1
0.025 ~ 0.035 Ω at 20 °C (68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
8 - 22
STARTER MOTOR
ELEC
–
+
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit
5.0 mm (0.20 in)
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
7.65 ~ 10.01 N
(780 ~ 1021 gf, 27.54 ~ 36.03 oz)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bushing
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
EBS00515
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush seat 1
NOTE:
Align the projection a on the rear bracket with
the slot b in the yoke.
_
8 - 23
STARTER MOTOR
b
a
b
ELEC
–
+
2. Install:
• yoke
• bracket
NOTE:
Align the match marks a on the yoke with the
match mark b on the front bracket and the
rear bracket.
_
8 - 24
–
ELEC
CHARGING SYSTEM
+
EBS00516
CHARGING SYSTEM
CIRCUIT DIAGRAM
L/W
Sb
L/Y
W
W W
W W
G/W L/Y
W
W
R
G/Y O/B Br
W
Lg G/L W/L
C
Br
(GRAY)
2
L/Y B/L
B
B/L
1
W
W
W
W
W
W
Br O/B G/Y
3
D
W/L G/L Sb
R
E
B
O/B
5
Br/G
R
R
R
R
R R
R
R
R
4
i
ON
OFF
R
6
(GRAY)
7
B
B
(BLACK)
Br
8
(GRAY)
R
L/W Br
Br/L R
Br
L/W
B
L/W
L/W R/B
0
R/W
G/
10A
R
20A
W
Br/G
B
Br/L
B
B
Lg
B
9
A
R/W
Br
R/W
h
R/L
Br
Br
Y/R
B/Y
L/B
L/R
R/L
Sb
Y/R
R/L
R/L
f
10A
Br
Br/L
Sb
B R/L
L
B
g
B
B/Y
e
10A
Br/L
B/Y B
d
A
Sb
X
Br/Y
B
Sb
B
15A
Br/L
Br/R
W
B
B
Br/Y
Y Br/Y
(BLACK)
B
Y
Br/Y
c
b
B
B
Y Br/Y
(BLACK)
(BLACK)
Br R/B
Z
[
OFF
LO
B
L/B
Y
L Y
Y
B R/B
Br L/B
L/B Br
(BLACK)
(BLACK)
B
L
B
L
L
Y
Y
G
]
B
Y Y
(BLACK)
Y G
Y G
`
B
B
Y G
B
(BLACK)
(BLACK)
G
Y
`
Y G
B
B
G
Y
2 A.C. magneto
3 Rectifier/regulator
6 Battery
7 Main fuse
(BLACK)
B
B
(BLACK)
Y L
Br/R
R/B B
G B
L Y
B
8 - 25
Y
Y/R
OFF
PUSH
L Y
a
L
\
OFF
RUN
HI
(BLACK)
Y
Br/R
CHARGING SYSTEM
EBS01065
ELEC
–
+
EBS01044
TROUBLESHOOTING
2. Battery
The battery is not being charged.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. front tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
NO
_
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EBS01043
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main fuse OK?
NO
YES
Replace
fuse.
the
main
8 - 26
• Clean the battery
terminals.
• Recharge or
replace the battery.
CHARGING SYSTEM
EBS01066
ELEC
–
+
EBS0110
4. Stator coil resistance
3. Charging voltage
• Disconnect the A.C. magneto coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
stator coils.
• Connect the engine tachometer to the
spark plug lead.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe →
positive battery terminal 1
Negative tester probe →
negative battery terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 3
Tester (+) lead → White terminal 2
Tester (–) lead → White terminal 3
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
• Measure the stator coil resistance.
Charging voltage
14 V at 5,000 r/min
Stator coil resistance
0.248 ~ 0.372 Ω at 20 °C (68 °F)
NOTE:
Make sure the battery is fully charged.
_
YES
• Is the charging voltage within specification?
NO
Replace the crankshaft position sensor/
stator assembly.
YES
The charging circuit
is OK.
NO
5. Wiring
• Check the entire charging system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
YES
Replace the rectifier/
regulator.
8 - 27
NO
Properly connect or
repair the charging
system’s wiring.
