Yamaha YZF-R1 2000 Service manual

Yamaha YZF-R1 2000 Service manual
YZF-R1
’98
4XV1-AE1
SERVICE MANUAL
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and
repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone
without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EB002000
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person checking or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EB003000
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner
of each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each
page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start
of each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
EB004000
1
SYMBOLS
2
GEN
INFO
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 Carburetor(-s)
7 Chassis
8 Electrical system
9 Troubleshooting
ENG
5
6
COOL
CARB
7
8
CHAS
ELEC
9
–
Symbols 0 to G indicate the following.
0
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
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication points.
G
E
K
L
B
M
M
LS
N
M
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum disulfide oil
K Wheel bearing grease
L Lithium soap base grease
M Molybdenum disulfide grease
New
N Apply locking agent (LOCTITE)
O Replace the part
CHAPTER TITLES
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING
CARBURETION
CHASSIS
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
CARB
6
CHAS
7
–
ELECTRICAL
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION .................................................................1-1
VEHICLE IDENTIFICATION NUMBER ..................................................1-1
MODEL CODE .......................................................................................1-1
IMPORTANT INFORMATION .......................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................1-2
REPLACEMENT PARTS ........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ................................................1-2
USING A DYNAMOMETER ..................................................................1-3
LOCK WASHERS/PLATES AND COTTER PINS ..................................1-3
BEARINGS AND OIL SEALS ................................................................1-3
CIRCLIPS ...............................................................................................1-3
CHECKING THE CONNECTIONS .................................................................1-4
SPECIAL TOOLS ...........................................................................................1-5
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering
head pipe.
EB100020
MODEL CODE
The model code label 1 is affixed to the
frame. This information will be needed to
order spare parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EB102000
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.
EB102010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EB102020
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.
1-2
IMPORTANT INFORMATION
GEN
INFO
USING A DYNAMOMETER
The YZF-R1 has a carbon muffler that may
change color when exposed to high temperatures. Therefore, when using a dynamometer always use a fan to cool the
muffler.
EB102030
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 washer tabs and the cotter
pin ends along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. 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 base grease. Oil bearings
liberally when installing, if appropriate.
1 Oil seal
CAUTION:
ACHTUNG:
Do not spin the bearing with compressed air because this will damage
the bearing surfaces.
1 Bearing
EB102050
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 that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip
receives.
4 Shaft
1-3
CHECKING THE CONNECTIONS
GEN
INFO
EB103000
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 that all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112
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.
1-4
SPECIAL TOOLS
GEN
INFO
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/Function
Flywheel puller
90890-01080
This tool is used to remove the generator
rotor.
Rotor holding tool
90890-01235
This tool is used to hold the generator
rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt.
Drive chain cutter
90890-01286
This tool is used to remove the drive
chain.
Piston pin puller
90890-01304
This tool is used to remove the piston
pins.
Fuel level gauge
90890-01312
This tool is used to measure the fuel level
in the float chamber.
Radiator cap
tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Damper rod holder
90890-01423
This tool is used to hold the damper rod
assembly when loosening or tightening
the damper rod assembly bolt.
1-5
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Oil filter wrench
90890-01426
This tool is needed to loosen or tighten
the oil filter cartridge.
Rod holder
90890-01434
This tool is used to support the damper
adjusting rod.
Rod puller
90890-01437
Rod puller
attachment
90890-01436
Rod puller
Rod puller attachment
These tools are used to pull up the front
fork damper rod.
Fork spring compressor
90890-01441
This tool is used to disassemble or assemble the front fork legs.
Fork seal driver
90890-01442
This tool is used to install the front fork’s
oil seal and dust seal.
Micrometer
90890-03008
This tool is used to measure the piston
skirt diameter.
Vacuum gauge
90890-03094
Vacuum gauge
attachment
90890-03060
Vacuum gauge
Vacuum gauge attachment
Compression
gauge
90890-03081
Adapter
90890-04136
Compression gauge
Adapter
This gauge is used to synchronize the carburetors.
These tools are used to measure engine
compression.
Pocket tester
90890-03112
This tool is used to check the electrical
system.
1-6
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Engine tachometer
90890-03113
This tool is used to check engine speed.
Timing light
90890-03141
This tool is used to check the ignition timing.
Carburetor angle driver
90890-03158
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring compressor
90890-04019
Attachment
90890-04108
90890-04114
Valve spring compressor
Attachment
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to remove or install
the valve assemblies.
These tools are used to install the water
pump seal.
Clutch holding tool
90890-04086
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
Valve guide remover
90890-04111
90890-04116
This tool is used to remove or install the
valve guides.
Valve guide installer
90890-04112
90890-04117
This tool is used to install the valve
guides.
Valve guide reamer
90890-04113
90890-04118
This tool is used to rebore the new valve
guides.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Ignition checker
90890-06754
This tool is used to check the ignition system components.
Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
1-8
GEN
INFO
Illustration
SPEC
2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS .......................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-15
TIGHTENING TORQUES ............................................................................2-18
GENERAL TIGHTENING TORQUES ..................................................2-18
ENGINE TIGHTENING TORQUES .....................................................2-19
CHASSIS TIGHTENING TORQUES ...................................................2-22
LUBRICATION POINTS AND LUBRICANT TYPES ...................................2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES .............2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...........2-24
OIL FLOW DIAGRAMS ...............................................................................2-25
COOLANT FLOW DIAGRAMS ...................................................................2-29
CABLE ROUTING ........................................................................................2-33
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
2,035 mm (except for N, S, SF)
2,095 mm (for N, S, SF)
695 mm
1,095 mm
815 mm
1,395 mm
140 mm
3,400 mm
-------------------------
198 kg
177 kg
197 kg
----------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
998 cm3
Forward-inclined parallel 4-cylinder
74 × 58 mm
11.8:1
1,050 ~ 1,150 r/min
29.3 kPa (220 mm Hg)
----------------------
1,450 kPa (14.5 kgf/cm2) at 400 r/min
----
Regular gasoline
----
18 L
5.5 L
-------
Wet sump
-------
SAE20W40SE or SAE10W30SE
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
3.6 L
2.7 L
-------
2.9 L
----
45 kPa at 1,100 r/min
(0.45 kgf/cm2 at 1,100 r/min)
490 ~ 570 kPa (4.9 ~ 5.7 kgf/cm2)
----
2-2
----
ENGINE SPECIFICATIONS
Item
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
Starting system type
Spark plugs
Model (manufacturer) × quantity
Spark plug gap
Cylinder head
Max. warpage
Standard
SPEC
Limit
Cartridge (paper)
180 ~ 220 kPa (1.8 ~ 2.2 kgf/cm2)
-------
Trochoidal
0.09 ~ 0.15 mm
-------
0.03 ~ 0.08 mm
----
2.55 L
95 ~ 125 kPa (0.95 ~ 1.25 kgf/cm2)
----
340 mm
298 mm
24 mm
----------
0.45 L
----
Single-suction centrifugal pump
68/43 × 28/28 (1.581)
---Electric starter
CR9E/U27ESR-N (NGK/DENSO) × 4
0.7 ~ 0.8 mm
----
------0.15 mm
------0.1 mm
2-3
ENGINE SPECIFICATIONS
Item
Standard
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Intake camshaft lobe dimensions
Chain drive (right)
24.500 ~ 24.521 mm
24.437 ~ 24.450 mm
0.050 ~ 0.084 mm
SPEC
Limit
-------------
C
A
B
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
32.5 ~ 32.6 mm
24.95 ~ 25.05 mm
7.45 ~ 7.65 mm
32.4 mm
24.85 mm
----
32.95 ~ 33.05 mm
24.95 ~ 25.05 mm
7.75 ~ 7.95 mm
----
32.85 mm
24.85 mm
---0.03 mm
C
A
B
Measurement A
Measurement B
Measurement C
Max. camshaft runout
2-4
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
SPEC
Limit
RH2015 / 130
Automatic
-------
0.11 ~ 0.20 mm
0.21 ~ 0.30 mm
-------
B
C
D
A
Head Diameter
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
Valve stem runout
Valve seat width
Intake
Exhaust
Seat Width
Face Width
Margin Thickness
22.9 ~ 23.1 mm
24.4 ~ 24.6 mm
-------
1.76 ~ 2.90 mm
1.76 ~ 2.90 mm
-------
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
-------
0.5 ~ 0.9 mm
0.5 ~ 0.9 mm
-------
3.975 ~ 3.900 mm
4.460 ~ 4.475 mm
3.945 mm
4.43 mm
4.000 ~ 4.012 mm
4.500 ~ 4.512 mm
4.05 mm
4.55 mm
0.010 ~ 0.037 mm
0.025 ~ 0.052 mm
----
0.08 mm
0.1 mm
0.01 mm
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
2-5
-------
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
Standard
-------
34.5 mm
35 mm
-------
82 ~ 96 N (8.36 ~ 9.79 kgf)
110 ~ 126 N (11.22 ~ 12.85 kgf)
-------
----
Exhaust
----
Cylinders
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
Limit
38.9 mm
40.67 mm
Intake
Winding direction (top view)
Intake
Exhaust
SPEC
2.5˚ /
1.7 mm
2.5˚ /
1.8 mm
Clockwise
Clockwise
Forward-inclined, parallel 4-cylinder
74 × 58 mm
11.8:1
74.00 ~ 74.010 mm
-------
2-6
-------
------------0.05 mm
0.05 mm
ENGINE SPECIFICATIONS
Item
Standard
Pistons
Piston-to-cylinder clearance
Diameter D
0.03 ~ 0.055 mm
73.955 ~ 73.970 mm
SPEC
Limit
0.12 mm
----
H
D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
5 mm
----
17.002 ~ 17.013 mm
0.5 mm
Intake side
----------
16.991 ~ 17.000 mm
0.002 ~ 0.022 mm
---0.072 mm
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2nd ring
Barrel
0.90 × 2.75 mm
0.19 ~ 0.31 mm
0.030 ~ 0.065 mm
-------------
Taper
0.8 × 2.8 mm
0.30 ~ 0.45 mm
0.020 ~ 0.055 mm
-------------
1.5 × 2.6 mm
0.10 ~ 0.35 mm
-------
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
2-7
ENGINE SPECIFICATIONS
Item
Standard
Connecting rods
Crankshaft-pin-to-big-end-bearing clearance
Bearing color code
Crankshaft
F
C
SPEC
C
Limit
0.016 ~ 0.040 mm
----
–1 = Violet 0 = White 1 = Blue 2 = Black
----
C
E
D
A
B
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
52.40 ~ 57.25 mm
300.75 ~ 302.65 mm
0.160 ~ 0.262 mm
0.004 ~ 0.028 mm
------0.03 mm
-------
–1 = Pink/violet 0 = Pink/white
1 = Pink/blue 2 = Pink/black
3 = Pink/brown
----
Wet, multiple disc
Rack and pinion (pull rod type)
Cable operation
Right-foot operation
10 ~ 15 mm
----------------
2.9 ~ 3.1 mm
8
2.8 mm
----
1.9 ~ 2.1 mm
7
----
------0.1 mm
6.5 mm
1 spring per valve
2-8
-------
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Installed shift rod length
Air filter type
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Carburetors
Model (manufacturer) × quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Standard
Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
43/16 (2.688)
Left-foot operation
SPEC
Limit
-------------------
39/15 (2.600)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)
-------
------------------0.08 mm
0.08 mm
Shift drum
---305 mm
Dry element
---0.1 mm
-------
Electrical
4SV (MITSUBISHI)
20 kPa (0.2 kgf/cm2)
----------
BDSR40 (MIKUNI) × 4
3 ~ 5 mm
-------
4XV1 00
#130
Carburetors 1 and 4: #60
Carburetors 2 and 3: #65
6DEY5-53-3
P-0
#120
1.0
#17.5
0.8
0.9
0.8
2.5
1.5
----------
2-9
-------------------------------
ENGINE SPECIFICATIONS
Item
Starter jet 1
Starter jet 2
Butterfly valve size
Fuel level (below the line on the
float chamber)
Max. EXUP cable free play (at the
EXUP valve pulley)
Standard
SPEC
Limit
#35
0.7
#100
4.1 ~ 5.1 mm
-------------
1.5 mm
----
2 - 10
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 197 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
24˚
92 mm
----------
Cast wheel
----
17 × MT3.50
Aluminum
135 mm
----------
-------
1 mm
0.5 mm
Cast wheel
----
17 × MT6.00
Aluminum
130 mm
----------
-------
1 mm
0.5 mm
Tubeless
120/70 ZR17 (58W)
MEZ3 FRONT (METZELER) (for GB)
TX15 (MICHELIN) (for N, D, NL, B, E, P,
I, GR)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
----
2 - 11
----------
---------1.6 mm
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 197 kg
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake discs
Diameter × thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Standard
Limit
Tubeless
190/50 ZR17 (73W)
MEZ3 (METZELER) (for GB)
TX25 (MICHELIN) (for N, D, NL, B, E, P,
I, GR)
----------
250 kPa (2.5 kg/cm2, 2.5 bar)
290 kPa (2.9 kg/cm2, 2.9 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
---Dual-disc brake
Right-hand operation
DOT 4
298 × 5 mm
------5.5 mm
Master cylinder inside diameter
14 mm
Caliper cylinder inside diameter
30.2 mm and 27 mm
Rear brake
Brake type
Single-disc brake
Operation
Right-foot operation
Brake pedal position (from the top 35 ~ 40 mm
of the brake pedal to the bottom of
the rider footrest bracket)
Recommended fluid
DOT 4
Brake discs
Diameter × thickness
245 × 5 mm
Min. thickness
---Max. deflection
---Brake pad lining thickness
5 mm
Master cylinder inside diameter
Caliper cylinder inside diameter
SPEC
12.7 mm
38.2 mm
2 - 12
---------1.6 mm
------------4.5 mm
0.1 mm
0.5 mm
----------------
------4.5 mm
0.1 mm
0.5 mm
-------
CHASSIS SPECIFICATIONS
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Damper adjusting rod locknut distance
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
* from the fully turned-in position
Standard
SPEC
Limit
Telescopic fork
Coil spring/oil damper
135 mm
----------
255 mm
85 mm
242.4 mm
7.35 N/mm (0.75 kgf/mm)
0 ~ 135 mm
No
----------
Suspension oil “01” or equivalent
477 cm3
78 mm
----------
11 mm
----
8
6
1
----------
13
5
1
----------
11
5
1
----------
2 - 13
-------
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
* from the fully turned-in position
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
Standard
SPEC
Limit
Angular ball bearings
----
Swingarm (link suspension)
Coil spring/gas-oil damper
-------
65 mm
----
176 mm
162.5 mm
7.84 N/mm (0.8 kgf/mm)
0 ~ 65 mm
No
1,200 kPa (12 kgf/cm2)
-------------------
1
4
9
----------
12
6
1
----------
12
8
1
----------
-------
1 mm
1 mm
50ZVM (DAIDO)
114
40 ~ 50 mm
150.1 mm
2 - 14
-------------
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit
model (manufacturer)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug caps
Material
Resistance
Throttle position sensor standard
resistance
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance
Voltage regulator
Regulator type
Model
No-load regulated voltage
Rectifier
Model
Rectifier capacity
Withstand voltage
Battery
Battery type
Battery voltage/capacity
Headlight type
Indicator light type × quantity
Bulbs (voltage/wattage × quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Meter light
Standard
Limit
12 V
----
Transistorized coil ignition
5˚ BTDC at 1,100 r/min
55˚ BTDC at 5,000 r/min
Throttle position sensor and electrical
248 ~ 372 Ω / Gy–B
TNDF41 (DENSO)
-------------------
JO313 (DENSO)
6 mm
1.87 ~ 2.53 Ω
12 ~ 18 kΩ
-------------
Resin
10 kΩ
4 ~ 6 kΩ
----------
AC magneto
F4T361 (MITSUBISHI)
14 V / 26 A at 5,000 r/min
0.45 ~ 0.55 Ω at 20˚C
-------------
Semiconductor, field control
SH650A-12
14.1 ~ 14.9 V
----------
SH650A-12
18 A
200 V
----------
GT12B-4
12V / 10AH
Halogen bulb
LED × 5
-------
12 V 60 W / 55 W × 2
12 V 5 W × 2
12 V 5 W / 21 W × 2
12 V 21 W × 4
12 V 1.4 W × 4
----------------
2 - 15
ELECTRICAL SPECIFICATIONS
Item
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Horn
Horn type
Model (manufacturer) × quantity
Max. amperage
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Oil level switch model (manufacturer)
Fuel sender
Model (manufacturer)
Resistance
Sidestand relay
Model
Coil resistance
Fuel pump maximum amperage
Fuel pump relay model (manufacturer)
Radiator fan model (manufacturer)
Thermo switch model (manufacturer)
Standard
SPEC
Limit
Constant mesh
----
SM-13 (MITSUBA)
0.8 kW
-------
10 mm
7.03 ~ 10.63 N (717 ~ 1,084 gf)
0.025 ~ 0.035 Ω
28 mm
0.7 mm
5 mm
------27 mm
----
MS5F-631 (JIDECO)
100 A
4.18 ~ 4.62 Ω
----------
Plain
YF-12 (NIKKO) × 1
3A
----------
Full-transistor
FE246BH (DENSO)
No
60 ~ 120 cycles/min.
21 W × 2
3GM (DENSO)
-------------------
3GM (DENSO)
899.7 ~ 900.3 kΩ at 25 ˚C
-------
3EN-00
225 Ω
1.2 A
3EN-00 (OMRON)
-------------
4XV (TOYO RADIATOR)
3LN (NIPPON THERMOSTAT)
-------
2 - 16
ELECTRICAL SPECIFICATIONS
Item
Temperature sender
Model (manufacturer)
Resistance
Fuses (amperage × quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
Standard
SPEC
Limit
2YK (NIPPON SEIKI)
47.5 ~ 56.8 Ω at 80 ˚C
16.5 ~ 20.5 Ω at 115 ˚C
-------
30 A × 1
20 A × 1
20 A × 1
15 A × 1
7.5 A × 1
7.5 A × 1
-------------------
2 - 17
SPEC
CONVERSION TABLE/TIGHTENING TORQUES
EB201000
EB202001
CONVERSION TABLE
TIGHTENING TORQUES
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.
GENERAL TIGHTENING TORQUES
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.
Ex.