–
ELEC
LIGHTING SYSTEM
+
EBS00518
LIGHTING SYSTEM
CIRCUIT DIAGRAM
L/W Lg
Sb G/W
L/Y
W
W
W W
W W
G/W L/Y
W
W
R
G/Y O/B Br
W
Lg G/L W/L
C
Br
(GRAY)
2
L/Y B/L
B
B/L
1
W
W
W
W
W
W
Br O/B G/Y
3
D
W/L G/L Sb
R
E
B
O/B
5
Br/G
R
R
R
R
R R
R
R
4
ON
OFF
R
Br
(GRAY)
6
7
B
Br/L R
B
(BLACK)
Br
8
(GRAY)
R
L/W Br
20A
R
i
L/W
B
L/W
L/W R/B
0
R/W
G/Y
10A
R
Br/G
B
Br/L
B
B
Lg
B
9
A
R/W
Br
R/W
h
R/L
Br
Br
Y/R
B/Y
L/B
L/R
R/L
Sb
Y/R
R/L
R/L
f
10A
Br
Br/L
Sb
B R/L
L
B
g
B
B/Y
e
10A
Br/L
B/Y B
d
A
Sb
X
Br/Y
B
Sb
B
15A
Br/L
Br/R
W
B
Br
Br/Y
c
Y Br/Y
(BLACK)
B
Y
Br/Y
b
B
B
Y Br/Y
(BLACK)
(BLACK)
Br R/B
Z
[
OFF
LO
B
L/B
L Y
R/B B
B
G B
L Y
B
Y
L
B
L
L
Y
Y
G
]
B
Y Y
(BLACK)
4 Main switch
6 Battery
7 Main fuse
Z Light switch
] Headlight relay
_ Headlight
a Tail/brake light
d Headlight fuse
Y
Y/R
OFF
PUSH
Y
L Y
a
L
\
OFF
RUN
HI
(BLACK)
Y
Br/R
Y G
`
B
Y G
B
Y G
B
(BLACK)
(BLACK)
(BLACK)
G
Y
B
8 - 28
Y G
`
B
B
G
Y
B
(BLACK)
Y L
Br/R
B R/B
Br L/B
L/B Br
(BLACK)
(BLACK)
LIGHTING SYSTEM
EBS01067
–
ELEC
+
EBS01044
TROUBLESHOOTING
2. Battery
Any of the following fail to light: headlight, tail/brake light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and headlight fuses
2. battery
3. main switch
4. light switch
5. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NO
YES
Replace
switch.
EBS01043
the
main
1. Main and headlight fuses
• Check the main and headlight fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and headlight fuses OK?
YES
EAS00783
4. Light switch
NO
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the light switch OK?
YES
Replace the fuse(s).
NO
Replace the handlebar switch.
8 - 29
ELEC
LIGHTING SYSTEM
EBS01069
–
+
2. Headlight relay
5. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
È high beam
É low beam
Positive battery terminal → yellow 1
Negative battery terminal → black 2
NO
YES
• Remove the headlight relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay as shown.
Properly connect or
repair the lighting
system’s wiring.
Positive tester probe → blue 3
Negative tester probe → yellow 4
È
3
4
2
1
EBS01070
CHECKING THE LIGHTING SYSTEM
1. The headlights fail to come on.
B
G
Y
Y
L
1. Headlight bulb and socket
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the headlight bulb and socket OK?
YES
É
3
4
B
NO
G
Y
Y
L
Replace the headlight bulb, socket or
both.
• Does the headlight relay have continuity
between blue and yellow? È
• Does the headlight relay have continuity
between blue and green? É
YES
NO
Replace the headlight relay.
8 - 30
LIGHTING SYSTEM
ELEC
–
+
2. The tail light fails to come on.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight couplers as shown.
1. Tail/brake light
• Disconnect the tail/brake light coupler (tail/
brake light assembly side).
• Connect the battery (12 V) to the corresponding coupler terminals as shown.
• When the jumper leads are connected to
the terminals the tail/brake light should illuminate.
È When the light switch is set to “LO”
É When the light switch is set to “HI”
Headlight coupler (wire harness side)
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
Positive battery terminal → blue 1
Negative battery terminal → black 2
É
1
1
2
DC20V
G
Y
L
B
Y
B
È
2
3
• Set the main switch to “ON”.
• Set the light switch to “LO” or “HI”.
• Measure the voltage (DC 12 V) of yellow
1 or green 2 on the headlight coupler
(wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
8 - 31
• Is the tail/brake light OK?
YES
NO
Replace the
brake light.
tail/
LIGHTING SYSTEM
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler as shown.
Tail/brake light coupler (wire harness side)
Tail/brake light
Positive tester probe → blue 1
Negative tester probe → black 2
1
L
Y
B
Y
L
B
2
• Set the main switch to “ON”.
• Set the light switch to “LO” or “HI”.
• Measure the voltage (DC 12 V) of blue 1
on the tail/brake light coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
8 - 32
ELEC
–
+
W W
G/W L/Y
W W
L/Y B/L
B/L
2
1
L/Y
W
W
W
W
W
W
Br
R/W
Y/R
R
3
(GRAY)
R
W
W
B
W
B R/L
L
B
R/L
B
R/L
R/L
Y/R
Br
R/W
R/W
4 Main switch
6 Battery
i
7 Main fuse
0 Relay unit
D Fuel level warning light
E Engine
trouble
warning light
F Coolant temperature warning light
G Reverse indicatorg
light
H Neutral indicator
light
I Reverse switch
K ECU
P Coolant temperature sensor
U Fuel pump
V Resistor
W Neutral switch
a Tail/brake light
b Rear brake light
switch
c Front brake light
switch
e Signaling system
fuse
f Ignition fuse
W
W
h
B
R
ON
OFF
R
Br/L
8 - 33
(BLACK)
Y Br/Y
Br/L
Br/L
a
B
L Y
Y
L Y
B
(BLACK)
B
Y
B
L
(BLACK)
B
(BLACK)
B
Y Br/Y
Br/R
Br/Y
Br
b
Br/Y
15A
10A
10A
Br/G
c
B
d
e
f
(GRAY)
Br/L
Br/L R
10A
Br
R
5
(GRAY)
4
R
G
L
Y
G
B
B
Y
9
B
B
]
(BLACK)
Y G
B
`
L
HI
OFF
LO
Z
B
Y G
Y Y
G B
L Y
B
X
8
B
7
R R
Br/R
B/Y B
Y
(BLACK)
Y
B
B
B
R
R
R
B
Y
B
(BLACK)
G
OFF
PUSH
\
Br
L/B
B
B/Y
L/B
L/W
L/W R/B
(BLACK)
`
Br R/B
A
0
Y G
B
OFF
RUN
[
Y G
B
B/Y
L/W
Br
(BLACK)
L/W Br
R
W/L G/L Sb
Br O/B G/Y
Lg G/L W/L
G/Y O/B Br
(BLACK)
Br L/B
R/B B
Y
Y/R
L
Lg
B R/B
L/B Br
(BLACK)
Br
G/Y
E
C
Y L
Br/R
W
Sb
Sb
A
Sb
Sb
B
L/R
R/L
Br/G
O/B
D
Br
B
B
G/L
G
Br O/G
O/G
L/W L/R Br
V
Br/G L/W
W/L
F
J
B
B
R/L
B
O/G
R/B L/B R/L
Sb B/Y Lg
Br
U
B Br
Lg
Lg
H
Lg
R
Lg
B O/G
L/R
R/L
Y/R
Sb
G/L
W/L
L/W
O/B
Lg
G/Y
G/W
L/Y
Br
(GRAY)
R/L B
B
I
G/W
G/W
A
G/W
O
B
B/W
K
B
P/L
Y/G
O/G
Y
W
B/L
L
B/Y
Br/W
R/B
O
B/Y
(GREEN)
B/Y B/L
Br/W
(BLACK)
Br/W B/W
R/B
(GLAY)
R/L R/B
O
R/B
N
P
O
R/L
L
S
R
L W
B/L
L Y/G B/L
(GRAY)
G/W Sb
A
Sb G/W
(GRAY)
Y B/L
(BLACK)
B/L P/L L
(BLACK)
L
P O/R
B/W
Q
MAIN HARNESS WIRE SUB LEAD
W
B/L
L Y/G B/L
T
P/L
B/L
L
Y
B/L
L
B/L
B/W
M
L
ELEC
(BLACK)
Y
Br/Y
B
6
R
R
20A
L/W Lg Y/G O/G W L/Y B/W G/Y L G/L Br O/B
Sb G/W B/Y Br/W P/L Y B/L L/R Y/R W/L R/L R/B
SIGNALING SYSTEM
–
+
EBS00521
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
EBS01073
–
ELEC
+
EBS01044
TROUBLESHOOTING
2. Battery
Any of the following fail to light: brake
light or an indicator light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition and signaling system fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and light)
4. front fender
• Troubleshoot with the following special
tool(s).
_
• Clean the battery
terminals.
• Recharge or
replace the battery.
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NO
YES
EBS01043
Replace
switch.
1. Main, ignition and signaling system fuses
• Check the main, ignition and signaling system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition and signaling system fuses OK?
YES
the
main
EBS01074
4. Wiring
• Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
NO
YES
NO
Replace the fuse(s).
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8 - 34
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
EBS01075
EBS01076
1. Tail/brake light
• Disconnect the tail/brake light coupler from
the wire harness.
• Connect the battery (12V) to the tail/brake
light coupler as shown.
• When the jumper leads are connected to
the terminals the tail/brake light should illuminate.
Positive tester probe → yellow 1
Negative tester probe → black 2
1
L
Y
B
Positive battery terminal → yellow 1
Negative battery terminal → black 2
Y
L
B
2
1
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (DC 12 V) of yellow
1 on the tail/brake light coupler (wire harness side).
• Is the voltage within specification?
Y
B
2
• Is the tail/brake light OK?
YES
NO
NO
This circuit is OK.
Replace the
brake light.
tail/
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
+
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
1. The brake light fails to come on.
YES
–
3. Voltage
CHECKING THE SIGNALING SYSTEM
L
ELEC
NO
Replace the brake
light switch.