METRIC
MULTIPLIER
** mm ×
0.03937
=
2 mm ×
0.03937
=
IMPERIAL
** in
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit Multiplier
m·kg
Tightenm·kg
ing torque cm·kg
cm·kg
Imperial unit
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
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
55.997
kg/cm2
14.2234
Centigrade
9/5+32
(˚C)
A: Width across flats
B: Thread diameter
lb/in
psi (lb/in2)
Fahrenheit (˚F)
2 - 18
A
(nut)
B
(bolt)
10 mm
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
TIGHTENING TORQUES
SPEC
ENGINE TIGHTENING TORQUES
Item
Tightening
torque
Fastener Thread size Q’ty
Nm m·kgf
Remarks
Spark plugs
Cylinder head
–
Nut
M10
M10
4
8
13
50
1.3
5.0
E
Cylinder head
Cap nut
M10
2
50
5.0
E
Cylinder head
Camshaft caps
Bolt
Bolt
M6
M6
2
28
12
10
1.2
1.0
E
Bolt
Bolt
Stud bolt
M6
M8
M8
6
1
8
12
20
15
1.2
2.0
1.5
E
Connecting rod caps
Generator rotor
Nut
Bolt
M8
M10
8
1
36
95
3.6
9.5
Crankshaft sprocket
Bolt
M10
1
60
6.0
Cap bolt (timing chain tensioner)
Camshaft sprocket
Water pump inlet pipe
Water pump outlet pipe
Oil/water pump assembly driven
sprocket
Oil pump
Oil cooler
Bolt
Bolt
Bolt
Bolt
M6
M7
M6
M6
1
4
1
1
10
24
10
10
1.0
2.4
1.0
1.0
Bolt
M6
1
15
1.5
Bolt
Bolt
M6
M20
1
1
10
35
1.0
3.5
–
Bolt
M14
M6
1
2
43
10
4.3
1.0
Bolt
M6
1
10
1.0
Bolt
Bolt
–
M6
M20
M20
1
1
1
10
70
17
1.0
7.0
1.7
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Stud bolt
M8
M8
M6
M6
M8
M8
M10
8
3
4
3
2
1
10
20
20
10
10
10
20
10
2.0
2.0
1.0
1.0
1.0
2.0
1.0
Crankcase
Bolt
M9
10
32
3.2
E
Crankcase
Bolt
M6
2
14
1.4
E
Crankcase
Bolt
M6
18
12
1.2
E
Crankcase
Bolt
M8
4
24
2.4
E
Generator rotor cover
Drive sprocket cover
Bolt
Bolt
M6
M6
9
5
12
10
1.2
1.0
Cylinder head cover
Oil passage check bolt
Cylinder head (exhaust pipe)
Engine oil drain bolt
Oil strainer housing
Oil/water pump assembly driven
sprocket cover
Oil pipe
Oil filter bolt
Oil filter cartridge
Exhaust pipes
Muffler clamp
Exhaust pipe emission check bolts
EXUP valve pulley cover
EXUP cable holder
Exhaust pipe bracket
Crankcase (cylinder head)
2 - 19
M
E
E
LT
LT
LT
E
LT
LT
LT
E
LT
E
TIGHTENING TORQUES
Item
SPEC
Tightening
torque
Fastener Thread size Q’ty
Nm m·kgf
Clutch cover
Pickup coil rotor cover
Shift shaft cover
Oil baffle plate
Timing mark accessing screw
Starter clutch idle gear shaft
Starter clutch
Bolt
Bolt
Bolt
Bolt
–
Bolt
Bolt
M6
M6
M6
M6
M8
M6
M6
8
8
5
5
1
1
3
12
12
12
10
15
10
12
1.2
1.2
1.2
1.0
1.5
1.0
1.2
Clutch boss
Nut
M20
1
70
7.0
Clutch springs
Bolt
M6
6
8
0.8
Drive sprocket
Nut
M22
1
85
8.5
Screw
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
–
Bolt
–
–
M6
M6
M8
M6
M6
M6
M6
M10
M6
–
M16
3
2
1
2
1
3
1
1
2
1
1
12
10
22
7
10
10
10
20
10
15
23
1.2
1.0
2.2
0.7
1.0
1.0
1.0
2.0
1.0
1.5
2.3
Main axle bearing housing
Shift drum retainer
Shift shaft spring stopper
Shift rod locknut
Shift arm
Stator coil
Ignitor unit
Neutral switch
Pickup coil
Temperature sender
Thermo switch
2 - 20
Remarks
LT
LT
Use a lock
washer.
Use a lock
washer.
LT
LT
LT
LT
LT
TIGHTENING TORQUES
Crankcase tightening sequence:
2 - 21
SPEC
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Item
Thread size
Upper bracket pinch bolts
Steering stem nut
Handlebar pinch bolts
Lower ring nut
Lower bracket pinch bolts
Brake fluid reservoir cap stopper
Front brake hose union bolts
Front brake master cylinder
Engine mounting
Left front mounting bolts
Right front mounting bolt
Rear mounting bolts
Pinch bolts
Exhaust pipe bracket
Pivot shaft nut
Connecting arms
Relay arm and connecting arms
Relay arm
Rear shock absorber and relay arm
Rear shock absorber assembly
Fuel cock
Fuel sender and fuel tank
Coolant reservoir and radiator
Rider footrest bracket
Passenger footrest bracket
Rear master cylinder
Rear brake hose union bolts
Sidestand
Front wheel axle
Rear wheel axle nut
Front brake caliper and front fork
Rear brake caliper and bracket
Brake disc and wheel
Rear wheel sprocket and rear wheel drive hub
Brake caliper and bleed screw
Pinch bolt (front wheel axle)
Tightening
torque
Nm
m·kgf
M8
M28
M8
M30
M8
M4
M10
M6
23
115
17
9
23
12
30
13
2.3
11.5
1.7
0.9
2.3
1.2
3.0
1.3
M10
M12
M10
M8
M8
M18
M10
M10
M10
M10
M10
M6
M6
M6
M8
M8
M8
M10
M10
M18
M24
M10
M10
M6
M10
M8
M8
40
55
55
24
24
125
40
40
40
40
40
7
7
5
28
28
23
30
63
72
150
40
40
18
69
6
23
4.0
5.5
5.5
2.4
2.4
12.5
4.0
4.0
4.0
4.0
4.0
0.7
0.7
0.5
2.8
2.8
2.3
3.0
6.3
7.2
15.0
4.0
4.0
1.8
6.9
0.6
2.3
Remarks
See NOTE.
HINWEIS:
NOTE:
1.First, tighten the ring nut to approximately 28 Nm (2.8 m • kg) with a torque wrench, then
loosen the ring nut completely.
2.Retighten the ring nut to specification.
2 - 22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Oil seal lips
LS
O-rings
LS
Bearings
E
Crankshaft pins
E
Piston surfaces
E
Piston pins
E
Connecting rod bolts and nuts
M
Crankshaft journals
E
Camshaft lobes
M
Camshaft journals
M
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
E
Water pump impeller shaft
E
Oil pump rotors (inner and outer)
E
Oil pump housing
E
Oil strainer
E
Starter clutch idle gear inner surface
E
Starter clutch assembly
E
Primary driven gear
E
Transmission gears (wheel and pinion)
M
Main axle and drive axle
M
Shift drum
E
Shift forks and shift fork guide bars
E
Shift shaft
E
Shift shaft boss
LS
Engine mounting bolts (rear)
LS
Cylinder head cover mating surface
Yamaha bond
No.1215
Crankcase mating surface
Yamaha bond
No.1215
Clutch cover (crankcase mating surface)
Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)
Yamaha bond
No.1215
Cylinder head cover
Yamaha bond
No.1215
2 - 23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EB202010
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
LS
Front wheel oil seal (right and left)
LS
Rear wheel oil seal
LS
Rear wheel drive hub oil seal
LS
Rear wheel drive hub mating surface
LS
Rear brake pedal
LS
Sidestand pivoting point and metal-to-metal moving parts
LS
Throttle grip inner surface
LS
Brake lever pivoting point and metal-to-metal moving parts
LS
Clutch lever pivoting point and metal-to-metal moving parts
LS
Rear shock absorber assembly oil seal
LS
Rear shock absorber assembly bearing
LS
Rear shock absorber assembly spacer
LS
Pivot shaft
LS
Connecting arm bearing (left and right)
LS
Spacer (relay arm and connecting arm)
LS
Oil seal (relay arm and connecting arm)
LS
2 - 24
OIL FLOW DIAGRAMS
EB203000
OIL FLOW DIAGRAMS
1 Intake camshaft
2 Exhaust camshaft
3 Crankshaft
4 Oil cooler
5 Oil pipe
6 Oil strainer
7 Oil pump
2 - 25
SPEC
OIL FLOW DIAGRAMS
1 Exhaust camshaft
2 Intake camshaft
3 Oil filter
2 - 26
SPEC
OIL FLOW DIAGRAMS
1 Cylinder head
2 Crankshaft
2 - 27
SPEC
OIL FLOW DIAGRAMS
1 Main axle
2 Oil delivery pipe
3 Drive axle
2 - 28
SPEC
OIL FLOW DIAGRAMS
EB203000
COOLANT FLOW DIAGRAMS
1 Thermostat
2 Radiator cap
3 Coolant reservoir
4 Radiator
5 Oil cooler
6 Water jacket joint
2 - 29
SPEC
OIL FLOW DIAGRAMS
1 Thermostat housing
2 Water pump
3 Radiator
4 Radiator fan
2 - 30
SPEC
OIL FLOW DIAGRAMS
1 Radiator cap
2 Thermostat
3 Thermostat housing
4 Water pump
2 - 31
SPEC
OIL FLOW DIAGRAMS
1 Radiator
2 Thermo switch
3 Temperature sender
2 - 32
SPEC
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1 Throttle cables
2 Front brake hose
3 Clutch cable
4 Starter cable
5 Left handlebar switch lead
6 Main switch lead
7 Right handlebar switch lead
Å Properly insert the meter assembly coupler and rubber boot
into the meter assembly.
ı Route the meter assembly lead through the left side of the
headlight housing.
Ç Install the headlight relays onto the headlight housing bridge.
Î Connect to the right front turn signal connectors.
‰ Route the turn signal leads between the headlight housing
and headlight housing boss.
2 - 33
CABLE ROUTING
Ï Fasten the auxiliary light leads with a plastic locking tie.
Ì Fasten the wire harness to the headlight housing
boss with a plastic locking tie.
Ó Route the headlight lead through the plastic
guide.
È Route the right handlebar switch lead behind the
throttle cables. Do not cross the throttle cables
and the right handlebar switch lead.
Ô Route the thermo switch/temperature sender subwire harness to the outside of the radiator cap.
2 - 34
SPEC
 Route the right handlebar switch lead in
front of the throttle cables.
Ò Make sure that the horn leads face out.
˜ Route the throttle cables and right handlebar switch lead between the frame and
plastic frame panel and then between the
lower bracket and lower bracket panel.
Make sure that the right handlebar switch
lead is routed to the outside and the throttle cables are routed to the inside.
CABLE ROUTING
1 Rear brake switch lead
2 Charcoal canister (California only)
3 Rollover valve (California only)
4 Thermostat assembly breather hose
5 Radiator inlet hose
6 Coolant reservoir breather hose
7 Clutch cable
8 Pickup coil lead
Å Route the rollover-valve-to-fuel-tank hose to
the inside of the fuel hose (California only).
ı Route the coolant reservoir breather hose
SPEC
over the timing chain tensioner.
Ç Insert the plastic clip through the hole in the
plastic frame panel and then fasten the wire harness and coolant reservoir breather hose with it.
Î Route the clutch cable between the radiator
bracket and frame and in front of the thermostat assembly breather hose.
‰ Route the clutch cable to the inside of the radiator inlet hose.
Ï Insert the plastic clamp into the hole in the
coolant reservoir’s tab.
2 - 35
CABLE ROUTING
1 Air filter case breather hose
2 Water pump breather hose
3 Sidestand switch lead
4 Oil level switch lead
5 Right handlebar switch lead
6 Throttle cables
7 Coolant reservoir breather hose
8 Fuel tank overflow hose and fuel
tank breather hose
SPEC
Å Route the air filter case breather hose to the inside of the
wire harness.
ı Route the stator coil lead over all of the hoses and leads and
then fasten them with a plastic clip.
Ç Align the wire harness with the indent in the upper rear
fender.
Î Route the seat lock cable over the wire harness.
‰ Fasten the wire harness with a plastic clamp.
Ï Route the rear left turn signal lead through the plastic clamp.
Ì Route the rear left turn signal lead through the hole in the
upper rear fender.
2 - 36
CABLE ROUTING
Ó 50 mm
È Fasten the sidestand switch lead, engine oil
level switch lead, and water pump breather
hose with a plastic clip.
Ô Do not crush the water pump breather hose
and plastic clip.
 Route both of the leads (3 and 4) to the
inside of the radiator outlet hose.
Ò Route the fuel tank overflow hose and fuel
tank breather hose over the radiator outlet
hose. Route the air filter case drain hose and
2 - 37
SPEC
coolant reservoir breather hose to the inside
of the radiator outlet hose. Make sure that
the ends of all of the hoses are below the
radiator outlet hose and are not touching the
bottom cowling.
˜ Route the sidestand switch lead and oil level
switch lead to the inside of the drive sprocket
cover.
CABLE ROUTING
1 Speed sensor lead
2 Charcoal canister (California only)
3 Neutral switch lead
4 EXUP cables
Å Route the EXUP cables on the outside of the engine mount.
ı Fasten the EXUP cables with a plastic locking tie.
2 - 38
SPEC
CABLE ROUTING
1 Headlight sub-wire harness
2 Left handlebar switch lead
3 Main switch lead
4 Starter cable
5 Right handlebar switch coupler
6 Throttle cables
7 Ignition coil coupler
8 Pickup coil coupler
9 Rear brake switch coupler
0 Fuel pump coupler
A Speed sensor coupler
B Neutral switch connector
SPEC
C Fuel tank overflow hose
D Fuel tank breather hose (except for California)
E Starter motor lead
F Battery positive lead
G Battery negative lead
H Crankcase breather hose
I Fuel sender coupler
J Sidestand switch coupler
K Engine oil level switch lead
L Generator coupler
M EXUP servomotor coupler
N Ignition coils
2 - 39
CABLE ROUTING
Å Route the horn lead over the horn bracket
and make sure that the lead has no slack.
ı Do not cross the throttle cables and right
handlebar switch lead.
Ç Fasten the wire harness with a plastic clamp.
Î Route the ignition coil sub-wire harness
under the throttle position sensor.
‰ Route the coolant reservoir breather hose
over the battery negative lead and starter
motor lead.
Ï Fasten the wire harness and ignition coil sub-
SPEC
wire harness with a plastic clamp.
Ì Fasten the EXUP servomotor lead, fuel pump
lead, speed sensor lead, neutral switch lead,
EXUP cables, and wire harness with a plastic
locking tie.
Ó Fasten the fuel pump lead, speed sensor
lead, neutral switch lead, battery negative
lead, starter motor lead, EXUP cables, and
wire harness with a plastic locking tie.
È Fasten the battery positive lead and starter
motor lead with a plastic locking tie.
2 - 40
CABLE ROUTING
Ô Route the wire harness and turn signal leads
under the rear cowling mounting post on the
tail/brake light bracket.
 Insert the tail/brake light coupler and turn signal leads between the tail/brake light and
tail/brake light bracket.
Ò Position the ground coupler over the oil level
relay lead.
˜ Fasten the starter relay lead, ground lead,
and wire harness with a plastic locking tie.
ˆ Fasten the battery negative lead and wire
SPEC
harness with a plastic locking tie.
Ø Route the fuel tank overflow hose and fuel
tank breather hose in front of the crankcase
breather hose and under the fuel hose and
EXUP servomotor.
∏ Fasten the sidestand switch lead, engine oil
level switch lead, generator lead, and wire
harness with a plastic locking tie.
2 - 41
CABLE ROUTING
ΠFasten the wire harness with a plastic clamp
and then insert the clamp into the frame.
 Route the charcoal canister hose under the
EXUP servomotor lead, battery negative
lead, starter motor lead, and EXUP cables
(California only).
Í Insert the plastic clamp into the hole in the
frame.
Ê Route the radiator fan lead over the wire harness.
SPEC
Ë Fasten the wire harness and radiator fan lead to
the plastic frame panel with a plastic locking tie.
◊ The end of the plastic locking tie must face in.
„ Route the vacuum chamber air vent hoses
through the hole and slit in the rubber baffle.
Ù Route the ignition coil sub-wire harness in front
of the foam damper on the ignition coil plate,
then connect the connectors to the ignition coil
terminals, and make sure that the lead side of
the connectors face up.
2 - 42
CABLE ROUTING
Á Install the rubber baffle over the carburetor
air funnels.
Û The end of the plastic locking tie must face in
and down.
2 - 43
SPEC
SPEC
2 - 44
CHK
ADJ
3
CHK
ADJ
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ...........................................................................................3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...................3-1
SEATS ...........................................................................................................3-3
FUEL TANK ...................................................................................................3-4
COWLINGS ...................................................................................................3-5
REMOVAL .............................................................................................3-6
INSTALLATION .....................................................................................3-6
AIR FILTER CASE AND IGNITION COIL PLATE ..........................................3-7
REMOVAL .............................................................................................3-8
INSTALLATION .....................................................................................3-8
ENGINE .........................................................................................................3-9
ADJUSTING THE VALVE CLEARANCE ...............................................3-9
VALVE PAD SELECTION TABLE ........................................................3-13
SYNCHRONIZING THE CARBURETORS ...........................................3-14
ADJUSTING THE ENGINE IDLING SPEED .......................................3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................3-18
CHECKING THE SPARK PLUGS ........................................................3-20
CHECKING THE IGNITION TIMING ...................................................3-21
MEASURING THE COMPRESSION PRESSURE ...............................3-22
CHECKING THE ENGINE OIL LEVEL .................................................3-24
CHANGING THE ENGINE OIL ............................................................3-25
ADJUSTING THE CLUTCH CABLE FREE PLAY ................................3-28
CLEANING THE AIR FILTER ELEMENT .............................................3-29
CHECKING THE CARBURETOR JOINTS ...........................................3-29
CHECKING THE FUEL HOSES AND FUEL FILTER ...........................3-30
CHECKING THE CRANKCASE BREATHER HOSE ............................3-30
CHECKING THE EXHAUST SYSTEM ................................................3-31
ADJUSTING THE EXUP CABLES ......................................................3-32
CHECKING THE COOLANT LEVEL ....................................................3-33
CHECKING THE COOLING SYSTEM .................................................3-34
CHANGING THE COOLANT ...............................................................3-35
CHASSIS .....................................................................................................3-38
ADJUSTING THE FRONT BRAKE ......................................................3-38
ADJUSTING THE REAR BRAKE ........................................................3-38
CHECKING THE BRAKE FLUID LEVEL ..............................................3-40
CHK
ADJ
CHECKING THE BRAKE PADS ...........................................................3-41
ADJUSTING THE REAR BRAKE LIGHT SWITCH ..............................3-41
CHECKING THE BRAKE HOSES ........................................................3-42
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................3-42
ADJUSTING THE SHIFT PEDAL ........................................................3-44
ADJUSTING THE DRIVE CHAIN SLACK ...........................................3-44
LUBRICATING THE DRIVE CHAIN .....................................................3-46
CHECKING AND ADJUSTING THE STEERING HEAD .....................3-46
CHECKING THE FRONT FORK ...........................................................3-49
ADJUSTING THE FRONT FORK LEGS ..............................................3-50
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..............3-52
CHECKING THE TIRES .......................................................................3-54
CHECKING THE WHEELS ...................................................................3-56
CHECKING AND LUBRICATING THE CABLES .................................3-57
LUBRICATING THE LEVERS AND PEDALS ......................................3-57
LUBRICATING THE SIDESTAND .......................................................3-57
LUBRICATING THE REAR SUSPENSION .........................................3-57
ELECTRICAL SYSTEM ................................................................................3-58
CHECKING AND CHARGING THE BATTERY ....................................3-58
CHECKING THE FUSES ......................................................................3-63
REPLACING THE HEADLIGHT BULBS ..............................................3-65
ADJUSTING THE HEADLIGHT BEAMS ............................................3-66
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
CHK
ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This
information applies to vehicles already in service as well as to new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
EVERY
No.