8 - 35
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
SIGNALING SYSTEM
EBS01077
–
ELEC
+
EBS01053
2. The neutral indicator light fails to come on.
3. Relay unit (diode)
1. Indicator light assembly
• Disconnect the indicator light assembly
coupler from the wire harness.
• Connect the battery (12V) to the indicator
light assembly coupler as shown.
• When the jumper leads are connected to
the terminals the neutral indicator light
should illuminate.
Positive battery terminal → brown 1
Negative battery terminal → sky blue 2
• Remove the relay unit from the wire harness.
• Connect the pocket tester (Ω × 1) to the
relay unit as shown.
• Measure the relay unit for continuity as follows.
NOTE:
The pocket tester 90890-03112 and the analog pocket tester YU-03112-C readings are
shown in the following table.
_
Positive tester probe →
sky blue 1
Continuity
Negative tester probe →
light green 2
1
Br O/B G/Y
Positive tester probe →
light green 2 No
continuity
Negative tester probe →
sky blue 1
W/L G/L Sb
2
• Is the indicator light assembly OK?
YES
1
NO
2
Replace the indicator light assembly.
Br/G L/W
L/W L/R Br
2. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
R/B L/B R/L
Sb B/Y Lg
• Are the testing readings correct?
NO
YES
NO
Replace
unit.
Replace the neutral
switch.
8 - 36
the
relay
SIGNALING SYSTEM
ELEC
–
+
EBS01083
4. Voltage
3. The reverse indicator light fails to come on.
• Connect the pocket tester (DC 20 V) to the
indicator light assembly coupler (wire harness side) as shown.
1. Indicator light assembly
• Disconnect the indicator light assembly
coupler from the wire harness.
• Connect the battery (12V) to the indicator
light assembly coupler as shown.
• When the jumper leads are connected to
the terminals the reverse indicator light
should illuminate.
Positive tester probe → brown 1
Negative tester probe → light green 2
1
Br O/B G/Y
W/L G/L Sb
Positive battery terminal → brown 1
Negative battery terminal → green/blue 2
G/Y O/B Br
Lg G/L W/L
2
1
• Set the main switch to “ON”.
• Shift the transmission into the neutral position.
• Measure the voltage (DC 12 V) of brown
1 and light green 2 at the indicator light
assembly coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
Br O/B G/Y
W/L G/L Sb
2
• Is the indicator light assembly OK?
YES
NO
The wiring circuit
from the main switch
to the indicator light
assembly coupler is
faulty and must be
repaired.
NO
Replace the indicator light assembly.
2. Reverse switch
• Check the reverse switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the reverse switch OK?
YES
NO
Replace the reverse
switch.
8 - 37
SIGNALING SYSTEM
ELEC
–
+
EBS01083
3. Voltage
• Connect the pocket tester (DC 20 V) to the
indicator light assembly coupler (wire harness side) as shown.
Positive tester probe → brown 1
Negative tester probe → green/blue 2
4. The coolant temperature warning light does
not come on when the main switch is set to
“ON”, or if the coolant temperature warning
light does not come on when the temperature is high (more than 110 ~ 115 °C (230 ~
239 °F)).
1. Indicator light assembly
• Disconnect the indicator light assembly
coupler (from the wire harness).
• Connect the battery (12V) to the indicator
light assembly coupler as shown.
• When the jumper leads are connected to
the terminals the coolant temperature
warning light should illuminate.
1
Br O/B G/Y
W/L G/L Sb
G/Y O/B Br
Lg G/L W/L
2
• Set the main switch to “ON”.
• Shift the transmission into the reverse
position.
• Measure the voltage (DC 12 V) of brown
1 and green/blue 2 at the indicator light
assembly coupler (wire harness side).
• Is the voltage within specification?
YES
Positive battery terminal → brown 1
Negative battery terminal → white/blue 2
1
Br O/B G/Y
W/L G/L Sb
NO
2
The wiring circuit
from the main switch
to the indicator light
assembly coupler is
faulty and must be
repaired.
8 - 38
• Is the indicator light assembly OK?
YES
NO
Replace the indicator light assembly.
SIGNALING SYSTEM
ELEC
–
+
EBS00812
2. Coolant temperature sensor
• Remove the coolant temperature sensor
from the cylinder head.
• Connect the pocket tester (Ω × 10) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
_
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
Test
step
Coolant
temperature
Resistance
1
20 °C (68 °F)
2.32 ~ 2.59 kΩ
2
80 °C (176 °F)
0.310 ~ 0.326 kΩ
3
110 °C (230 °F)
0.140 ~ 0.144 kΩ
• Does the coolant temperature sensor
operate properly?
YES
NO
Replace the coolant
temperature sensor.
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.
T.
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
R.
8 - 39
SIGNALING SYSTEM
ELEC
–
+
5. The fuel level warning light fails to come on.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
indicator light assembly coupler (wire harness side) as shown.