ITEM
CHECKS AND MAINTENANCE JOBS
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
2
*
Fuel filter
• Check condition.
• Replace if necessary.
Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
Valves
• Check valve clearance.
• Adjust if necessary.
5
Air filter element
• Clean or replace if necessary.
6
Clutch
• Check operation.
• Adjust or replace cable.
3
4
*
INITIAL
(1,000 km)
12,000 km
6,000 km or
or
6 months
12 months
(whichever
(whichever
comes first)
comes first)
√
√
√
√
√
√
Every 42,000 km or 42 months (whichever comes first)
√
√
√
√
√
7
*
Front brake
• Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
√
√
√
8
*
Rear brake
• Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
√
√
√
9
*
Wheels
• Check balance, runout and for damage.
• Rebalance or replace if necessary.
√
√
10
*
Tires
•
•
•
•
√
√
11
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
√
√
12
*
Swingarm
• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
√
√
Drive chain
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is
properly aligned.
• Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in rain
Steering bearings
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every
24,000 km or 24 months (whichever comes first).
13
14
*
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
3-1
√
√
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EVERY
No.
15
*
16
ITEM
CHECKS AND MAINTENANCE JOBS
INITIAL
(1,000 km)
12,000 km
6,000 km or
or
6 months
12 months
(whichever
(whichever
comes first)
comes first)
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
√
√
Sidestand
• Check operation.
• Lubricate and repair if necessary.
√
√
√
√
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
√
√
19
*
Rear shock absorber
assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
√
√
20
*
Rear suspension relay
arm and connecting
arm pivoting points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
√
√
21
*
Carburetors
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
√
√
√
22
Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
√
√
√
23
Engine oil filter cartridge
• Replace.
√
24 * Cooling system
√
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km or 24 months (whichever comes first).
√
√
√
* Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:
• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid after disassembling the master cylinder or caliper cylinder.
– Check the brake fluid level and add fluid as required.
– Replace the master cylinder and caliper cylinder oil seals every two years.
– Replace the brake hoses every four years, or if cracked or damaged.
3-2
SEATS
CHK
ADJ
EB302000
SEATS
Order
1
2
Job/Part
Removing the seats
Passenger seat
Rider seat
Q’ty
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
FUEL TANK
CHK
ADJ
EB302010
FUEL TANK
Order
Q’ty
1
2
3
4
Job/Part
Removing the fuel tank
Rider seat
Bolt
Bolt
Fuel sender coupler
Fuel hose
5
6
7
8
Fuel tank overflow hose
Fuel tank breather hose
Fuel tank
Fuel tank side panel
1
1
1
2
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
NOTE:
Before disconnecting the fuel hose,
set the fuel cock to “OFF”.
For installation, reverse the removal
procedure.
3-4
COWLINGS
CHK
ADJ
EB302020
COWLINGS
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the cowlings
Rider and passenger seats
Rear cowling
Bottom cowling
Front cowling inner panel (left)
Front cowling inner panel (right)
Left side cowling
Right side cowling
Windshield
Rear view mirror
Front cowling
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
1
1
1
1
1
1
1
2
1
For installation, reverse the removal
procedure.
3-5
COWLINGS
CHK
ADJ
REMOVAL
1. Remove:
• rear cowling
• side cowlings
NOTE:
To remove the quick fastener, push its
center in with a screwdriver, then pull
the fastener out.
INSTALLATION
1. Install:
• side cowlings
• rear cowling
NOTE:
To install the quick fastener, push its pin
so that it protrudes from the fastener
head, then insert the fastener into the
cowling and push the pin a in with a
screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-6
AIR FILTER CASE AND IGNITION COIL PLATE
CHK
ADJ
EB302040
AIR FILTER CASE AND IGNITION COIL PLATE
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Removing the air filter case and igniRemove the parts in the order listed.
tion coil plate
Rider seat and fuel tank
Refer to “SEATS” and “FUEL TANK”.
Crankcase breather hose
1
Air filter case breather hose
1
Clamp screw
4
Loosen.
Bolt
1
Air filter case
1
Quick fastener
2
Ignition coil coupler
1
Disconnect.
Spark plug cap
4
Ignition coil plate/ignition coil
1/2
Rubber baffle
1
For installation, reverse the removal
procedure.
3-7
AIR FILTER CASE AND IGNITION COIL PLATE
CHK
ADJ
REMOVAL
1. Remove:
• rubber baffle
NOTE:
To remove the quick fastener, push its
center in with a screwdriver, then pull
the fastener out.
INSTALLATION
1. Install:
• rubber baffle
NOTE:
To install the quick fastener, push its pin
so that it protrudes from the fastener
head, then insert the fastener into the
rubber baffle and push the pin a in with
a screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-8
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EB303001
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.
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS” and “FUEL TANK”.
• air filter case
• rubber baffle
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
• bottom cowling
• side cowlings
Refer to “COWLINGS”.
• carburetor assembly
Refer to “CARBURETORS” in chapter 6.
• radiator assembly
• thermostat assembly
Refer to “RADIATOR” and “THERMOSTAT ASSEMBLY” in chapter 5.
2. Remove:
• spark plugs
• cylinder head cover 1
• cylinder head cover gasket
3. Remove:
• pickup coil rotor cover 1
3-9
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
4. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.11 ~ 0.20 mm
Exhaust valve
0.21 ~ 0.30 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC
mark a on the pickup coil rotor with
the crankcase mating surface b.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
c. Measure the valve clearance with a
thickness gauge 1.
NOTE:
• If the valve clearance is incorrect,
record the measured reading.
• Measure the valve clearance in the following sequence.
Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
Å Front
d. To measure the valve clearances of
the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft
counterclockwise as specified in the
following table.
ı Degrees that the crankshaft is turned
counterclockwise
Ç Cylinder
Î Combustion cycle
Cylinder #2
180˚
Cylinder #4
360˚
Cylinder #3
540˚
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
5. Remove:
• timing chain tensioner
• timing chain guide (exhaust side)
• intake camshaft caps
• exhaust camshaft caps
• timing chain
(from the camshaft sprockets)
• intake camshaft
• exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• When removing the timing chain and
camshafts, fasten the timing chain
with a wire to retrieve it if it falls into
the crankcase.
6. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter 1 and the
valve pad 2.
NOTE:
• Cover the timing chain opening with a
rag to prevent the valve pad from falling into the crankcase.
• Make a note of the position of each
valve lifter 1 and valve pad 2 so that
they can be installed in the correct
place.
b. Select the proper valve pad from the
following table.
Valve pad thickness range
Nos.
120 ~
240
1.20 ~
2.40 mm
Available valve
pads
25 thicknesses in
0.05 mm increments
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters
on the side that touches the valve
lifter.
• Since valve pads of various sizes are
originally installed, the valve pad number must be rounded in order to reach
the closest equivalent to the original.
3 - 11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
c. Round off the original valve pad number according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
d. Locate the rounded number of the
original valve pad and the measured
valve clearance in the valve pad
selection table. The point where the
column and row intersect is the new
valve pad number.
NOTE:
The new valve pad number is only an
approximation. The valve clearance
must be measured again and the above
steps should be repeated if the measurement is still incorrect.
e. Install the new valve pad 1 and the
valve lifter 2.
NOTE:
• Lubricate the valve pad with molybdenum disulfide grease.
• Lubricate the valve lifter with molybdenum disulfide oil.
• The valve lifter must turn smoothly
when rotated by hand.
• Install the valve lifter and the valve pad
in the correct place.
f. Install the exhaust and intake camshafts, timing chain and camshaft
caps.
T.
Camshaft cap bolt
10 Nm (1.0 m • kg)
R.
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• Lubricate the camshaft lobes and camshaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the
camshaft cap marks.
• Turn the crankshaft counterclockwise
several full turns to seat the parts.
3 - 12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE PAD SELECTION TABLE
INTAKE
Å ORIGINAL VALVE PAD NUMBER
ı
MEASURED
VALVE CLEARANCE
0.00 ~ 0.02
0.03 ~ 0.07
0.08 ~ 0.10
0.11 ~ 0.20
0.21 ~ 0.22
0.23 ~ 0.27
0.28 ~ 0.32
0.33 ~ 0.37
0.38 ~ 0.42
0.43 ~ 0.47
0.48 ~ 0.52
0.53 ~ 0.57
0.58 ~ 0.62
0.63 ~ 0.67
0.68 ~ 0.72
0.73 ~ 0.77
0.78 ~ 0.82
0.83 ~ 0.87
0.88 ~ 0.92
0.93 ~ 0.97
0.98 ~ 1.02
1.03 ~ 1.07
1.08 ~ 1.12
1.13 ~ 1.17
1.18 ~ 1.22
1.23 ~ 1.27
1.28 ~ 1.32
1.33 ~ 1.37
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
150
155
160
170 175 180 185 190 195 200 205 210 215 220
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
165 170 175 180 185 190 195 200 205 210 215
Ç STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220 225
175 180 185 190 195 200 205 210 215 220 225 230
180 185 190 195 200 205 210 215 220 225 230 235
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
Example:
235 240
Valve Clearance (cold)
240
225
210
215
220
230
215
220
225
235
220
225
230
240
225
230
235
230 235 240
235 240
240
0.11 ~ 0.20 mm
Rounded value 150
Measured valve clearance is 0.24 mm
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm
Pad No. 160 = 1.60 mm
Always install the valve pad with the
number facing down.
EXHAUST
ı MEASURED
VALVE CLEARANCE
0.00 ~ 0.02
0.03 ~ 0.07
0.08 ~ 0.12
0.13 ~ 0.17
0.18 ~ 0.20
0.21 ~ 0.30
0.31 ~ 0.32
0.33 ~ 0.37
0.38 ~ 0.42
0.43 ~ 0.47
0.48 ~ 0.52
0.53 ~ 0.57
0.58 ~ 0.62
0.63 ~ 0.67
0.68 ~ 0.72
0.73 ~ 0.77
0.78 ~ 0.82
0.83 ~ 0.87
0.88 ~ 0.92
0.93 ~ 0.97
0.98 ~ 1.02
1.03 ~ 1.07
1.08 ~ 1.12
1.13 ~ 1.17
1.18 ~ 1.22
1.23 ~ 1.27
1.28 ~ 1.32
1.33 ~ 1.37
1.38 ~ 1.42
1.43 ~ 1.47
Å ORIGINAL VALVE PAD NUMBER
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
140
145
150
155
160
170 175 180 185 190 195 200 205 210 215 220
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
165 170 175 180 185 190 195 200 205 210 215
Ç STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220 225
175 180 185 190 195 200 205 210 215 220 225 230
180 185 190 195 200 205 210 215 220 225 230 235
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
Example:
235 240
Valve Clearance (cold)
240
225
200
205
210
215
220
230
205
210
215
220
225
235
210
215
220
225
230
240
215
220
225
230
235
230 235 240
235 240
240
0.21 ~ 0.30 mm
Rounded value 175
Measured valve clearance is 0.35 mm
Replace pad 150 with pad 185
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
Always install the valve pad with the
number facing down.
3 - 13
ADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
g. Measure the valve clearance again.
h. If the valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• all removed parts
NOTE:
For installation, reverse the removal
procedure. Note the following points.
8. Install:
• timing chain guide (exhaust side)
• timing chain tensioner
• pickup coil rotor cover
• cylinder head cover
• spark plugs
Refer to “CAMSHAFTS” in chapter 4.
EB303010
SYNCHRONIZING THE CARBURETORS
NOTE:
Prior to synchronizing the carburetors,
the valve clearance and the engine
idling speed should be properly
adjusted and the ignition timing should
be checked.
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable
stand.
2. Remove:
• rider seat
• fuel tank
• Refer to “SEATS” and “FUEL TANK”.
3 - 14
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
3. Remove:
• bolts 1
• copper washers
4. Install:
• vacuum gauge attachments
(into the bolt holes)
• vacuum gauge 1
(onto the vacuum gauge attachments)
• engine tachometer 2
(onto the spark plug lead of cylinder #1)
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-03113
5. Start the engine and let it warm up for
several minutes.
6. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
1,050 ~ 1,150 r/min
7. Adjust:
• carburetor synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing
screw 1 in either direction until both
gauges read the same.
3 - 15
SYNCHRONIZING THE CARBURETORS/
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
NOTE:
After each step, rev the engine two or
three times, each time for less than a
second, and check the synchronization
again.
b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing
screw 2 in either direction until both
gauges read the same.
c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing
screw 3 in either direction until both
gauges read the same.
Vacuum pressure at engine
idling speed
29.3 kPa (0.293 kg/cm2, 220
mm Hg)
NOTE:
The difference in vacuum pressure
between two carburetors should not
exceed 1.33 kPa (10 mm Hg).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Measure:
• engine idling speed
Out of specification → Adjust.
9. Stop the engine and remove the measuring equipment.
10.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm
EB303020
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling
speed, the carburetor synchronization
should be adjusted properly, the air filter
element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for
several minutes.
3 - 16
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
2. Remove:
• air filter case
• quick fasteners 1
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
3. Install:
• engine tachometer
(onto the spark plug lead of cylinder #1)
Engine tachometer
90890-03113
4. Install:
• air filter case
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
5. Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
1,050 ~ 1,150 r/min
6. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pilot screw 1 in until it is
lightly seated.
b. Turn the pilot screw out the specified
number of turns.
Carburetor angle driver
90890-03158
Pilot screw setting
2-1/2 turns out
c. Turn the throttle stop screw 2 in
direction a or b until the specified
engine idling speed is obtained.
Direction a
Engine idling speed is
increased.
Direction b
Engine idling speed is
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 17
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
7. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed and carburetor
synchronization
should
be
adjusted properly.
1. Measure:
• throttle cable free play a
Out of specification → Adjust.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm
2. Remove:
• rider seat
• fuel tank
Refer to “SEATS” and “FUEL TANK”.
• air filter case
• ignition coil plate
(along with the ignition coils)
• rubber baffle
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
3 - 18
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
3. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
When the throttle is opened, the accelerator cable 1 is pulled.
Carburetor side
a. Loosen the locknut 2 on the decelerator cable.
b. Turn the adjusting nut 3 in direction
a or b to take up any slack on the
decelerator cable.
c. Loosen the locknut 4 on the accelerator cable.
d. Turn the adjusting nut 5 in direction
a or b until the specified throttle
cable free play is obtained.
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play
cannot be obtained on the carburetor
side of the cable, use the adjusting nut
on the handlebar side.
Handlebar side
a. Slide back the rubber cover 6.
b. Loosen the locknut 7.
c. Turn the adjusting nut 8 in direction
c or d until the specified throttle
cable free play is obtained.
Direction c
Throttle cable free play
is increased.
Direction d
Throttle cable free play
is decreased.
d. Tighten the locknut.
WARNING
WARNING
After adjusting the throttle cable free
play, start the engine and turn the handlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 19
CHECKING THE SPARK PLUGS
CHK
ADJ
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS” and “FUEL TANK”.
• air filter case
• ignition coil plate
(along with the ignition coils)
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
CAUTION:
ACHTUNG:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to prevent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect → Change.
Spark plugs
Model (manufacturer)
CR9E (NGK)
U27ESR-N (DENSO)
5. Check:
• electrodes 1
Damage/wear → Replace the spark
plug.
• insulator 2
Abnormal color → Replace the spark
plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire
brush)
7. Measure:
• spark plug gap a
(with a wire gauge)
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm
3 - 20
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
T.
R.
8. Install:
• spark plug
CHK
ADJ
13 Nm (1.3 m · kg)
NOTE:
Before installing the spark plug, clean
the spark plug and gasket surface.
EB303050
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing,
check the wiring connections of the
entire ignition system. Make sure that all
connections are tight and free of corrosion.
1. Remove:
• bottom cowling
Refer to “COWLINGS”.
• rider seat
• fuel tank
Refer to “SEATS” and “FUEL TANK”.
• air filter case
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
• timing mark accessing screw 1
2. Install:
• timing light 1
• engine tachometer
(onto the spark plug lead of cylinder #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several minutes, and then let it run at the
specified engine idling speed.
Engine idling speed
1,050 ~ 1,150 r/min
3 - 21
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
b. Check that the mark a is within the
required firing range b on the pickup
coil rotor.
Incorrect firing range → Check the
ignition system.
NOTE:
The ignition timing is not adjustable.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB303060
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of
the cylinders.
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 stop it.
3. Remove:
• rider seat
• fuel tank
Refer to “SEATS” and “FUEL TANK”.
• air filter case
• ignition coil plate
(along with the ignition coils)
• rubber baffle
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”.
4. Remove:
• spark plug
CAUTION:
ACHTUNG:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
3 - 22
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
5. Install:
• compression gauge 1
Compression gauge
90890-03081
Adapter
90890-04136
6. Measure:
• compression pressure
Out of specification → Refer to steps
(c) and (d).
Compression pressure (at sea
level)
Minimum
1,350 kPa (13.5 kg/cm2,
13.5 bar)
Standard
1,450 kPa (14.5 kg/cm2,
14.5 bar)
Maximum
1,500 kPa (15.0 kg/cm2,
15.0 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
WARNING
To prevent sparking, ground all spark
plug leads before cranking the engine.
NOTE:
The difference in compression pressure
between cylinders should not exceed
100 kPa (1 kg/cm2, 1 bar).
c. If the compression pressure is above
the maximum specification, check the
cylinder head, valve surfaces, and
piston crown for carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below
the minimum specification, squirt a
few drops of oil into the cylinder and
measure again.
3 - 23
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than without oil
Piston wear or
damage → Repair.
Same as without
oil
Piston ring(-s),
valve(-s), cylinder
head gasket or
piston possibly
defective →
Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
R.
7. Install:
• spark plug
13 Nm (1.3 m · kg)
EB303070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure that the motorcycle is
upright.
2. Start the engine, let it idle for several
minutes, and then stop it.
3. Check:
• engine oil level
The engine oil level should be between
the minimum level mark a and maximum level mark b.
Below the minimum level mark → Add
the recommended engine oil to the
proper level.
Recommended oil
Refer to the chart for the
engine oil grade which is
best suited for certain atmospheric temperatures.
API standard
SE or higher grade
(Non-Friction modified)
3 - 24
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
CAUTION:
ACHTUNG:
• 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 allow foreign materials to
enter the crankcase.
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.
EB303081
CHANGING THE ENGINE OIL
1. Remove:
• bottom cowling
Refer to “COWLINGS”.
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Place a container under the engine oil
drain bolt.
4. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the washer)
5. Drain:
• engine oil
(completely from the crankcase)
6. If the oil filter cartridge is also to be
replaced, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge 1 with
an oil filter wrench 2.
Oil filter wrench
90890-01426
3 - 25
CHK
ADJ
CHANGING THE ENGINE OIL
b. Lubricate the O-ring 3 of the new oil
filter cartridge with a thin coat of
engine oil.
CAUTION:
ACHTUNG:
Make sure that the O-ring 3 is positioned correctly in the groove of the oil
filter cartridge.
c. Tighten the new oil filter cartridge to
specification with an oil filter wrench.
T.
Oil filter cartridge
17 Nm (1.7 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Check:
• engine oil drain bolt washer
Damage → Replace.
8. Install:
• engine oil drain bolt
T.
R.
43 Nm (4.3 m · kg)
9. Fill:
• crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
3.6 L (3.2 lmp qt)
Without oil filter cartridge
replacement
2.7 L (2.4 lmp qt)
With oil filter cartridge
replacement
2.9 L (2.6 lmp qt)
10.Install:
• engine oil filler cap
11.Start the engine, warm it up for several
minutes, and then turn it off.
12.Check:
• engine
(for engine oil leaks)
13.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
14.Install:
• bottom cowling
Refer to “COWLINGS”.
3 - 26
CHANGING THE ENGINE OIL
CHK
ADJ
15.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 cartridge and the oil pump for
damage or leakage. Refer to “OIL
PAN AND 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
20 Nm (2.0 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 27
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
EB303100
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Measure:
• clutch cable free play a
Out of specification → Adjust.
Clutch cable free play (at the
end of the clutch lever)
10 ~ 15 mm
2. Adjust:
• clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Turn the adjusting bolt 1 in direction
a or b until the specified clutch
cable free play is obtained.
Direction a
Clutch cable free play is
increased.
Direction b
Clutch cable free play is
decreased.
NOTE:
If the specified clutch cable free play
cannot be obtained on the handlebar
side of the cable, use the adjusting nut
on the engine side.
Engine side
a. Loosen the locknut 2.
b. Turn the adjusting nut 3 in direction
c or d until the specified clutch
cable free play is obtained.
Direction c
Clutch cable free play is
increased.
Direction d
Clutch cable free play is
decreased.
c. Tighten the locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 28
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE CARBURETOR JOINTS
CHK
ADJ
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank
Refer to “FUEL TANK”.
• air filter case cover 1
• air filter element
2. Clean:
• air filter element
Apply compressed air to the outer surface of the air filter element.
3. Check:
• air filter element
Damage → Replace.
4. Install:
• air filter element
• air filter case cover
CAUTION:
ACHTUNG:
Never operate the engine without the
air filter element installed. Unfiltered air
will cause rapid wear of engine parts
and may damage the engine. Operating
the engine without the air filter element
will also affect the carburetor tuning,
leading to poor engine performance and
possible overheating.
NOTE:
When installing the air filter element
into the air filter case cover, make sure
that their sealing surfaces are aligned to
prevent any air leaks.
5. Install:
• fuel tank
Refer to “FUEL TANK”.
EB303171
CHECKING THE CARBURETOR JOINTS
The following procedure applies to all of
the carburetor joints and intake manifolds.
1. Remove:
• carburetor assembly
Refer to “CARBURETORS” in chapter 6.
3 - 29
CHECKING THE CARBURETOR JOINTS/
CHECKING THE FUEL HOSES AND FUEL FILTER/
CHECKING THE CRANKCASE BREATHER HOSE
CHK
ADJ
2. Check:
• carburetor joint 1
Cracks/damage → Replace.
Refer to “CARBURETORS” in chapter 6.
3. Install:
• carburetor assembly
Refer to “CARBURETORS” in chapter 6.
EB303181
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of
the fuel hoses.
1. Remove:
• fuel tank
Refer to “FUEL TANK”.
2. Check:
• fuel hose 1
Cracks/damage → Replace.
• fuel filter 2
Contaminants/damage → Replace.
NOTE:
• Drain and flush the fuel tank if abrasive
damage to any components of the fuel
line is evident.
• The arrow mark on the fuel filter must
point towards the fuel pump 3 as
shown.
3. Install:
• fuel tank
Refer to “FUEL TANK”.
EB303190
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
• fuel tank
Refer to “FUEL TANK”.
3 - 30
CHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
2. Check:
• crankcase breather hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
ACHTUNG:
Make sure that the crankcase breather
hose is routed correctly.
3. Install:
• fuel tank
Refer to “FUEL TANK”.
EB303200
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of
the exhaust pipes and gaskets.
1. Remove:
• radiator assembly
Refer to “RADIATOR” in chapter 5.
2. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
• gasket 3
Exhaust gas leaks → Replace.
3. Measure:
• tightening torque
T.
R.
Exhaust pipe nut 4
20 Nm (2.0 m • kg)
Muffler clamp bolt 5
20 Nm (2.0 m • kg)
Exhaust pipe bolt 6
20 Nm (2.0 m • kg)
Muffler bolt 7
38 Nm (3.8 m • kg)
4. Install:
• radiator assembly
Refer to “RADIATOR” in chapter 5.
3 - 31
ADJUSTING THE EXUP CABLES
CHK
ADJ
EB303210
ADJUSTING THE EXUP CABLES
1. Remove:
• fuel tank
• bottom cowling
Refer to “FUEL TANK” and “COWLINGS”.
2. Remove:
• EXUP valve pulley cover 1
3. Check:
• EXUP system operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the EXUP servomotor
coupler 1.
b. Connect the battery to the EXUP servomotor coupler and check if the servomotor operates properly.
Battery positive lead → black/yellow 2
Battery negative lead → black/red 3
CAUTION:
ACHTUNG:
To avoid damaging the servomotor, do
not leave the battery connected to it for
more than a few seconds.
c. Check that the EXUP valve operates
properly.
d. Connect the EXUP servomotor coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• EXUP cable free play a
Max. EXUP cable free play
(at the EXUP valve pulley)
1.5 mm
3 - 32
ADJUSTING THE EXUP CABLES/
CHECKING THE COOLANT LEVEL
CHK
ADJ
5. Adjust:
• EXUP cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 1.
b. Insert a 4-mm long pin through the
notch in the EXUP valve pulley and
into the hole in the EXUP valve cover.
c. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable
free play.
d. Turn both adjusting bolts 1/2 of a turn
clockwise.
e. Tighten both locknuts
remove the pin.
and
then
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• EXUP valve pulley cover
T.
R.
10 Nm (1.0 m · kg)
7. Install:
• bottom cowling
• fuel tank
Refer to “COWLINGS” and “FUEL
TANK”.
EB303220
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
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.
CAUTION:
ACHTUNG:
• 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 - 33
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
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.
EB303230
CHECKING THE COOLING SYSTEM
1. Remove:
• bottom cowling
• side cowlings
Refer to “COWLINGS”.
2. Check:
• radiator 1
• radiator inlet hose 2
• radiator outlet hose 3
• oil cooler 4
• oil cooler inlet hose 5
• oil cooler outlet hose 6
• water jacket joint inlet hose 7
• water pump inlet pipe 8
• water pump outlet pipe 9
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 5.
3. Install:
• side cowlings
• bottom cowling
Refer to “COWLINGS”.
3 - 34
CHANGING THE COOLANT
CHK
ADJ
EB303240
CHANGING THE COOLANT
1. Remove:
• bottom cowling
• right side cowling
Refer to “COWLINGS”.
2. Disengage:
• clutch cable holder 1
(from the coolant reservoir)
3. Remove:
• coolant reservoir bolts 2
• coolant reservoir cap 3
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the reservoir so that coolant cannot flow
through the coolant reservoir breather
hose 4.
4. Drain:
• coolant
(from the coolant reservoir)
5. Install:
• coolant reservoir bolts
6. Engage:
• clutch cable holder
7. Remove:
• radiator cap 1
WARNING
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, turn the radiator cap counterclockwise while pressing down on it
and then remove it.
3 - 35
CHK
ADJ
CHANGING THE COOLANT
8. Remove:
• coolant drain bolt 1
(along with the copper washer)
9. Drain:
• coolant
10.Check:
• copper washer 1
• coolant drain bolt 2
Damage → Replace.
T.
R.
11.Install:
• coolant drain bolt
7 Nm (0.7 m · kg)
12.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
2.75 L (2.42 lmp qt)
Coolant reservoir capacity
0.45 L (0.4 lmp qt)
Handling notes for coolant
Coolant is potentially harmful and should
be handled with special care.
WARNING
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.
3 - 36
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
ACHTUNG:
• 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.
• If coolant comes into contact with
painted surfaces, immediately wash
them with water.
• Do not mix different types of antifreeze.
13.Install:
• radiator cap
14.Fill:
• coolant reservoir
(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 turn it off.
17.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has settled.
18.Install:
• right side cowling
• bottom cowling
Refer to “COWLINGS”.
3 - 37
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EB304001
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• brake lever position
(distance a from the throttle grip to
the brake lever)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While pushing the brake lever forward, turn the adjusting dial 1 until
the brake lever is in the desired position.
NOTE:
Be sure to align the setting on the
adjusting dial with the arrow mark 2 on
the brake lever holder.
Position #1 Distance a is the largest.
Position #5 Distance a is the smallest.
WARNING
WARNING
After adjusting the brake lever position,
make sure that the pin on the brake
lever holder is firmly inserted in the hole
in the adjusting dial.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304010
ADJUSTING THE REAR BRAKE
1. Measure:
• brake pedal position
(distance a from the top of the brake
pedal to the bottom of the rider footrest bracket)
Out of specification → Adjust.
Brake pedal position (from the
top of the brake pedal to the
bottom of the rider footrest
bracket)
35 ~ 40 mm
3 - 38
ADJUSTING THE REAR BRAKE
CHK
ADJ
2. Adjust:
• brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction
a or b until the specified brake pedal
position is obtained.
Direction a Brake pedal is raised.
Direction b Brake pedal is lowered.
WARNING
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is visible through the hole d.
c. Tighten the locknut 1 to specification.
T.
Locknut
16 Nm (1.6 m • kg)
R.
WARNING
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an accident.
Therefore, check and, if necessary,
bleed the brake system.
CAUTION:
ACHTUNG:
After adjusting the brake pedal position,
make sure that there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH”.
3 - 39
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Å
Recommended brake fluid
DOT 4
Å Front brake
ı Rear brake
WARNING
WARNING
ı
• 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:
ACHTUNG:
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 fluid reservoir is horizontal.
3 - 40
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
EB304032
Å
CHECKING THE BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached → Replace the
brake pads as a set.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
ı
Brake pad wear limit
0.5 mm
Å Front brake
ı Rear brake
EB304050
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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 41
CHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
WARNING
Bleed the hydraulic brake system whenever:
• the brake system was disassembled,
• a brake hose was 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 fluid reservoir to overflow.
• When bleeding the hydraulic brake
system, make sure that 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 - 42
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
5. Bleed:
• hydraulic brake system
Å
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
Å Front brake
ı Rear brake
ı
d. Place the other end of the hose into a
container.
e. Slowly apply the brake 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)
R.
k. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE
FLUID LEVEL”.
WARNING
WARNING
After bleeding the hydraulic brake system, check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 43
ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
EB304081
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined
by the installed shift rod length a.
1. Measure:
• installed shift rod length a
Incorrect → Adjust.
Installed shift rod length
305 mm
2. Adjust:
• installed shift rod length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 1.
b. Turn the shift rod 2 in direction b or
c to obtain the correct shift pedal
position.
Direction b
Installed shift rod length
increases.
Direction c
Installed shift rod length
decreases.
c. Tighten both locknuts.
d. Make sure that the installed shift rod
length is within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at
the tightest point on the chain.
CAUTION:
ACHTUNG:
A drive chain that is too tight will overload the engine and other vital parts,
and one that is too loose can skip and
damage the swingarm or cause an accident. Therefore, keep the drive chain
slack within the specified limits.
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
3 - 44
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Rotate the rear wheel several times and
check the drive chain to locate its tightest point.
3. Measure:
• drive chain slack a
Out of specification → Adjust.
Drive chain slack
40 ~ 50 mm
4. Adjust:
• drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the wheel axle nut 1.
b. Loosen both locknuts 2.
c. Turn both adjusting bolts 3 in direction a or b until the specified drive
chain slack is obtained.
Direction a
Drive chain slack is
reduced.
Direction b
Drive chain slack is
increased.
NOTE:
To maintain the proper wheel alignment, adjust both sides evenly.
d. Tighten both locknuts to specification.
T.
Locknut
16 Nm (1.6 m • kg)
R.
e. Tighten the wheel axle nut to specification.
T.
Wheel axle nut
150 Nm (15.0 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 45
LUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EB304100
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly.
Therefore, the drive chain should be serviced, especially when the motorcycle is
used in dusty areas. This motorcycle has a
drive chain with small rubber O-rings
between each side plate. Steam cleaning,
high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable
for O-ring chains. Do not use any other
lubricants on the drive chain since they may
contain solvents that could damage the Orings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EB304130
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs
and gently rock the front fork.
Looseness/binding → Adjust the steering head.
3 - 46
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
3. Remove:
• front brake fluid reservoir 1
• plastic caps 2
4. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
5. Remove:
• upper bracket bolts 3
• handlebars
(from the upper bracket)
6. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
7. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench
90890-01403
T.
R.
3 - 47
Lower ring nut (initial tightening torque)
28 Nm (2.8 m • kg)
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
c. Loosen the lower ring nut completely,
then tighten it to specification.
WARNING
WARNING
Do not overtighten the lower ring nut.
T.
R.
Lower ring nut (final tightening torque)
9 Nm (0.9 m • kg)
d. Check the steering head for looseness
or binding by turning the front fork all
the way in both directions. If any
binding is felt, remove the lower
bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 7.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2,
then align the slots of both ring nuts.
If necessary, hold the lower ring nut
and tighten the upper ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure that the lock washer tabs a
sit correctly in the ring nut slots b.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• steering stem nut
T.
R.
115 Nm (11.5 m · kg)
• upper bracket bolt
T.
R.
13 Nm (1.3 m · kg)
• handlebar pinch bolt
T.
R.
17 Nm (1.7 m · kg)
• upper bracket pinch bolt
T.
R.
26 Nm (2.6 m · kg)
9. Measure:
• steering head tension
(with the motorcycle still on the stand)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Make sure that all of the cables and
wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely
around the end of the handlebar as
shown.
3 - 48
c. Hook a spring gauge 2 onto the plastic locking tie.
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
d. Hold the spring gauge at a 45˚ angle
from the handlebar, pull the spring
gauge, and record the measurement
when the handlebar starts to turn.
Steering head tension
200 ~ 500 g
e. Repeat the above procedure on the
opposite handlebar.
f. If the steering head tension is out of
specification (both handlebars should
be within specification), remove the
upper bracket and loosen or tighten
the upper ring nut.
g. Reinstall the upper bracket and measure the steering head tension again
as described above.
h. Repeat the above procedure until the
steering head tension is within specification.
i. Grasp the bottom of the front fork
legs and gently rock the front fork.
Looseness or binding → Adjust the
steering head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304141
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
• inner tube 1
Damage/scratches → Replace.
• oil seal 2
Oil leakage → Replace.
3. Hold the motorcycle upright and apply
the front brake.
4. Check:
• front fork operation
Push down hard on the handlebars
several times and check if the front
fork rebounds smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 7.
3 - 49
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
EB304153
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNING
WARNING
• Always adjust both front fork legs
evenly. Uneven adjustment can result
in poor handling and loss of stability.
• Securely support the motorcycle so
that there is no danger of it falling
over.
Spring preload
CAUTION:
ACHTUNG:
• Grooves are provided to indicate the
adjustment position.
• Never go beyond the maximum or
minimum adjustment positions.
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt 1 in direction
a or b.
Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 8
Standard: 6
Maximum: 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 50
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
Rebound damping
CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a or b.
Rebound damping is
Direction a increased (suspension is
harder).
Rebound damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 13 clicks out*
Standard: 5 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a or b.
Compression damping is
Direction a increased (suspension is
harder).
Compression damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 11 clicks out*
Standard: 5 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 51
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
EB304162
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• spring preload
NOTE:
Adjust the spring preload with the special wrench and extension bar included
in the owner’s tool kit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting ring 1 in direction
a or b.
b. Align the desired position on the
adjusting ring with the position indicator 2.
Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 52
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
Rebound damping
CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a or b.
Rebound damping is
Direction a increased (suspension is
harder).
Rebound damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 12 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a or b.
Compression damping is
Direction a increased (suspension is
harder).
Compression damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 12 clicks out*
Standard: 8 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 53
CHECKING THE TIRES
CHK
ADJ
EB304170
CHECKING THE TIRES
The following procedure applies to both of
the tires.
1. Measure:
• tire pressure
Out of specification → Regulate.
WARNING
WARNING
• The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
• The tire pressure and the suspension
must be adjusted according to the
total weight (including cargo, rider,
passenger and accessories) and the
anticipated riding speed.
• Operation of an overloaded motorcycle could cause tire damage, an accident or an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
and a full
fuel tank)
198 kg
Maximum
load*
197 kg
Cold tire
pressure
Up to 90 kg
load*
Front
Rear
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar)
2.5 bar)
290 kPa
250 kPa
90 kg ~ max(2.5 kgf/cm2, (2.9 kgf/cm2,
imum load*
2.5 bar)
2.9 bar)
High-speed
riding
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar)
2.5 bar)
* total of cargo, rider, passenger and
accessories
WARNING
WARNING
It is dangerous to ride with a worn-out
tire. When the tire tread reaches the
wear limit, replace the tire immediately.
3 - 54
CHECKING THE TIRES
CHK
ADJ
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
WARNING
Å
ı
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid
tire failure and personal injury from
sudden deflation.
• When using a tube tire, be sure to
install the correct tube.
• Always replace a new tube tire and a
new tube as a set.
• To avoid pinching the tube, make sure
that the wheel rim band and tube are
centered in the wheel groove.
• Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and
replace the tube as soon as possible
with a good quality replacement.
Å Tire
ı Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
• After extensive tests, the tires listed
below have been approved by
Yamaha Motor Co., Ltd. for this
model. The front and rear tires should
always be by the same manufacturer
and of the same design. No guarantee
concerning handling characteristics
can be given if a tire combination
other than one approved by Yamaha is
used on this motorcycle.