1. Indicator light assembly
• Disconnect the indicator light assembly
coupler from the wire harness.
• Connect the battery (12V) to the indicator
light assembly coupler as shown.
• When the jumper leads are connected to
the terminals the fuel level warning light
should illuminate.
Positive tester probe → brown 1
Negative tester probe → white/blue 2
1
Br O/B G/Y
W/L G/L Sb
Positive battery terminal → brown 1
Negative battery terminal →
orange/black 2
G/Y O/B Br
Lg G/L W/L
2
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
1 and white/blue 2 at the indicator light
assembly coupler (wire harness side).
NOTE:
The voltage can only be measured during the
initial test of the indicator light assembly after
the main switch is set to “ON”.
2
1
Br O/B G/Y
W/L G/L Sb
• Is the indicator light assembly OK?
YES
NO
• Is the voltage within specification?
YES
This circuit is OK.
Replace the indicator light assembly.
NO
The wiring circuit
from the main switch
to the indicator light
assembly coupler is
faulty and must be
repaired.
8 - 40
SIGNALING SYSTEM
2. Fuel sender
ELEC
–
+
3. Resistor
• Drain the fuel from the fuel tank and then
remove the fuel pump (fuel sender) from
the fuel tank.
• Connect the pocket tester (DC 5 A) and
battery (12 V) to the fuel pump terminals
as shown.
• Immerse the fuel sender in a container
filled with fuel.
• Disconnect the resistor coupler from the
wire harness.
• Connect the pocket tester (Ω × 100) to the
resistor terminal as shown.
Positive tester probe → black 1
Negative tester probe → black 2
Positive tester probe → orange/green 1
Negative tester probe →
positive battery terminal
Negative battery terminal → black 2
B
Br O/G
B
• Measure the fuel sender current.
2
a Fuel level
Fuel sender current
Less than 109.85 (4.32 in) mm a
→ Less than 60 mA
More than 109.85 (4.32 in) mm
a → More than 135 mA
1
• Measure the resistor resistance.
Resistor resistance
68 Ω at 20 °C (68 °F)
• Is the resistor OK?
YES
NO
DC 5A
2
1
O/G B
Replace the resistor
assembly.
B R/L
4. Wiring
• Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
a
YES
Replace the ECU.
• Is the fuel sender OK?
NO
YES
Replace
pump.
the
fuel
8 - 41
NO
Properly connect or
repair the signaling
system’s wiring.
8 - 42
W W
G/W L/Y
W W
L/Y B/L
B/L
2
1
L/Y
W
W
B R/L
W
W
W
W
L
Br
B
R/L
R/W
Y/R
i
B
g
R/L
R/L
Y/R
Br
R/W
R/W
R
3
(GRAY)
R
W
W
B
W
h
B
R
ON
OFF
R
Br/L
Y Br/Y
Br/L
Br/L
a
B
L Y
Y
L Y
B
(BLACK)
B
Y
B
L
(BLACK)
B
(BLACK)
B
Y Br/Y
Br/R
Br/Y
Br
b
Br/Y
15A
10A
10A
Br/G
c
B
d
e
f
(GRAY)
Br/L
Br/L R
10A
Br
5
(GRAY)
R
R
4
(BLACK)
4 Main switch
6 Battery
7 Main fuse
K ECU
P Coolant temperature sensor
f Ignition fuse
g Radiator fan motor
h Radiator fan motor relay
i Circuit breaker (fan motor)
W
W
G
L
Y
G
B
B
Y
9
B
B
]
(BLACK)
Y G
B
`
L
HI
OFF
LO
Z
B
Y G
Y Y
G B
L Y
B
X
8
B
7
R R
Br/R
B/Y B
Y
(BLACK)
Y
B
B
B
R
R
R
B
Y
B
(BLACK)
G
OFF
PUSH
\
Br
L/B
B
B/Y
L/B
L/W
L/W R/B
(BLACK)
`
Br R/B
A
0
Y G
B
OFF
RUN
[
Y G
B
B/Y
L/W
Br
(BLACK)
L/W Br
R
W/L G/L Sb
Br O/B G/Y
Lg G/L W/L
G/Y O/B Br
(BLACK)
Br L/B
R/B B
Y
Y/R
L
Lg
B R/B
L/B Br
(BLACK)
Br
G/Y
E
C
Y L
Br/R
W
Sb
Sb
A
Sb
Sb
B
L/R
R/L
Br/G
O/B
D
Br
B
B
G/L
G
Br O/G
O/G
L/W L/R Br
V
Br/G L/W
W/L
F
J
B
B
R/L
B
O/G
R/B L/B R/L
Sb B/Y Lg
Br
U
B Br
Lg
Lg
H
Lg
R
Lg
B O/G
L/R
R/L
Y/R
Sb
G/L
W/L
L/W
O/B
Lg