Front tire
Manufacturer
BRIDGESTONE
METZELER
METZELER
DUNLOP
MICHELIN
MICHELIN
PIRELLI
3 - 55
PIRELLI
Size
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
120/70 ZR17
(58W)
Model
BT56F
BT57F
MEZ1
FRONT RACING
MEZ3 FRONT
D207FN
TX15
MACADAM
90XS
MTR01
MTR01
CORSA
CHECKING THE TIRES/
CHECKING THE WHEELS
Rear tire
Manufacturer
BRIDGESTONE
METZELER
METZELER
DUNLOP
MICHELIN
MICHELIN
PIRELLI
PIRELLI
CHK
ADJ
Size
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
190/50 ZR17
(73W)
Model
BT56R
BT57R
MEZ1
RACING
MEZ3
D207L
TX25
MACADAM
90X
MTR02
MTR02
CORSA
WARNING
WARNING
After mounting a new tire, ride conservatively for a while to become accustomed to the “feel” of the new tire and
to allow the tire to seat itself properly in
the rim. Failure to do so could lead to an
accident with possible injury to the rider
or damage to the motorcycle.
NOTE:
For tires with a direction of rotation
mark 1:
• Install the tire with the mark pointing
in the direction of wheel rotation.
• Align the mark 2 with the valve installation point.
EB304180
CHECKING THE WHEELS
The following procedure applies to both of
the wheels.
1. Check:
• wheel
Damage/out-of-round → Replace.
WARNING
WARNING
Never attempt to make any repairs to
the wheel.
NOTE:
After a tire or wheel has been changed
or replaced, always balance the wheel.
3 - 56
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EB304200
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of
the cable sheaths and cables.
WARNING
WARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement. Replace damaged cable
sheaths and cables as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a
few drops of lubricant into the cable
sheath or use a suitable lubing device.
EB304210
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-tometal moving parts of the levers and pedals.
Recommended lubricant
Lithium soap base grease
EB304220
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-tometal moving parts of the sidestand.
Recommended lubricant
Lithium soap base grease
EB304240
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-tometal moving parts of the rear suspension.
Recommended lubricant
Lithium soap base grease
3 - 57
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
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:
ACHTUNG:
• 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 - 58
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:
• rider seat
Refer to “SEATS”.
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
ACHTUNG:
First, disconnect the negative lead 1,
then the positive lead 2.
3. Remove:
• battery
4. Measure:
• battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a digital voltmeter to the battery terminals.
Tester positive probe → battery positive terminal
Tester negative probe → battery
negative terminal
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.
b. Check the charge of the battery, as
shown in the charts and the following
example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 59
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
5. Charge:
• battery
(refer to the appropriate charging
method illustration)
WARNING
WARNING
Do not quick charge a battery.
CAUTION:
ACHTUNG:
• 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 motorcycle. (If
charging has to be done with the battery mounted on the motorcycle, disconnect the negative 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 that the battery charger
lead clips are in full contact with the
battery terminal and that they are not
shorted. A corroded battery charger
lead clip may generate heat in the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the
touch at any time during the charging
process, disconnect the battery
charger and let the battery cool before
reconnecting it. Hot batteries can
explode!
• As shown in the following illustration,
the open-circuit voltage of an MF battery stabilizes about 30 minutes after
charging has been completed. Therefore, wait 30 minutes after charging is
completed before measuring the
open-circuit voltage.
3 - 60
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-voltage charger
3 - 61
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant-voltage charger
3 - 62
CHK
ADJ
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Install:
• battery
7. Connect:
• battery leads
(to the battery terminals)
CAUTION:
ACHTUNG:
First, connect the positive lead 1, then
the negative 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:
• rider seat
Refer to “SEATS”.
EB305040
CHECKING THE FUSES
The following procedure applies to all of
the fuses.
CAUTION:
ACHTUNG:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• rider seat
Refer to “SEATS”.
2. Check:
• continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
b. If the pocket tester indicates “∞”,
replace the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 63
CHECKING THE FUSES
CHK
ADJ
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct
amperage.
c. Set the main switch to “ON” and verify if the electrical circuit is operational.
d. If the fuse immediately blows again,
check the electrical circuit.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Item
Amperage
Q’ty
Main fuse
30 A
1
Headlight
fuse
20 A
1
Signaling
system fuse
20 A
1
Ignition
fuse
15 A
1
Radiator
fan motor
fuse
7.5 A
1
Backup fuse
(odometer)
7.5 A
1
WARNING
WARNING
Never use a fuse with an amperage
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:
• rider seat
Refer to “SEATS”.
3 - 64
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of
the headlight bulbs.
1. Disconnect:
• headlight coupler 1
• headlight bulb holder cover 2
2. Detach:
• headlight bulb holder 1
3. Remove:
• headlight bulb 2
WARNING
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
4. Install:
New
• headlight bulb
Secure the new headlight bulb with
the headlight bulb holder.
CAUTION:
ACHTUNG:
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.
5. Attach:
• headlight bulb holder
6. Install:
• headlight bulb holder cover
7. Connect:
• headlight coupler
3 - 65
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
EB305061
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of
the headlights.
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a or b.
Direction a Headlight beam is raised.
Direction b
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob 1 in direction a or b.
Left headlight
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beam moves
to the left.
Right headlight
Direction a
Headlight beam moves
to the left.
Direction b
Headlight beam moves
to the right.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 66
ENG
4
ENG
CHAPTER 4.
OVERHAULING THE ENGINE
ENGINE .........................................................................................................4-1
INSTALLING THE ENGINE ...................................................................4-7
CAMSHAFTS .................................................................................................4-8
REMOVING THE CAMSHAFTS ..........................................................4-11
CHECKING THE CAMSHAFTS ...........................................................4-12
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES ........................................................4-13
CHECKING THE TIMING CHAIN TENSIONER ..................................4-14
INSTALLING THE CAMSHAFTS ........................................................4-15
CYLINDER HEAD ........................................................................................4-18
REMOVING THE CYLINDER HEAD ....................................................4-19
CHECKING THE CYLINDER HEAD .....................................................4-19
INSTALLING THE CYLINDER HEAD ..................................................4-20
VALVES AND VALVE SPRINGS ................................................................4-21
REMOVING THE VALVES ..................................................................4-23
CHECKING THE VALVES AND VALVE GUIDES ...............................4-24
CHECKING THE VALVE SEATS .........................................................4-26
CHECKING THE VALVE SPRINGS .....................................................4-28
CHECKING THE VALVE LIFTERS .......................................................4-29
INSTALLING THE VALVES .................................................................4-29
GENERATOR ...............................................................................................4-32
REMOVING THE GENERATOR ..........................................................4-33
INSTALLING THE GENERATOR ........................................................4-33
PICKUP COIL ...............................................................................................4-35
REMOVING THE PICKUP COIL ROTOR .............................................4-37
INSTALLING THE PICKUP COIL ROTOR ...........................................4-37
CLUTCH .......................................................................................................4-39
REMOVING THE CLUTCH ..................................................................4-43
CHECKING THE FRICTION PLATES ..................................................4-43
CHECKING THE CLUTCH PLATES .....................................................4-44
CHECKING THE CLUTCH SPRING PLATE ........................................4-44
CHECKING THE CLUTCH HOUSING .................................................4-44
CHECKING THE CLUTCH BOSS ........................................................4-45
CHECKING THE PRESSURE PLATE ..................................................4-45
CHECKING THE PULL LEVER SHAFT AND PULL ROD ....................4-45
CHECKING THE STARTER CLUTCH ..................................................4-45
INSTALLING THE CLUTCH ................................................................4-46
ENG
SHIFT SHAFT ..............................................................................................4-49
CHECKING THE SHIFT SHAFT ...........................................................4-50
CHECKING THE STOPPER LEVER .....................................................4-50
INSTALLING THE SHIFT SHAFT ........................................................4-50
OIL PAN AND OIL PUMP ...........................................................................4-51
REMOVING THE OIL PAN ..................................................................4-54
CHECKING THE OIL PUMP ................................................................4-54
CHECKING THE RELIEF VALVE .........................................................4-55
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE .........................4-55
CHECKING THE OIL STRAINER .........................................................4-55
ASSEMBLING THE OIL PUMP ...........................................................4-55
INSTALLING THE OIL PUMP .............................................................4-56
INSTALLING THE OIL STRAINER ......................................................4-56
INSTALLING THE OIL PAN ................................................................4-56
CRANKCASE ...............................................................................................4-57
DISASSEMBLING THE CRANKCASE ................................................4-60
CHECKING THE CRANKCASE ...........................................................4-61
CHECKING THE BEARINGS AND OIL SEALS ...................................4-61
CHECKING THE SPROCKETS AND CHAINS ....................................4-61
ASSEMBLING THE CRANKCASE ......................................................4-62
CONNECTING RODS AND PISTONS ........................................................4-64
REMOVING THE CONNECTING RODS AND PISTONS ...................4-65
CHECKING THE CYLINDERS AND PISTONS ....................................4-66
CHECKING THE PISTON RINGS ........................................................4-67
CHECKING THE PISTON PINS ...........................................................4-68
CHECKING THE BIG END BEARINGS ...............................................4-69
INSTALLING THE PISTONS AND CONNECTING RODS .................4-71
CRANKSHAFT .............................................................................................4-74
REMOVING THE CRANKSHAFT ........................................................4-75
CHECKING THE CRANKSHAFT .........................................................4-75
CHECKING THE CRANKSHAFT JOURNAL BEARINGS ...................4-75
INSTALLING THE CRANKSHAFT ......................................................4-78
TRANSMISSION .........................................................................................4-79
REMOVING THE TRANSMISSION ....................................................4-85
CHECKING THE SHIFT FORKS ..........................................................4-85
CHECKING THE SHIFT DRUM ASSEMBLY ......................................4-86
CHECKING THE TRANSMISSION .....................................................4-86
INSTALLING THE TRANSMISSION ..................................................4-87
4
ENGINE
ENG
EB400011
OVERHAULING THE ENGINE
ENGINE
Order
1
2
3
4
5
6
Job/Part
Removing the drive sprocket
Locknut
Shift rod
Drive sprocket cover
Lock washer
Drive sprocket
Shift arm
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
1
1
1
For installation, reverse the removal
procedure.
4-1
ENGINE
Order
Job/Part
Removing the exhaust assembly
Rider seat and fuel tank
Q’ty
Bottom cowling and side cowlings
Coolant
1
2
3
4
5
6
7
8
Radiator assembly
EXUP valve pulley cover
Spring
Washer
EXUP valve pulley
Locknut
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
1
1
1
1
2
2
1
4
4-2
ENG
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Refer to “RADIATOR” in chapter 5.
Loosen.
ENGINE
Order
9
10
11
12
13
14
Job/Part
Muffler
EXUP cable holder
EXUP valve cover
Spacer
EXUP valve
Spacer
Q’ty
1
1
1
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4-3
ENGINE
Order
Job/Part
Disconnecting the leads and hoses
Air filter case
Q’ty
Carburetor assembly and carburetor
joints
Engine oil and oil filter cartridge
Battery negative lead
Battery positive lead
1
1
4-4
Remarks
Disconnect the parts in the order listed.
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.
Refer to “CARBURETORS” in chapter 6.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Refer to “OIL COOLER” and “THERMOSTAT ASSEMBLY” in chapter 5.
Oil cooler and thermostat assembly
1
2
ENG
CAUTION:
ACHTUNG:
First, disconnect the negative lead,
then the positive lead.
ENGINE
Order
3
4
5
6
7
8
9
10
11
12
Job/Part
Clutch cable
Crankcase breather hose
Starter motor lead
Ground lead
Starter motor
Stator coil assembly coupler
Pickup coil coupler
Oil level switch connector
Neutral switch
Speed sensor
Q’ty
1
1
1
1
1
1
1
1
1
1
ENG
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For connecting, reverse the disconnection procedure.
4-5
ENGINE
Order
Job/Part
Removing the engine
Q’ty
ENG
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
1
2
3
4
5
6
7
8
9
Pinch bolt
Right front mounting bolt
Washer
Spacer
Left front mounting bolt
Washer
Self-locking nut
Rear mounting bolt
Spacer
2
1
1
1
2
2
2
2
1
Loosen.
For installation, reverse the removal
procedure.
4-6
ENG
ENGINE
EB400700
INSTALLING THE ENGINE
1. Install:
• spacer 1
• rear mounting bolts 2
• self-locking nuts 3
• washers 4
• left front mounting bolts 5
• spacer 6
• washer 7
• right front mounting bolt 8
NOTE:
• Lubricate the rear mounting bolt
threads with lithium soap base grease.
• Do not fully tighten the nuts and bolts.
T.
2. Tighten:
55 Nm (5.5 m · kg)
• self-locking nut
• left front mounting bolts
R.
T.
R.
40 Nm (4.0 m · kg)
• right front mounting bolt
T.
R.
R.
T.
R.
3. Install:
• shift arm1
T.
• pinch bolts 9
55 Nm (5.5 m · kg)
24 Nm (2.4 m · kg)
10 Nm (1.0 m · kg)
NOTE:
Align the punch mark a in the shift shaft
with the slot in the shift arm.
4. Install:
• drive sprocket cover
T.
R.
10 Nm (1.0 m · kg)
NOTE:
Refer to “CABLE ROUTING” in chapter 2.
4-7
CAMSHAFTS
ENG
EB401000
CAMSHAFTS
Order
1
2
3
4
Job/Part
Removing the cylinder head cover
Carburetor assembly
Radiator assembly and thermostat
assembly
Spark plug
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CARBURETORS” in chapter 6.
Refer to “RADIATOR” and “THERMOSTAT ASSEMBLY” in chapter 5.
4
1
1
1
For installation, reverse the removal
procedure.
4-8
CAMSHAFTS
ENG
EB401011
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the camshafts
Pickup coil rotor cover
Float chamber air vent hose holder
Timing chain tensioner
Timing chain tensioner gasket
Timing chain guide (exhaust side)
Intake camshaft cap
Dowel pin
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Q’ty
1
1
1
1
3
6
3
6
1
1
4-9
Remarks
Remove the parts in the order listed.
Refer to “PICKUP COIL”.
NOTE:
During removal, the dowel pins may
still be connected to the camshaft
caps.
CAMSHAFTS
Order
11
12
13
14
Job/Part
Intake camshaft sprocket
Exhaust camshaft sprocket
Pin
Timing chain guide (intake side)
Q’ty
1
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 10
CAMSHAFTS
ENG
EB401101
REMOVING THE CAMSHAFTS
1. Align:
• TDC mark on the pickup coil rotor
(with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC
mark a on the pickup coil rotor with
the crankcase mating surface b.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• float chamber air vent hose holder
• timing chain tensioner
3. Remove:
• timing chain guide (exhaust side)
4. Remove:
• camshaft caps
• dowel pins
CAUTION:
ACHTUNG:
To prevent damage to the cylinder
head, camshafts or camshaft caps,
loosen the camshaft cap bolts in stages
and in a crisscross pattern, working
from the outside in.
5. Remove:
• intake camshaft 1
• exhaust camshaft 2
NOTE:
To prevent the timing chain from falling
into the crankcase, fasten it with a
wire 3.
4 - 11
CAMSHAFTS
ENG
EB401401
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the
camshaft.
Camshaft lobe dimensions
limit
Intake camshaft
a 32.40 mm
b 24.85 mm
Exhaust camshaft
a 32.85 mm
b 24.85 mm
3. Measure:
• camshaft runout
Out of specification → Replace.
Max. camshaft runout
0.03 mm
4. Measure:
• camshaft-journal-to-camshaft-cap
clearance
Out of specification → Measure the
camshaft journal diameter.
Camshaft-journal-to-camshaft-cap clearance
0.050 ~ 0.084 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder
head (without the dowel pins and
camshaft caps).
b. Position a strip of Plastigauge 1
onto the camshaft journal as shown.
c. Install the dowel pins and camshaft
caps.
4 - 12
CAMSHAFTS
ENG
NOTE:
• Tighten the camshaft cap bolts in
stages and in a crisscross pattern,
working from the inner caps out.
• Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap
clearance
with
the
Plastigauge.
T.
Camshaft cap bolt
10 Nm (1.0 m • kg)
R.
d. Remove the camshaft caps and then
measure the width of the Plastigauge 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• camshaft journal diameter a
Out of specification → Replace the
camshaft.
Within specification → Replace the cylinder head and the camshaft caps as a
set.
Camshaft journal diameter
24.437 ~ 24.450 mm
EB401421
CHECKING THE TIMING CHAIN,
CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES
The following procedure applies to all of
the camshaft sprockets and timing chain
guides.
1. Check:
• timing chain 1
Damage/stiffness → Replace the timing chain and camshaft sprockets as a
set.
4 - 13
CAMSHAFTS
ENG
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a → Replace
the camshaft sprockets and the timing
chain as a set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
• timing chain guide (exhaust side) 1
• timing chain guide (intake side) 2
• timing chain guide (top side) 3
Damage/wear → Replace the defective
part(-s).
EB401430
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
NOTE:
While pressing the timing chain tensioner rod, wind it clockwise with a thin
screwdriver 1 until it stops.
b. Remove the screwdriver and slowly
release the timing chain tensioner
rod.
c. Make sure that the timing chain tensioner rod comes out of the timing
chain tensioner housing smoothly. If
there is rough movement, replace the
timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 14
ENG
CAMSHAFTS
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side) 1
2. Install:
• intake camshaft sprocket
T.
R.
24 Nm (2.4 m · kg)
• exhaust camshaft sprocket
T.
R.
24 Nm (2.4 m · kg)
3. Install:
• exhaust camshaft
• intake camshaft
• exhaust camshaft caps
• intake camshaft caps
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the camshafts.
CAUTION:
ACHTUNG:
Do not turn the crankshaft when installing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake camshaft caps.
T.
Camshaft cap bolt
10 Nm (1.0 m • kg)
R.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment → Reinstall.
e. Remove the wire from the timing
chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 15
CAMSHAFTS
ENG
4. Install:
• timing chain guide (exhaust side)
5. Install:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
b. While pressing the timing chain tensioner rod, wind it clockwise with a
thin screwdriver 1 until it stops.
c. With the screwdriver still inserted
into the timing chain tensioner, install
the timing chain tensioner 2, gasket,
and float chamber air vent hose
holder 3 onto the cylinder block.
Then, tighten the timing chain tensioner bolts 4 to the specified torque.
WARNING
WARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain tensioner should face up.
T.
Timing chain tensioner bolt
10 Nm (1.0 m • kg)
R.
d. Remove the screwdriver, make sure
that the timing chain tensioner rod
releases, and tighten the cap bolt to
the specified torque.
T.
Cap bolt
10 Nm (1.0 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Turn:
• crankshaft
(several turns counterclockwise)
4 - 16
CAMSHAFTS
ENG
7. Check:
• TDC mark a
Make sure that the TDC mark is
aligned with the crankcase mating surface b.
• camshaft punch mark c
Make sure that the camshaft punch
mark is aligned with the arrow mark d
on the camshaft cap.
Out of alignment → Adjust.
Refer to the installation steps above.
8. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
9. Install:
• cylinder head cover gasket
• cylinder head cover
NOTE:
• Apply bond TB1541 onto the mating
surfaces of the cylinder head cover
and cylinder head cover gasket.
• Apply bond 1215B onto the mating
surfaces of the cylinder head cover
gasket and cylinder head.
• Tighten the cylinder head cover bolts
in stages and in a crisscross pattern.
4 - 17
CYLINDER HEAD
ENG
EB402000
CYLINDER HEAD
Order
1
2
3
Job/Part
Removing the cylinder head
Engine
Intake and exhaust camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
1
1
2
For installation, reverse the removal
procedure.
4 - 18
CYLINDER HEAD
ENG
EB402102
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head bolts
• cylinder head nuts
NOTE:
Loosen each bolt and nut 1/2 of a turn at
a time, in stages and in a crisscross pattern. After all of the bolts and nuts are
fully loosened, remove them.
EB402402
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.
Max. cylinder head warpage
0.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness gauge 2 across the cylinder
head.
b. Measure the warpage.
c. If the limited is exceeded, resurface
the cylinder head as follows.
4 - 19
ENG
CYLINDER HEAD
d. Place a 400 ~ 600 grit wet sandpaper
on the surface plate and resurface the
cylinder head using a figure-eight
sanding pattern.
NOTE:
To ensure an even surface, rotate the
cylinder head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB402702
INSTALLING THE CYLINDER HEAD
T.
R.
T.
R.
1. Install:
• cylinder head
• cylinder head nut
• cylinder head bolt
50 Nm (5.0 m · kg)
12 Nm (1.2 m · kg)
NOTE:
• Lubricate the cylinder head nuts with
engine oil.
• Tighten the cylinder head nuts and
bolts in two stages and in a crisscross
pattern.
4 - 20
VALVES AND VALVE SPRINGS
ENG
EB403000
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
12
12
24
12
12
12
12
12
12
4 - 21
VALVES AND VALVE SPRINGS
Order
10
11
12
13
14
15
16
17
18
Job/Part
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Q’ty
12
12
24
12
12
12
12
12
12
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 22
VALVES AND VALVE SPRINGS
ENG
EB403100
REMOVING THE VALVES
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 that the
valves properly seal.
1. Remove:
• valve lifter 1
• valve pad 2
NOTE:
Make a note of the position of each
valve lifter and valve pad so that they
can be reinstalled in their original place.
2. Check:
• valve
(for leakage)
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat
width.
Refer to “CHECKING THE VALVE
SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake
and exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve
seat 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 23
VALVES AND VALVE SPRINGS
ENG
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compressing the valve spring with the valve spring
compressor 2 and attachment 3.
Valve spring compressor
90890-04019
Attachment
(for the intake valve)
90890-04114
(for the exhaust valve)
90890-04108
4. Remove:
• upper spring seat 1
• valve spring 2
• valve 3
• oil seal 4
• lower spring seat 5
NOTE:
Identify the position of each part very
carefully so that it can be reinstalled in
its original place.
EB403400
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of
the valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the
valve guide.
Valve-stem-to-valve-guide
clearance
Intake
0.010 ~ 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 ~ 0.052 mm
<Limit>: 0.1 mm
4 - 24
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 in an
oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with a valve
guide remover 1.
b. Install the new valve guide with the
valve guide installer 2 and valve
guide remover 1.
c. After installing the valve guide, bore
the valve guide with a valve guide
reamer 3 to obtain the proper valvestem-to-valve-guide clearance.
NOTE:
After replacing the valve guide, reface
the valve seat.
Valve guide remover
Intake (4.0 mm)
90890-04111
Exhaust (4.5 mm)
90890-04116
Valve guide installer
Intake (4.0 mm)
90890-04112
Exhaust (4.5 mm)
90890-04117
Valve guide reamer
Intake
90890-04113
Exhaust
90890-04118
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger
than the body of the valve stem →
Replace the valve.
4 - 25
VALVES AND VALVE SPRINGS
ENG
5. Measure:
• valve margin thickness a
Out of specification → Replace the
valve.
Valve margin thickness
0.5 ~ 0.9 mm
6. Measure:
• valve stem runout
Out of specification → Replace the
valve.
NOTE:
• When installing a new valve, always
replace the valve guide.
• If the valve is removed or replaced,
always replace the oil seal.
Valve stem runout
0.01 mm
EB403410
CHECKING THE VALVE SEATS
The following procedure applies to all of
the valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder
head.
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder head.
Valve seat width
0.9 ~ 1.1 mm
<Limit>: 1.6 mm
4 - 26
VALVES AND VALVE SPRINGS
ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing
(Dykem) b onto the valve face.
dye
b. Install the valve into the cylinder
head.
c. Press the valve through the valve
guide and onto the valve seat to make
a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted one another, the blueing will have
been removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or
replacing the valve and valve guide, the
valve seat and valve face should be
lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a
to the valve face.
CAUTION:
ACHTUNG:
Do not let the lapping compound enter
the gap between the valve stem and the
valve guide.
b. Apply molybdenum disulfide oil onto
the valve stem.
c. Install the valve into the cylinder
head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then
clean off all of the lapping compound.
NOTE:
For the best lapping results, lightly tap
the valve seat while rotating the valve
back and forth between your hands.
4 - 27
VALVES AND VALVE SPRINGS
ENG
e. Apply a fine lapping compound to the
valve face and repeat the above
steps.
f. After every lapping procedure, be
sure to clean off all of the lapping
compound from the valve face and
valve seat.
g. Apply Mechanic’s blueing
(Dykem) b onto the valve face.
dye
h. Install the valve into the cylinder
head.
i. Press the valve through the valve
guide and onto the valve seat to make
a clear impression.
j. Measure the valve seat width c
again. If the valve seat width is out of
specification, reface and lap the valve
seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB403420
CHECKING THE VALVE SPRINGS
The following procedure applies to all of
the valve springs.
1. Measure:
• valve spring free length a
Out of specification → Replace the
valve spring.
Valve spring free length
Intake valve spring
38.90 mm
<Limit>: 36.96 mm
Exhaust valve spring
40.67 mm
<Limit>: 38.64 mm
4 - 28
VALVES AND VALVE SPRINGS
ENG
2. Measure:
• compressed spring force a
Out of specification → Replace the
valve spring.
b Installed length
Compressed spring force
(installed)
Intake valve spring
8.36 ~ 9.79 kg at 34.5 mm
Exhaust valve spring
11.22 ~ 12.85 kg at 35.0 mm
3. Measure:
• valve spring tilt a
Out of specification → Replace the
valve spring.
Max. spring tilt
Intake valve spring
1.7 mm
Exhaust valve spring
1.8 mm
EB403430
CHECKING THE VALVE LIFTERS
The following procedure applies to all of
the valve lifters.
1. Check:
• valve lifter
Damage/scratches → Replace
valve lifters and cylinder head.
the
EB403702
INSTALLING THE VALVES
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
• oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
4 - 29
VALVES AND VALVE SPRINGS
ENG
3. Install:
• lower spring seat 1
• oil seal 2 New
• valve 3
• valve spring 4
• upper spring seat 5
(into the cylinder head)
NOTE:
• Make sure that each valve is installed
in its original place. Refer to the following embossed marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “4XV”
• Install the valve spring with the larger
pitch a facing up.
b Smaller pitch
4. Install:
• valve cotters 1
NOTE:
Install the valve cotters by compressing
the valve spring with the valve spring
compressor 2 and attachment 3.
Valve spring compressor
90890-04019
Attachment
(for the intake valve spring)
90890-04114
(for the exhaust valve spring)
90890-04108
5. To secure the valve cotters 1 onto the
valve stem, lightly tap the valve tip with
a soft-face hammer.
CAUTION:
ACHTUNG:
Hitting the valve tip with excessive
force could damage the valve.
4 - 30
VALVES AND VALVE SPRINGS
ENG
6. Lubricate:
• valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
• valve pad
• valve lifter
NOTE:
• The valve lifter must move smoothly
when rotated with a finger.
• Each valve lifter and valve pad must be
reinstalled in its original position.
4 - 31
GENERATOR
ENG
EB410000
GENERATOR
Order
Job/Part
Removing the stator coil assembly
Rider seat and fuel tank
Q’ty
Bottom cowling
Engine oil
1
2
3
4
5
6
7
8
Generator rotor cover
Generator rotor cover gasket
Dowel pin
Generator rotor bolt
Generator rotor
Stator coil assembly coupler
Stator coil assembly lead holder
Stator coil assembly
1
1
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
4 - 32
GENERATOR
ENG
EB410110
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
2. Remove:
• generator rotor bolt 1
• washer
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, loosen the
generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
• generator rotor 1
(with the flywheel puller 2 and rotor
holding tool 3)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)
Yamaha bond No. 1215
90890-85505
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNING
WARNING
Always use a new generator rotor bolt.
4 - 33
CAUTION:
ACHTUNG:
• Clean the tapered portion of the crankshaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
threads with engine oil.
ENG
GENERATOR
3. Tighten:
• generator rotor bolt 1
New
T.
R.
95 Nm (9.5 m · kg)
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, tighten
the generator rotor bolt.
Rotor holding tool
90890-01235
4. Install:
• generator rotor cover
NOTE:
Tighten the generator rotor cover bolts
in stages and in a crisscross pattern.
4 - 34
PICKUP COIL
ENG
PICKUP COIL
Order
Job/Part
Removing the pickup coil and
pickup coil rotor
Rider seat and fuel tank
Q’ty
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Bottom cowling and right side cowling
Engine oil
1
2
3
4
5
6
Generator rotor cover
Clutch cable
Clutch cable holder
Pickup coil lead holder
Pickup coil rotor cover
Pickup coil rotor cover gasket
Dowel pin
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Refer to “GENERATOR”.
1
1
1
1
1
2
4 - 35
Remarks
Remove the parts in the order listed.
PICKUP COIL
Order
Job/Part
7
Pickup coil coupler
8
Pickup coil
9
Pickup coil rotor
ENG
Q’ty
Remarks
1
Disconnect.
1
1
For installation, reverse the removal
procedure.
4 - 36
PICKUP COIL
ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• clutch cable holder 1
• pickup coil lead holder 2
• pickup coil rotor cover 3
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. Remove:
• pickup coil rotor bolt 1
• washer
• pickup coil rotor 2
NOTE:
While holding the generator rotor 3
with the rotor holding tool 4, loosen the
pickup coil rotor bolt.
Rotor holding tool
90890-01235
INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the pin 2 in the crankshaft
sprocket with the groove a in the
pickup coil rotor.
4 - 37
ENG
PICKUP COIL
2. Tighten:
• pickup coil rotor bolt 1
T.
R.
60 Nm (6.0 m · kg)
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, tighten
the pickup coil rotor bolt.
Rotor holding tool
90890-01235
3. Apply:
• sealant
(onto the pickup coil lead grommet)
Yamaha bond No. 1215
90890-85505
4. Install:
• pickup coil rotor cover
• pickup coil lead holder
• clutch cable holder
NOTE:
• When installing the pickup coil rotor
cover, align the timing chain guide
(intake side) pin 1 of the with the hole
2 in the pickup coil rotor cover.
• Tighten the pickup coil rotor cover
bolts in stages and in a crisscross pattern.
4 - 38
CLUTCH
ENG
EB405000
CLUTCH
Order
1
2
3
4
Job/Part
Removing the clutch cover
Bottom cowling and right side cowling
Engine oil
Q’ty
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Remarks
Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1
1
1
2
For installation, reverse the removal
procedure.
4 - 39
CLUTCH
ENG
EB405010
Order
1
2
3
4
5
6
Job/Part
Removing the pull lever shaft
Circlip
Pull lever
Pull lever spring
Pull lever shaft
Oil seal
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
1
1
2
For installation, reverse the removal
procedure.
4 - 40
CLUTCH
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Removing the clutch
Clutch spring plate retainer
Clutch spring plate
Clutch spring plate seat
Pressure plate
Pull rod
Friction plate
Clutch plate
Lock washer
Wire circlip
Clutch plate
Friction plate
Clutch damper spring
Clutch damper spring seat
Clutch boss
Q’ty
1
1
1
1
1
7
6
1
1
1
1
1
1
1
4 - 41
ENG
Remarks
Remove the parts in the order listed.
Inside diameter =124 mm
Inside diameter =135 mm
CLUTCH
Order
15
16
17
18
19
20
21
22
Job/Part
Thrust washer
Clutch housing
Bearing
Starter clutch gear
Bearing
Starter clutch assembly
Circlip
Starter clutch idle gear
Q’ty
1
1
1
1
1
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 42
CLUTCH
ENG
EB405102
REMOVING THE CLUTCH
1. Remove:
• clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, loosen the
clutch boss nut.
Clutch holding tool
90890-04086
4. Remove:
• clutch boss nut 1
• lock washer 2
• clutch boss assembly 3
NOTE:
There is a built-in damper between the
clutch boss and the friction plate. It is
not necessary to remove the wire circlip
4 and disassemble the built-in damper
unless there is serious clutch chattering.
EB405400
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.
Friction plate thickness
2.9 ~ 3.1 mm
<Limit>: 2.8 mm
4 - 43
CLUTCH
ENG
EB405410
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.
Max. clutch plate warpage
0.1 mm
EB405430
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate
Damage → Replace.
2. Check:
• clutch spring plate seat
Damage → Replace.
EB405440
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.
2. Check:
• bearing
Damage/wear → Replace the clutch
housing.
4 - 44
CLUTCH
ENG
EB405450
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.
EB405460
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.
EB405470
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 rod
and pull lever shaft as a set.
2. Check:
• pull rod bearing
Damage/wear → Replace.
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch gear
• starter clutch idle gear
Chips/pitting/roughness/wear →
Replace the defective part(-s).
4 - 45
CLUTCH
ENG
2. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto
the starter clutch 2 and hold the
starter clutch.
b. When turning the starter clutch gear
clockwise Å, the starter clutch and
the starter clutch gear should engage,
otherwise the starter clutch is faulty
and must be replaced.
c. When turning the starter clutch gear
counterclockwise ı, it should turn
freely, otherwise the starter clutch is
faulty and must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB405703
INSTALLING THE CLUTCH
1. Install:
• clutch housing
NOTE:
• Make sure that the slots a in the
clutch housing align with the tabs b
on the oil/water pump assembly drive
sprocket.
• Make sure that the primary driven gear
teeth and primary drive gear teeth
mesh correctly.
• Make sure that the starter clutch gear
teeth and starter clutch idle gear teeth
mesh correctly.
2. Install:
• clutch boss assembly 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.
4 - 46
ENG
CLUTCH
T.
R.
3. Install:
• lock washer New
• clutch boss nut 1
70 Nm (7.0 m · kg)
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, tighten the
clutch boss nut.
Clutch holding tool
90890-04086
4. Bend the lock washer tab along a flat
side of the nut.
5. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:
• friction plates
• clutch plates
NOTE:
First, install a friction plate and then
alternate between a clutch plate and a
friction plate.
7. Install:
• pressure plate 1
• clutch spring plate seat 2
• clutch spring plate 3
• clutch spring plate retainer 4
T.
R.
8 Nm (0.8 m · kg)
NOTE:
Tighten the clutch spring plate retainer
bolts in stages and in a crisscross pattern.
8. Install:
• pull lever
NOTE:
Install the pull lever with the “UP” mark
facing towards the clutch cover.
4 - 47
ENG
CLUTCH
T.
R.
9. Install:
• clutch cover
12 Nm (1.2 m · kg)
NOTE:
• When installing the clutch cover, push
the pull lever and check that the punch
mark a on the pull lever aligns with
the mark b on the clutch cover. Make
sure that the pull rod teeth and pull
lever shaft pinion gear are engaged.
• Tighten the clutch cover bolts in stages
and in a crisscross pattern.
4 - 48
SHIFT SHAFT
ENG
EB408000
SHIFT SHAFT
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the shift shaft and stopper lever
Drive sprocket cover
Throttle stop screw holder
Shift shaft cover
Shift shaft cover gasket
Dowel pin
Shift shaft
Shift shaft spring
Spacer
Stopper lever spring
Stopper lever
Circlip
Collar
Shift shaft spring stopper
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
1
1
1
2
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
4 - 49
ENG
SHIFT SHAFT
EB408401
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
Bends/damage/wear → Replace.
• shift shaft spring 2
Damage/wear → Replace.
EB408410
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the
stopper lever.
EB408703
INSTALLING THE SHIFT SHAFT
1. Install:
• shift shaft spring stopper 1
T.
R.
22 Nm (2.2 m · kg)
• stopper lever spring 2
• stopper lever 3
NOTE:
• Apply LOCTITE to the threads of the
shift shaft spring stopper.
• Hook the ends of the stopper lever
spring onto the stopper lever and the
crankcase boss.
• Mesh the stopper lever with the shift
drum segment assembly.
2. Install:
• shift shaft 1
• spacer
NOTE:
• Lubricate the oil seal lips with lithium
soap base grease.
• Install the end of the shift shaft spring
onto the shift shaft spring stopper 2.
4 - 50
OIL PAN AND OIL PUMP
ENG
EB411000
OIL PAN AND OIL PUMP
Order
Job/Part
Removing the oil pan and oil pump
Engine oil
Q’ty
Coolant
1
2
3
4
5
6
Radiator assembly and water pump
outlet pipe
Exhaust pipe assembly
Oil level switch connector
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
4 - 51
1
1
1
1
1
2
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Refer to “RADIATOR” and “OIL
COOLER” in chapter 5.
Refer to “ENGINE”.
Disconnect.
OIL PAN AND OIL PUMP
ENG
EB411001
Order
7
8
9
10
11
12
13
14
Job/Part
Drain pipe
Oil strainer
Oil pipe
Oil delivery pipe
Oil/water pump assembly drive
sprocket cover
Dowel pin
Oil/water pump assembly
Relief valve assembly
Q’ty
1
1
1
1
1
Remarks
1
1
1
For installation, reverse the removal
procedure.
4 - 52
OIL PAN AND OIL PUMP
ENG
EB411003
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the oil pump
Oil/water pump assembly driven
sprocket
Washer
Oil pump housing
Bearing
Pin
Oil pump outer rotor
Oil pump inner rotor
Pin
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
2
1
1
1
For installation, reverse the removal
procedure.
4 - 53
OIL PAN AND OIL PUMP
ENG
EB411100
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• oil pan gasket
• dowel pins
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.
EB411400
CHECKING THE OIL PUMP
1. Check:
• oil/water pump assembly driven
sprocket 1
• oil pump housing 2
Cracks/damage/wear → Replace the
defective part(-s).
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
0.09 ~ 0.15 mm
Outer-rotor-to-oil-pump-housing clearance
0.03 ~ 0.08 mm
4 - 54
OIL PAN AND OIL PUMP
ENG
3. Check:
• oil pump operation
Unsmooth → Repair or replace the
defective part(-s).