G/Y
G/W
L/Y
Br
(GRAY)
R/L B
B
I
G/W
G/W
A
G/W
O
B
B/W
K
B
P/L
Y/G
O/G
Y
W
B/L
L
B/Y
Br/W
R/B
O
B/Y
(GREEN)
B/Y B/L
Br/W
(BLACK)
Br/W B/W
R/B
(GLAY)
R/L R/B
O
R/B
N
P
O
R/L
L
S
R
L W
B/L
L Y/G B/L
(GRAY)
G/W Sb
A
Sb G/W
(GRAY)
Y B/L
(BLACK)
B/L P/L L
(BLACK)
L
P O/R
B/W
Q
MAIN HARNESS WIRE SUB LEAD
W
B/L
L Y/G B/L
T
P/L
B/L
L
Y
B/L
L
B/L
B/W
M
L
ELEC
(BLACK)
Y
Br/Y
B
6
R
R
20A
L/W Lg Y/G O/G W L/Y B/W G/Y L G/L Br O/B
Sb G/W B/Y Br/W P/L Y B/L L/R Y/R W/L R/L R/B
COOLING SYSTEM
–
+
EBS00532
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EBS01085
–
ELEC
+
EBS01044
TROUBLESHOOTING
2. Battery
The radiator fan motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. circuit breaker (fan motor)
7. coolant temperature sensor
8. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Replace
switch.
EBS01043
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
YES
NO
Replace the fuse(s).
8 - 43
the
main
COOLING SYSTEM
EBS01086
ELEC
–
+
5. Radiator fan motor relay
4. Radiator fan motor
• Remove the radiator fan motor relay from
the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor relay
terminal as shown.
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (12 V) as shown.
Positive battery lead → blue 1
Negative battery lead → black 2
CAUTION:
When checking the radiator fan motor
relay, reversing the polarity connections
will damage the relay. If a damaged relay
is installed and the main switch is turned
to “ON”, the ECU will also be damaged.
• Check the radiator fan motor relay of continuity.
Positive battery lead → brown 1
Negative battery lead → yellow/red 2
• Does the radiator fan motor turn?
YES
Positive tester probe → red/white 3
Negative tester probe → red/blue 4
NO
The
radiator
fan
motor is faulty and
must be replaced.
• Does the radiator fan motor relay have
continuity between red/white and red/
blue?
YES
NO
The
radiator
fan
motor relay is faulty
and
must
be
replaced.
8 - 44
COOLING SYSTEM
ELEC
–
+
EBS01089
6. Circuit breaker (fan motor)
• Remove the circuit breaker from the wire
harness.
7. Coolant temperature sensor
• Remove the coolant temperature sensor
from the cylinder head.
• Connect the pocket tester (Ω × 10) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
The circuit breaker 1 is attached to the wire
harness with white tape near the headlight
relay 2.
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
_
2
1
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
• Connect the pocket tester (Ω × 1) to the
circuit breaker.
Test
step
Coolant
temperature
Resistance
1
20 °C (68 °F)
2.32 ~ 2.59 kΩ
2
80 °C (176 °F)
0.310 ~ 0.326 kΩ
3
110 °C (230 °F)
0.140 ~ 0.144 kΩ
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.
Circuit breaker resistance
Zero Ω at 20 °C (68 °F)
YES
NO
Replace the circuit
breaker.
T.
R.
8 - 45
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
COOLING SYSTEM
ELEC
–
+
EBS01090
8. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES
Replace the ECU.
• Does the coolant temperature sensor
operate properly?
YES
NO
Replace the coolant
temperature sensor.
8 - 46
NO
Properly connect or
repair the cooling
system’s wiring.
STARTING FAILURE/HARD STARTING
TRBL
SHTG
EBS00537
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check,
adjustment and replacement of parts.