Refer to “WATER PUMP” in chapter 5.
EB411410
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear → Replace the defective
part(-s).
EB411421
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage → Replace.
Obstruction → Wash and blow out
with compressed air.
EB411430
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
EB411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• impeller shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
4 - 55
ENG
OIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
10 Nm (1.0 m · kg)
T.
R.
1. Install:
• oil pump 1
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
EB411720
INSTALLING THE OIL STRAINER
10 Nm (1.0 m · kg)
T.
R.
1. Install:
• oil strainer 1
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
EB411730
INSTALLING THE OIL PAN
T.
1. Install:
• dowel pins
• oil pan gasket New
10 Nm (1.0 m · kg)
• oil pan 1
• oil level switch 2
R.
T.
R.
10 Nm (1.0 m · kg)
• engine oil drain bolt 3
T.
R.
43 Nm (4.3 m · kg)
WARNING
WARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
4 - 56
CRANKCASE
ENG
CRANKCASE
Order
1
2
3
4
5
Job/Part
Separating the crankcase
Engine
Cylinder head
Pickup coil and pickup coil rotor
Stator coil assembly
Clutch housing and starter clutch
idle gear
Oil/water pump assembly
Timing chain
Crankshaft sprocket
Pin
Oil/water pump assembly drive
chain guide
Oil/water pump assembly drive
chain
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “PICKUP COIL”.
Refer to “GENERATOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
1
1
1
1
1
4 - 57
CRANKCASE
Order
Job/Part
6
Oil/water pump assembly drive
sprocket
7
Washer
8
Plate
9
Lower crankcase
10
Dowel pin
Q’ty
1
ENG
Remarks
1
1
1
3
For installation, reverse the removal
procedure.
4 - 58
CRANKCASE
Order
1
2
3
4
5
6
7
Job/Part
Removing the oil baffle plates and
oil filter bolt
Connecting rod assemblies
Q’ty
ENG
Remarks
Remove the parts in the order listed.
Refer to “CONNECTING RODS AND
PISTONS”.
Refer to “CRANKSHAFT”.
Refer to “TRANSMISSION”.
Crankshaft
Transmission
Oil baffle plate
Oil baffle plate
Oil delivery pipe
Bearing
Upper crankcase
Oil filter bolt
Lower crankcase
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
4 - 59
CRANKCASE
ENG
EB412100
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
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.
• Loosen the bolts in decreasing numerical order (refer to the numbers in the
illustration).
• The numbers embossed on the crankcase indicate the crankcase tightening
sequence.
2. Place the engine upside down.
3. Remove:
• lower crankcase
CAUTION:
ACHTUNG:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced portions of the crankcase, not on
the crankcase mating surfaces. Work
slowly and carefully and make sure that
the crankcase halves separate evenly.
M9 × 115 mm bolts: 1 ~ @
M8 × 60 mm bolt: K
M8 × 50 mm bolt: L
M6 × 70 mm bolts: G, I, O
M6 × 65 mm bolt: Q
M6 × 64 mm bolts: F, N
M6 × 60 mm bolt: M
M6 × 55 mm bolts: A ~ E
M6 × 50 mm bolt: H
M6 × 45 mm bolts: J, P, R
4. Remove:
• dowel pins
5. Remove:
• crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft
journal lower bearing so that it can be
reinstalled in its original place.
4 - 60
CRANKCASE
ENG
EB412420
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves
in a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• upper crankcase
• lower crankcase
Cracks/damage → Replace.
• oil delivery passages
Obstruction → Blow out with compressed air.
EB412440
CHECKING THE BEARINGS AND OIL SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
CHECKING THE SPROCKETS AND CHAINS
1. Check:
• crankshaft sprocket 1
• oil/water pump assembly drive
sprocket 2
Cracks/damage/wear → Replace the
defective part(-s).
2. Check:
• timing chain 1
Damage/stiffness → Replace the timing chain and crankshaft sprocket as a
set.
• oil/water pump assembly drive chain 2
Damage/stiffness → Replace the oil/
water pump assembly drive chain and
oil/water
pump
assembly
drive
sprocket as a set.
4 - 61
CRANKCASE
ENG
EB412743
ASSEMBLING THE CRANKCASE
1. Lubricate:
• crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
• sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into
contact with the oil gallery or crankshaft
journal bearings. Do not apply sealant to
within 2 ~ 3 mm of the crankshaft journal bearings.
3. Install:
• dowel pin
4. Install:
• crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
• Align the projections a on the crankshaft journal lower bearings with the
notches b in the lower crankcase.
• Install each crankshaft journal lower
bearing in its original place.
5. Set the shift drum assembly and transmission gears in the neutral position.
4 - 62
CRANKCASE
ENG
6. Install:
• lower crankcase 1
(onto the upper crankcase 2)
CAUTION:
ACHTUNG:
Before tightening the crankcase bolts,
make sure that the transmission gears
shift correctly when the shift drum
assembly is turned by hand.
7. Install:
• crankcase bolts
NOTE:
• Lubricate the bolt threads with engine
oil.
• Install a washer on bolts 1 ~ @.
• Tighten the bolts in the tightening
sequence cast on the crankcase.
M9 × 115 mm bolts: 1 ~ @
M8 × 60 mm bolt: K
M8 × 50 mm bolt: L
M6 × 70 mm bolts: G, I, O
M6 × 65 mm bolt: Q
M6 × 64 mm bolts: F, N
M6 × 60 mm bolt: M
M6 × 55 mm bolts: A ~ E
M6 × 50 mm bolt: H
M6 × 45 mm bolts: J, P, R
T.
R.
4 - 63
Bolt 1 ~ @
32 Nm (3.2 m • kg)
Bolt A ~ E, G ~ J, M, O ~ R
12 Nm (1.2 m • kg)
Bolt F, N
14 Nm (1.4 m • kg)
Bolt K, L
24 Nm (2.4 m • kg)
CONNECTING RODS AND PISTONS
ENG
EB404001
CONNECTING RODS AND PISTONS
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the connecting rods and
pistons
Crankcase
Q’ty
Connecting rod cap
Big end lower bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Big end upper bearing
Top ring
2nd ring
Oil ring
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
4
4
8
4
4
4
4
4
4
4
For installation, reverse the removal
procedure.
4 - 64
CONNECTING RODS AND PISTONS
ENG
EB412131
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of
the connecting rods and pistons.
1. Remove:
• connecting rod cap 1
• big end bearings
NOTE:
Identify the position of each big end
bearing so that it can be reinstalled in its
original place.
2. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
• connecting rod 4
CAUTION:
ACHTUNG:
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put
identification marks on the piston
crown.
• Before removing the piston pin, deburr
the piston pin clip groove and the piston pin bore area in the piston. If both
areas are deburred and the piston pin
is still difficult to remove, remove it
with the piston pin puller 4.
Piston pin puller
90890-01304
3. Remove:
• top ring
• 2nd ring
• oil ring
NOTE:
To remove a piston ring, open the end
gap with your fingers and lift the other
side of the ring over the piston crown.
4 - 65
ENG
CONNECTING RODS AND PISTONS
EB404403
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of
the cylinders and pistons.
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the
crankcases, and the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the
cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking
side-to-side and front-to-back measurements of the cylinder. Then, find the
average of the measurements.
Cylinder bore gauge
90890-03017
Cylinder bore “C”
74.000 ~ 74.010 mm
Max. taper “T”
0.05 mm
Out of round “R”
0.05 mm
“C”= maximum of D1 ~ D6
“T” = maximum of D1, or D2 – maximum of D5 or D6
“R” = maximum of D1, D3 or D5 – minimum of D2, D4 or D6
b. If out of specification, replace the
crankcases, and the pistons and piston rings as a set.
c. Measure piston skirt diameter “P”
with the micrometer.
Micrometer
90890-03008
a 5 mm from the bottom edge of the piston
Piston size “P”
Standard
4 - 66
73.955 ~ 73.970 mm
d. If out of specification, replace the piston and piston rings as a set.
CONNECTING RODS AND PISTONS
ENG
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
0.030 ~ 0.055 mm
<Limit>: 0.12 mm
f. If out of specification, replace the
crankcases, and the pistons and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB404410
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 ~ 0.065 mm
<Limit>: 0.115 mm
2nd ring
0.020 ~ 0.055 mm
<Limit>: 0.115 mm
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with
the piston crown.
a 5 mm
4 - 67
CONNECTING RODS AND PISTONS
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
0.19 ~ 0.31 mm
<Limit>: 0.56 mm
2nd ring
0.30 ~ 0.45 mm
<Limit>: 0.80 mm
Oil ring
0.10 ~ 0.35 mm
EB404421
CHECKING THE PISTON PINS
The following procedure applies to all of
the piston pins.
1. Check:
• piston pin
Blue discoloration/grooves → Replace
the piston pin and then check the lubrication system.
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston pin.
Piston pin outside diameter
16.991 ~ 17.000 mm
<Limit>: 16.971 mm
3. Measure:
• piston pin bore diameter (in the piston)
Out of specification → Replace the piston pin.
Piston pin bore diameter
(in the piston)
17.002 ~ 17.013 mm
<Limit>: 17.043 mm
4 - 68
CONNECTING RODS AND PISTONS
ENG
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter (in the
piston) –
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.002 ~ 0.022 mm
<Limit>: 0.072 mm
CHECKING THE BIG END BEARINGS
1. Measure:
• crankshaft-pin-to-big-end-bearing
clearance
Out of specification → Replace the big
end bearings.
Crankshaft-pin-to-big-endbearing clearance
0.016 ~ 0.040 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to all of
the connecting rods.
CAUTION:
ACHTUNG:
Do not interchange the big end bearings
and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage,
the big end bearings must be installed
in their original positions.
a. Clean the big end bearings, crankshaft pins, and bearing portions of
the connecting rods.
b. Install the big end upper bearing into
the connecting rod and the big end
lower bearing into the connecting rod
cap.
NOTE:
Align the projections a on the big end
bearings with the notches b in the connecting rod and connecting rod cap.
4 - 69
CONNECTING RODS AND PISTONS
ENG
c. Put a piece of Plastigauge 1 on the
crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or
crankshaft until the clearance measurement has been completed.
• Lubricate the bolt threads and nut
seats with molybdenum disulfide
grease.
• Make sure that the “Y” mark c on the
connecting rod faces towards the left
side of the crankshaft.
• Make sure that the characters d on
both the connecting rod and connecting rod cap are aligned.
e. Tighten the connecting rod nuts.
CAUTION:
ACHTUNG:
• When tightening the connecting rod
nuts, be sure to use an F-type torque
wrench.
• Without pausing, tighten the connecting rod nuts to the specified torque.
Apply continuous torque between 2.0
and 3.6 m • kg. Once you reach 2.0 m •
kg, DO NOT STOP TIGHTENING until
the specified torque is reached. If the
tightening is interrupted between 2.0
and 3.6 m • kg, loosen the connecting
rod nut to less than 2.0 m • kg and
start again.
Refer to “INSTALLING THE PISTONS
AND CONNECTING RODS”.
T.
Connecting rod nut
36 Nm (3.6 m • kg)
R.
f. Remove the connecting rod and big
end bearings.
Refer to “REMOVING THE CONNECTING RODS AND PISTONS”.
g. Measure the compressed Plastigauge width e on the crankshaft
pin.
If the crankshaft-pin-to-big-end-bearing clearance is out of specification,
select replacement big end bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 70
CONNECTING RODS AND PISTONS
ENG
2. Select:
• big end bearings (“P1”~ “P4”)
NOTE:
• The numbers stamped into the crankshaft web and the numbers on the
connecting rods are used to determine
the replacement big end bearing sizes.
• “P1”~“P4” refer to the bearings shown
in the crankshaft illustration.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the connecting rod
“P1” and the crankshaft web “P1” numbers are “5” and “1” respectively, then
the bearing size for “P1” is:
“P1” (connecting rod) – “P1” (crankshaft) – 2 =
5–1–2=2
BIG END BEARING COLOR CODE
–1
violet
0
white
1
blue
2
black
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB404704
INSTALLING THE PISTONS AND
CONNECTING RODS
The following procedure applies to all of
the pistons and cylinders.
1. Install:
• top ring
• 2nd ring
• oil ring
NOTE:
Be sure to install the piston rings so that
the manufacturer’s marks or numbers
face up.
4 - 71
CONNECTING RODS AND PISTONS
ENG
2. Install:
• piston 1
(onto the respective connecting rod 2)
• piston pin 3
• piston pin clip 4 New
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark a on the
connecting rod faces left when the
arrow mark b on the piston is pointing
up. Refer to the illustration.
• Reinstall each piston into its original
cylinder (numbering order starting
from the left: #1 to #4).
3. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
Å Intake side
4. Lubricate:
• piston
• piston rings
• cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Lubricate:
• bolt threads
• nut seats
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide grease
4 - 72
ENG
CONNECTING RODS AND PISTONS
6. Lubricate:
• crankshaft pins
• big end bearings
• connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
• big end bearings
• connecting rod assembly
(into the cylinder and onto the crankshaft pin)
• connecting rod cap
(onto the connecting rod)
NOTE:
• Align the projections on the big end
bearings with the notches in the connecting rods and connecting rod caps.
• Be sure to reinstall each big end bearing in its original place.
• While compressing the piston rings
with one hand, install the connecting
rod assembly into the cylinder with the
other hand.
• Make sure that the “Y” marks a on the
connecting rods face towards the left
side of the crankshaft.
• Make sure that the characters b on
both the connecting rod and connecting rod cap are aligned.
8. Align:
• bolt heads
(with the connecting rod caps)
9. Tighten:
• connecting rod nuts
T.
R.
36 Nm (3.6 m · kg)
CAUTION:
ACHTUNG:
• When tightening the connecting rod
nuts, be sure to use an F-type torque
wrench.
• Without pausing, tighten the connecting rod nuts to the specified torque.
Apply continuous torque between 2.0
and 3.6 m • kg. Once you reach
2.0 m • kg DO NOT STOP TIGHTENING
until the specified torque is reached. If
the tightening is interrupted between
2.0 and 3.6 m • kg, loosen the connecting rod nut to less than 2.0 m • kg and
start again.
4 - 73
CRANKSHAFT
ENG
EB412000
CRANKSHAFT
Order
Job/Part
Removing the crankshaft assembly
Crankcase
Q’ty
Connecting rod caps
1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
1
5
5
For installation, reverse the removal
procedure.
4 - 74
CRANKSHAFT
ENG
EB412110
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft
journal upper bearing so that it can be
reinstalled in its original place.
EB412403
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
Out of specification → Replace the
crankshaft.
Max. crankshaft runout
0.03 mm
2. Check:
• crankshaft journal surfaces
• crankshaft pin surfaces
• bearing surfaces
Scratches/wear → Replace the crankshaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
• crankshaft-journal-to-crankshaft-journal-bearing clearance
Out of specification → Replace the
crankshaft journal bearings.
Crankshaft-journal-to-crankshaft-journal-bearing clearance
0.004 ~ 0.028 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
ACHTUNG:
Do not interchange the crankshaft journal bearings. To obtain the correct
crankshaft-journal-to-crankshaft-journal-bearing clearance and prevent
engine damage, the crankshaft journal
bearings must be installed in their original positions.
4 - 75
CRANKSHAFT
ENG
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of the crankcase.
b. Place the upper crankcase upside
down on a bench.
c. Install the crankshaft journal upper
bearings 1 and the crankshaft into
the upper crankcase.
NOTE:
Align the projections a on the crankshaft journal upper bearings with the
notches b in the upper crankcase.
d. Put a piece of Plastigauge 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil
hole in the crankshaft journal.
e. Install the crankshaft journal lower
bearings into the lower crankcase and
assemble the crankcase.
NOTE:
• Align the projections a on the crankshaft journal lower bearings with the
notches b in the lower crankcase.
• Do not move the crankshaft until the
clearance measurement has been
completed.
f. Tighten the bolts to specification in
the tightening sequence cast on the
crankcase.
T.
R.
Bolt 1 ~ @
32 Nm (3.2 m • kg)
Bolt A ~ E, G ~ J, M, O ~ R
12 Nm (1.2 m • kg)
Bolt F, N
14 Nm (1.4 m • kg)
Bolt K, L
24 Nm (2.4 m • kg)
NOTE:
Lubricate the crankcase bolt threads
with engine oil.
4 - 76
CRANKSHAFT
ENG
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge width c on each crankshaft
journal.
If the clearance is out of specification,
select replacement crankshaft journal bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• crankshaft journal bearings (J1 ~ J5)
NOTE:
• The numbers stamped into the crankshaft web and the numbers stamped
into the lower crankcase are used to
determine the replacement crankshaft
journal bearing sizes.
• “J1” ~ “J5” refer to the bearings shown
in the crankshaft illustration.
• If “J1” ~ “J5” are the same, use the
same size for all of the bearings.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the crankcase “J1” and
crankshaft web “J1” numbers are “6”
and “2” respectively, then the bearing
size for “J1” is:
Bearing size for J1:
“J1” (crankcase) – “J1” (crankshaft
web) – 2 =
6–2–2=2
CRANKSHAFT JOURNAL BEARING
COLOR CODE
–1
pink/violet
0
pink/white
1
pink/blue
2
pink/black
3
pink/brown
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 77
CRANKSHAFT
ENG
EB412720
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft journal upper bearings
(into the upper crankcase)
NOTE:
• Align the projections a on the crankshaft journal upper bearings with the
notches b in the upper crankcase.
• Be sure to install each crankshaft journal upper bearing in its original place.
4 - 78
TRANSMISSION
ENG
EB413000
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the transmission, shift
drum assembly, and shift forks
Crankcase
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “SHIFT SHAFT”.
Stopper lever
Drive axle assembly
Circlip
Oil seal
Bearing
Shift drum retainer
Shift fork guide bar
Spring
Shift fork “L”
Shift fork “R”
1
1
1
1
1
2
4
1
1
4 - 79
TRANSMISSION
Order
Job/Part
10
Shift drum assembly
11
Shift fork “C”
12
Main axle assembly
Q’ty
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 80
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
@
ENG
Job/Part
Q’ty
Remarks
Disassembling the main axle assemRemove the parts in the order listed.
bly
2nd pinion gear
1
Toothed lock washer
1
Toothed lock washer retainer
1
6th pinion gear
1
Toothed spacer
1
Toothed washer
2
Circlip
2
3rd/4th pinion gears
1
5th pinion gear
1
Collar
1
4 - 81
TRANSMISSION
Order
Job/Part
A
Main axle/1st pinion gear
B
Bearing
C
Main axle bearing housing
Q’ty
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 82
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
@
ENG
Job/Part
Q’ty
Remarks
Disassembling the drive axle assemRemove the parts in the order listed.
bly
Washer
1
1st wheel gear
1
Spacer
1
5th wheel gear
1
Circlip
3
Washer
3
3rd wheel gear
1
Toothed spacer
2
Toothed lock washer
1
Toothed lock washer retainer
1
4 - 83
TRANSMISSION
Order
A
B
C
D
E
F
G
Job/Part
4th wheel gear
6th wheel gear
2nd wheel gear
Spacer
Drive axle
Bearing
Spacer
Q’ty
1
1
1
1
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
4 - 84
TRANSMISSION
ENG
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx wrench T30)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
the upper crankcase.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB413400
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 guide bar
Roll the shift fork guide bar on a flat
surface.