_
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel strainer
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
Air filter
• Clogged air filter element
ELECTRICAL SYSTEM
Spark plug
• Improper plug gap
• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap
Ignition coil
• Broken or shorted primary/secondary
• Faulty spark plug lead
• Broken body
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty clutch switch
• Loose connections
Starter motor
• Faulty starter motor
• Faulty starter relay
• Faulty relay unit
• Faulty starter clutch
Battery
• Faulty battery
COMPRESSION SYSTEM
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
• Worn, damaged or seized cylinder
Valves, camshaft and crankshaft
• Improperly sealed valve
• Improperly contacted valve and valve seat
• Improper valve timing
• Broken valve spring
• Seized camshaft
• Seized crankshaft
Piston and piston rings
• Improperly installed piston ring
• Worn, fatigued or broken piston ring
• Seized piston ring
• Seized or damaged piston
Crankcase and crankshaft
• Improperly seated crankcase
• Seized crankshaft
Valve train
• Improperly adjusted valve clearance
• Improperly adjusted valve timing
9-1
POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED
PERFORMANCE/FAULTY GEAR SHIFTING
TRBL
SHTG
EBS00538
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Electrical system
• Faulty spark plug
• Faulty ECU
• Faulty crankshaft position sensor
• Faulty ignition coil
Valve train
• Improperly adjusted valve clearance
Air filter
• Clogged air filter element
EBS00539
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
ENGINE
FUEL SYSTEM
Air filter
Fuel pump
• Clogged air filter element
• Faulty fuel pump
Air intake system
• Clogged or leaking air duct
EBS00541
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH DRAGGING”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Bent shift shaft
Shift cam, shift forks
• Groove jammed with impurities
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Jammed impurities
• Incorrectly assembled transmission
Shift guide
• Broken shift guide
JUMPS OUT GEAR
Shift shaft
• Improperly adjusted shift lever position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Improper thrust play
• Worn shift cam groove
Transmission
• Worn gear dog
9
9-2
CLUTCH SLIPPING/DRAGGING/
OVERHEATING/OVERCOOLING
TRBL
SHTG
EBS00545
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
Clutch
• Loose clutch spring
• Fatigued clutch spring
• Worn friction plate
• Worn clutch plate
• Incorrectly assembled clutch
Engine oil
• Low oil level
• Improper quality (low viscosity)
• Deteriorated oil
CLUTCH DRAGGING
Clutch
• Warped pressure plate
• Unevenly tensioned clutch springs
• Match marks not aligned
• Loose clutch boss nut
• Burnt primary driven gear bushing
• Bent clutch plate
• Swollen friction plate
• Broken clutch boss
Engine oil
• Improper quality (high viscosity)
• Deteriorated oil
EBS00546
OVERHEATING
OVERHEATING
Ignition system
• Improper spark plug gap
• Improper spark plug heat range
• Faulty ECU
Fuel system
• Clogged air filter element
Compression system
• Heavy carbon build-up
Engine oil
• Improper oil level
• Improper oil viscosity
• Inferior oil quality
Brake
• Brake drag
Cooling system
• Low coolant level
• Clogged or damaged radiator
• Damaged or faulty water pump
• Faulty fan motor
• Faulty coolant temperature sensor
• Thermostat stays closed
EBS00548
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
9-3
FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION/
UNSTABLE HANDLING
TRBL
SHTG
EBS00550
FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake
• Worn brake pads
• Worn disc
• Air in brake fluid
• Leaking brake fluid
• Faulty master cylinder kit cup
• Faulty caliper kit seal
• Loose union bolt
• Broken brake hose and pipe
• Oily or greasy disc/brake pads
• Improper brake fluid level
EBS00551
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
• Bent or damaged damper rod
• Damaged oil seal lip
• Fatigued shock absorber spring
• Leaking oil or gas
EBS00552
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar
• Improperly installed or bent
Steering
• Incorrect toe-in
• Bent steering stem
• Improperly installed steering stem
• Damaged bearing or bearing race
• Bent tie-rods
• Deformed steering knuckles
Tires
• Uneven tire pressures on both sides
• Incorrect tire pressure
• Uneven tire wear
Wheels
• Deformed wheel
• Loose bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent
• Damaged frame
Swingarm
• Worn bearing or bushing
• Bent or damaged
9-4
LIGHTING SYSTEM
TRBL
SHTG
EBS00553
LIGHTING SYSTEM
HEADLIGHT BULB BURNT OUT
• Improper bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded
• Faulty main switch
• Faulty light switch
• Bulb life expired
HEADLIGHT DOES NOT COME ON
• Improper bulb
• Too many electrical accessories
• Hard charging (broken stator coil and/or
faulty rectifier/regulator)
• Incorrect connection
• Improperly grounded
• Poor contacts (main or light switch)
• Bulb life expired
• Faulty headlight relay
TAIL/BRAKE LIGHT DOES NOT COME ON
• Too many electrical accessories
• Incorrect connection
• Wrong tail/brake light LED
9-5
YFM700RV WIRING DIAGRAM
A
R/B
L/W Lg Y/G O/G W L/Y B/W G/Y L G/L Br O/B
Sb G/W B/Y Br/W P/L Y B/L L/R Y/R W/L R/L R/B
O
B
O
L
M
L/Y
Br
L/Y
W
W W
W W
G/W L/Y
W
R
G/Y O/B Br
W
Lg G/L W/L
G/W
A
W
W
W
W
W
W
3
(GLAY)
G/W
Br O/B G/Y
D
W/L G/L Sb
R
E
F
G
Sb G/W
(GRAY)
(GRAY)
MAIN HARNESS WIRE SUB LEAD
R/L R/B
G/W
C
Br
(GRAY)
2
L/Y B/L
W
R/B
R/B
N
R/L
G/W
H
B
Br/W B/W
I
(BLACK)
O/B
5
R
R
R
4
Br
(GRAY)
Br/W
Br
R
6
7
O
B/W
Br/W
J
R
Lg
B/Y B/L
B
(GREEN)
Lg
B/Y
K
(BLACK)
B/Y
P
B/L
O/B
B
B
Br
8
B
L/W
L/W
B
L/W
L/W R/B
Br/G
B
Br/L
B
Lg
B Br
Lg
L/W Br
Br/L R
(GRAY)
R
0
R/W
Lg
R R
R
R
G/L
G/Y
R
ON
OFF
W/L
Br/G
R
i
G/Y
10A
R
20A
W
B
B/L
1
G/W Sb
O
B
Lg
L
L
W
B/L
W
B/L
B
9
L W
B/L
A
R/W
Q
P O/R
B/W
Br
R/W
Br
Br/G L/W
h
R/L
L/W L/R Br
Br
Y/R
B/Y
L/B
L/R
R/L
R/B L/B R/L
Sb B/Y Lg
R
L
W/L
Sb
Y
G/L
Y
B/L
L
Y/R
R/L
R/L
f
Y/R
Sb
L/R
10A
Br
Br/L
B R/L
L
B
g
B
e
R/L
10A
Br/L
B/Y B
d
B
(BLACK)
Sb
Sb
B
B/W
15A
Br/L
B/L P/L L
P/L
B/L
A
X
Br/Y
S
L
P/L
Y/G
O/G
Sb
B/Y
B
Br/R
W
L Y/G B/L
B
V
O/G
Br
T
B
Br/Y
b
c
Y Br/Y
(BLACK)
B
Y
Br/Y
B
B
Y Br/Y
(BLACK)
(BLACK)
Br R/B
Z
[
OFF
LO
B
L Y
Y
Y/R
Y L
Br/R
R/B B
B R/B
Br L/B
L/B Br
(BLACK)
(BLACK)
B
G B
L Y
B
a
L
OFF
PUSH
Y
L Y
Br O/G
L Y/G B/L
\
OFF
RUN
B
L/B
HI
(BLACK)
Y
Br/R
Y
R/L
O/G
U
L
B
L
L
Y
Y
G
R/L B
]
B
B
Y G
Y G
`
B
B
Y G
B
(BLACK)
(BLACK)
G
Y
B O/G
(GRAY)
Y Y
(BLACK)
`
Y G
B
(BLACK)
B
B
G
Y
B
(BLACK)
Y B/L
(BLACK)
B
YFM700RV WIRING DIAGRAM
1 Crankshaft position sensor
2 A.C. magneto
3 Rectifier/regulator
4 Main switch
5 Fuel injection system fuse
6 Battery
7 Main fuse
8 Starter relay
9 Starter motor
0 Relay unit
A Starting circuit cut-off relay
B Fuel pump relay
C Indicator light assembly
D Fuel level warning light
E Engine trouble warning light
F Coolant temperature warning
light
G Reverse indicator light
H Neutral indicator light
I Reverse switch
J Self-diagnosis signal coupler
K ECU
L Ignition coil
M Spark plug
N Fuel injector
O Intake air temperature sensor
P Coolant temperature sensor
Q Speed sensor
R Throttle position sensor
S Intake air pressure sensor
T Lean angle sensor
U Fuel pump
V Resistor
W Neutral switch
X Clutch switch
Y Handlebar switch
Z Light switch
[ Engine stop switch
\ Start switch
] Headlight relay
_ Headlight
a Tail/brake light
b Rear brake light switch
c Front brake light switch
d Headlight fuse
e Signaling system fuse
f Ignition fuse
g Radiator fan motor
h Radiator fan motor relay
i Circuit breaker (fan motor)
COLOR CODE
B ............Black
Br ...........Brown
G............Green
L.............Blue
Lg...........Light green
O............Orange
P ............Pink
R ............Red
Sb ..........Sky blue
W ...........White
Y ............Yellow
B/L .........Black/Blue
B/W........Black/White
B/Y.........Black/Yellow
Br/G .......Brown/Green
Br/L ........Brown/Blue
Br/R .......Brown/Red
Br/W.......Brown/White
Br/Y........Brown/Yellow
G/L.........Green/Blue
G/W .......Green/White
G/Y ........Green/Yellow
L/B .........Blue/Black
L/R .........Blue/Red
L/W ........Blue/White
L/Y .........Blue/Yellow
O/B ........Orange/Black
O/G ........Orange/Green
O/R ........Orange/Red
P/L .........Pink/Blue
R/B.........Red/Black
R/L .........Red/Blue
R/W........Red/White
W/L ........White/Blue
Y/G ........Yellow/Green
Y/R.........Yellow/Red
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.
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