Bends → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
shift fork guide bar.
4 - 85
TRANSMISSION
ENG
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift
fork(-s) and shift fork guide bar as a
set.
EB413410
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift
drum assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift
drum assembly.
EB413422
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial
gauge 1)
Out of specification → Replace the
main axle.
Max. main axle runout
0.08 mm
2. Measure:
• drive axle runout
(with a centering device and dial
gauge 1)
Out of specification → Replace the
drive axle.
Max. drive axle runout
0.08 mm
3. Check:
• transmission gears
Blue discoloration/pitting/wear →
Replace the defective gear(-s).
• transmission gear dogs
Cracks/damage/rounded edges →
Replace the defective gear(-s).
4 - 86
TRANSMISSION
ENG
4. Check:
• transmission gear engagement
(each pinion gear to its respective
wheel gear)
Incorrect → Reassemble the transmission axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the
defective part(-s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
INSTALLING THE TRANSMISSION
1. Install:
• main axle assembly
• shift fork “C”
• shift drum assembly
• shift fork “R”
• shift fork “L”
• springs
• shift fork guide bars
• drive axle assembly
NOTE:
• Carefully position the shift forks so
that they are installed correctly into the
transmission gears.
• Install shift fork “C” into the groove in
the 3rd and 4th pinion gear on the
main axle.
• Install shift fork “L” into the groove in
the 6th wheel gear and shift fork “R”
into the groove in the 5th wheel gear
on the drive axle.
• Make sure that the drive axle bearing
circlip is inserted into the grooves in
the upper crankcase.
2. Check:
• transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
4 - 87
ENG
4 - 88
COOL
5
COOL
CHAPTER 5.
COOLING SYSTEM
RADIATOR .....................................................................................................5-1
CHECKING THE RADIATOR .................................................................5-3
INSTALLING THE RADIATOR ..............................................................5-4
OIL COOLER ..................................................................................................5-5
CHECKING THE OIL COOLER ..............................................................5-6
INSTALLING THE OIL COOLER ...........................................................5-6
THERMOSTAT ASSEMBLY .........................................................................5-8
CHECKING THE THERMOSTAT .........................................................5-11
ASSEMBLING THE THERMOSTAT ASSEMBLY ..............................5-11
INSTALLING THE THERMOSTAT ASSEMBLY .................................5-12
WATER PUMP .............................................................................................5-13
DISASSEMBLING THE WATER PUMP ..............................................5-15
CHECKING THE WATER PUMP .........................................................5-15
ASSEMBLING THE WATER PUMP ....................................................5-16
COOL
RADIATOR
COOL
EB500000
COOLING SYSTEM
RADIATOR
Order
Job/Part
Removing the radiator
Rider seat and fuel tank
Q’ty
Air filter case and rubber cover
Bottom cowling and side cowlings
Drive sprocket cover
Coolant
1
2
3
4
5
6
Coolant reservoir breather hose
Coolant reservoir hose
Coolant reservoir
Thermo switch coupler
Temperature sender connector
Ground lead
1
1
1
1
1
1
5-1
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “ENGINE” in chapter 4.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Disconnect.
Disconnect.
Disconnect.
RADIATOR
Order
7
8
9
10
11
12
13
14
15
16
17
18
Job/Part
Thermo switch
Temperature sender
Thermostat assembly breather hose
Radiator inlet hose
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
Water pump inlet pipe
Radiator fan motor coupler
Horn bracket
Radiator
Radiator fan
COOL
Q’ty
Remarks
1
1
1
Disconnect.
1
1
Disconnect.
1
1
1
1
Disconnect.
1
1
1
For installation, reverse the removal
procedure.
5-2
RADIATOR
COOL
EB500010
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,
flat-head 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
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm2, 0.95 ~
1.25 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and
adapter 2 onto the radiator cap 3.
Radiator cap tester
90890-01325
Adapter
90890-01352
b. Apply the specified pressure for ten
seconds and make sure that 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
EB500020
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
OIL COOLER
COOL
EB501000
OIL COOLER
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the oil cooler
Radiator assembly
Exhaust pipe assembly
Engine oil
Q’ty
Oil cooler outlet hose
Bolt
Lock washer
Oil cooler
Oil cooler inlet hose
Water pump outlet pipe
Water jacket joint inlet hose
Water jacket joint
Remarks
Remove the parts in the order listed.
Refer to “RADIATOR”.
Refer to “ENGINE” in chapter 4.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-5
OIL COOLER
COOL
EB501010
CHECKING THE OIL COOLER
1. Check:
• oil cooler
Cracks/damage → Replace.
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
Cracks/damage/wear → Replace.
3. Check:
• water jacket joint
• water jacket joint inlet hose
• water pump outlet hose
Cracks/damage → Replace.
EB501020
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and
the crankcase
(with a cloth dampened with lacquer
thinner)
2. Install:
• O-ring New
• oil cooler 1
• lock washer 2
• bolt 3
New
T.
R.
35 Nm (3.5 m · kg)
NOTE:
• Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with
a thin coat of engine oil.
• Make sure that the O-ring is positioned
properly.
• Align the projection a on the oil
cooler with the slot b in the crankcase.
3. Bend the lock washer tab along a flat
side of the bolt.
5-6
OIL COOLER
COOL
4. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
• crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
5. Check:
• cooling system
Leaks → Repair or replace any faulty
part.
6. Measure:
• radiator cap opening pressure
Below the specified pressure →
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-7
THERMOSTAT ASSEMBLY
COOL
EB502000
THERMOSTAT ASSEMBLY
Order
Job/Part
Removing the thermostat assembly
Rider seat and fuel tank
Q’ty
Air filter case and rubber cover
Carburetor assembly
Coolant
1
2
3
4
Radiator inlet hose
Thermostat assembly breather hose
Thermostat assembly inlet hose
(left)
Thermostat assembly inlet hose
(right)
5-8
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.
Refer to “CARBURETORS” in chapter 6.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Disconnect.
THERMOSTAT ASSEMBLY
Order
Job/Part
Q’ty
5
Thermostat assembly
1
6
Thermostat assembly inlet pipe (left)
1
7
Thermostat assembly inlet pipe
1
(right)
COOL
Remarks
For installation, reverse the removal
procedure.
5-9
THERMOSTAT ASSEMBLY
COOL
EB502010
Order
1
2
3
Job/Part
Disassembling the thermostat
assembly
Thermostat housing cover
Thermostat
Thermostat housing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 10
THERMOSTAT ASSEMBLY
COOL
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 71 ~ 85 ˚C → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
Å Fully closed
ı Fully open
NOTE:
If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage → Replace.
EB502030
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing 1
• thermostat 2
• thermostat housing cover
NOTE:
Install the thermostat with its breather
hole a facing up.
5 - 11
THERMOSTAT ASSEMBLY
COOL
EB502040
INSTALLING THE THERMOSTAT
ASSEMBLY
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 - 12
WATER PUMP
COOL
EB503000
WATER PUMP
Order
Job/Part
Removing the impeller shaft
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
• The water pump and oil pump are
combined into one unit (oil/water
pump assembly).
• It is not necessary to remove the
impeller shaft unless the coolant
level is extremely low or coolant
leaks from the oil pan.
1
2
3
4
Oil/water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)
5 - 13
Refer to “OIL PAN AND OIL PUMP” in
chapter 4.
1
1
2
1
WATER PUMP
Order
Job/Part
5
Water pump seal
6
Oil seal
7
Bearing
Q’ty
1
1
1
COOL
Remarks
For installation, reverse the removal
procedure.
5 - 14
WATER PUMP
COOL
EB503020
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 Water pump housing
2. Remove:
• oil seal 1
• bearing 2
NOTE:
Tap out the bearing and oil seal from the
outside of the water pump housing.
3 Water pump housing
3. Remove:
• rubber damper holder 1
• rubber damper 2
(from the impeller, with a thin, flathead screwdriver)
NOTE:
Do not scratch the impeller shaft.
EB503032
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover 1
• water pump housing 2
• impeller 3
• rubber damper 4
• rubber damper holder 5
Cracks/damage/wear → Replace.
2. Check:
• water pump seal
• oil seal
• water pump inlet pipe
Cracks/damage/wear → Replace.
• bearing
Rough movement → Replace.
5 - 15
WATER PUMP
COOL
EB503040
ASSEMBLING THE WATER PUMP
1. Install:
New
• oil seal 1
(into the water pump housing 2)
NOTE:
• Before installing the oil seal, apply tap
water or coolant onto its outer surface.
• Install the oil seal with a socket that
matches its outside diameter.
2. Install:
• water pump seal 1
New
CAUTION:
ACHTUNG:
Never lubricate the water pump seal
surface with oil or grease.
NOTE:
• Install the water pump seal with the
special tools.
• Before installing the water pump seal,
apply Yamaha bond No.1215 2 to the
water pump housing 3.
Mechanical seal installer 4
90890-04078
Middle driven shaft bearing
driver 5
90890-04058
Yamaha bond No. 1215
90890-85505
Å Push down.
3. Install:
New
• rubber damper 1
• rubber damper holder 2
New
NOTE:
Before installing the rubber damper,
apply tap water or coolant onto its outer
surface.
5 - 16
WATER PUMP
COOL
4. Measure:
• impeller shaft tilt
Out of specification → Repeat steps (3)
and (4).
CAUTION:
ACHTUNG:
Make sure that the rubber damper and
rubber damper holder are flush with the
impeller.
Max. impeller shaft tilt
0.15 mm
1 Straightedge
2 Impeller
5 - 17
COOL
5 - 18
CARB
6
CARB
CHAPTER 6.
CARBURETORS
CARBURETORS ............................................................................................6-1
CHECKING THE CARBURETORS .........................................................6-6
ASSEMBLING THE CARBURETORS ...................................................6-8
INSTALLING THE CARBURETORS ....................................................6-10
MEASURING AND ADJUSTING THE FUEL LEVEL ..........................6-11
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ..........................................................................................6-12
CHECKING THE FUEL PUMP .............................................................6-15
CARB
CARBURETORS
CARB
EB600001
CARBURETORS
CARBURETORS
Order
Job/Part
Removing the carburetors
Rider seat and fuel tank
Q’ty
Air filter case and rubber baffle
1
2
3
4
5
6
7
8
9
Starter cable
Fuel hose
Throttle position sensor coupler
Float chamber air vent hose
Throttle stop screw
Carburetor joint clamp screw
Throttle cable
Carburetor assembly
Carburetor joint
1
1
1
2
1
8
2
1
4
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
6-1
CARBURETORS
CARB
EB600010
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Separating the carburetors
Starter plunger link
Connecting bolt
Copper washer
Connecting bolt
Spacer
Spacer
Spacer
Hose joint
Float chamber air vent hose
Float chamber air vent hose
Spring
Vacuum chamber air vent hose
Vacuum chamber pipe
Q’ty
1
1
1
1
1
1
1
2
1
1
2
2
1
6-2
Remarks
Remove the parts in the order listed.
R = 245 mm
R = 270 mm
R = 43 mm
R= 38 mm
R = 36 mm
R= 250 mm
R = 355 mm
CARBURETORS
Order
14
15
16
17
18
19
20
21
22
23
Job/Part
Fuel feed pipe
Fuel feed pipe
Fuel feed pipe
Pipe
Pipe
Pipe
Throttle stop screw
Throttle position sensor
Throttle position sensor bracket
Carburetor
Q’ty
1
1
1
1
1
1
1
1
1
4
CARB
Remarks
R = 37 mm
R = 32 mm
R= 29 mm
R = 73 mm
R= 68 mm
R = 66 mm
For installation, reverse the removal
procedure.
6-3
CARBURETORS
CARB
EB600021
Order
Job/Part
Disassembling the carburetor
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
The following procedure applies to all
of the carburetors.
1
2
3
4
5
6
7
8
9
0
A
Starter plunger
Air funnel
Air funnel joint
Pilot air jet
Vacuum chamber cover
Piston valve spring
Jet needle holder
Jet needle kit
Piston valve
Pilot screw
Fuel drain bolt
1
1
1
1
1
1
1
1
1
1
1
6-4
CARBURETORS
Order
B
C
D
E
F
G
H
I
Job/Part
Float chamber
Float pivot pin
Float
Needle valve
Needle valve seat
Main jet
Main jet holder
Pilot jet
Q’ty
1
1
1
1
1
1
1
1
CARB
Remarks
For assembly, reverse the disassembly
procedure.
6-5
CARBURETORS
CARB
EB600031
CHECKING THE CARBURETORS
The following procedure applies to all of
the carburetors.
1. Check:
• carburetor body
• float chamber
Cracks/damage → Replace.
2. Check:
• fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic
carburetor cleaning solution.
b. Blow out all of the passages and jets
with compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• float chamber body
Dirt → Clean.
4. Check:
• float chamber rubber gasket 1
Cracks/damage/wear → Replace.
5. Check:
• float
Damage → Replace.
6. Check:
• needle valve 1
• needle valve seat 2
Damage/obstruction/wear → Replace
the needle valve, needle valve seat and
O-ring as a set.
7. Check:
• O-ring 3
Damage/wear → Replace the needle
valve, needle valve seat and O-ring as
a set.
6-6
CARBURETORS
CARB
8. Check:
• piston valve 1
Damage/scratches/wear → Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.
9. Check:
• vacuum chamber cover 1
• piston valve spring 2
• jet needle holder 3
• jet needle spring 4
Cracks/damage → Replace.
10.Check:
• jet needle kit 1
• main jet 2
• main jet holder 3
• pilot jet 4
• pilot screw 5
• starter plunger 6
• pilot air jet 7
Bends/damage/wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
11.Check:
• piston valve movement
Insert the piston valve into the carburetor body and move it up and down.
Tightness → Replace the piston valve.
12.Check:
• fuel feed pipes 1
• pipes 2
• hose joints 3
Cracks/damage → Replace.
Obstruction → Clean.
Blow out the pipes with compressed
air.
6-7
CARBURETORS
CARB
13.Check:
• fuel hoses
Cracks/damage/wear → Replace.
Obstruction → Clean.
Blow out the hoses with compressed
air.
EB600043
ASSEMBLING THE CARBURETORS
The following procedure applies to all of
the carburetors.
CAUTION:
ACHTUNG:
• Before assembling the carburetors,
wash all of the parts in a petroleumbased solvent.
• Always use a new gasket.
1. Install:
• pilot screw kit 1
Pilot screw setting
2-1/2 turns out
2. Install:
• piston valve 1
• jet needle
• jet needle holder
• piston valve spring
• vacuum chamber cover
NOTE:
• Install the end of the piston valve
spring onto the spring guide on the
vacuum chamber cover.
• Align the tab a on the piston valve
diaphragm with the recess b in the
carburetor body.
6-8
CARBURETORS
CARB
3. Install:
• pipes
• fuel feed pipes
• vacuum chamber pipe
• vacuum chamber air vent hose
• springs
• float chamber air vent hoses
• hose joints
• spacers
• copper washer
• connecting bolts
NOTE:
• Do not tighten the connecting bolts,
yet.
• Install the throttle valve lever 1 onto
carburetors #1, #2, and #4 between the
spring 2 and synchronizing screw 3.
4. Install:
• starter plunger link 1
NOTE:
Install the starter plunger link 1 onto
each starter plunger.
T.
R.
5. Tighten:
• connecting bolts
7 Nm (0.7 m · kg)
NOTE:
• Place the carburetor assembly on a
surface plate with the intake manifold
side down. Then, tighten the connecting bolts while pushing down the carburetor assembly with an even force.
• After tightening the connecting bolts,
check that the throttle valve lever and
starter plunger link operate smoothly.
6. Install:
• starter cable 1
NOTE:
Install the starter cable holder 2 onto
the starter cable.
6-9
CARBURETORS
CARB
EB600051
INSTALLING THE CARBURETORS
1. Adjust:
• carburetor synchronization
Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3.
2. Adjust:
• engine idling speed
Engine idling speed
1,050 ~ 1,150 r/min
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.
3. Adjust:
• throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
6 - 10
CARBURETORS
CARB
EB600063
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel level a
Out of specification → Adjust.
Fuel level (below the line on
the float chamber)
4.1 ~ 5.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable
stand to ensure that the motorcycle is
standing straight up.
c. Install the fuel level gauge 1 onto the
fuel drain pipe 2.
Fuel level gauge
90890-01312
d. Loosen the fuel drain bolt 3.
e. Hold the fuel level gauge vertically
next to the line 4 on the float chamber.
f. Measure the fuel level a.
NOTE:
Fuel level readings should be equal on
both sides of the carburetor assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor assembly.
b. Check the needle valve seat and needle valve.
c. If either is worn, replace them as a
set.
d. If both are fine, adjust the float level
by slightly bending the float tang 1.
e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel
level is within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 11
CARBURETORS
CARB
EB600072
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position
sensor, the engine idling speed should
be properly adjusted.
1. Check:
• throttle position sensor
(installed on the carburetor)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler.
b. Connect the pocket tester (Ω × 1k) to
the throttle position sensor.
Tester positive probe → blue 1
Tester negative probe → black/blue 2
c. Measure the throttle position sensor
maximum resistance.
Out of specification → Replace the
throttle position sensor.
Throttle position sensor maximum resistance
4.0 ~ 6.0 kΩ at 20 ˚C
(blue — black/blue)
d. Connect the pocket tester (Ω × 1k) to
the throttle position sensor.
Tester positive probe → yellow 3
Tester negative probe → black/blue 2
e. While slowly opening the throttle,
check that the throttle position sensor
resistance is within the specified
range.
NOTE:
Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.
Out of specification or the resistance
changes abruptly → Go to step (2).
Throttle position sensor resistance
0 ~ 5 ± 1.0 kΩ at 20 ˚C
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 12
CARBURETORS
CARB
2. Check:
• throttle position sensor
(removed from the carburetor)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor
from the carburetor.
c. Connect the pocket tester (Ω × 1k) to
the throttle position sensor.
Tester positive probe → blue 1
Tester negative probe → black/blue 2
d. Measure the throttle position sensor
maximum resistance.
Out of specification → Replace the
throttle position sensor.
Throttle position sensor maximum resistance
4.0 ~ 6.0 kΩ at 20 ˚C
(blue — black/blue)
e. Connect the pocket tester (Ω × 1k) to
the throttle position sensor coupler.
Tester positive probe → yellow 3
Tester negative probe → black/blue 2
f. While slowly opening the throttle,
check that the throttle position sensor
resistance is within the specified
range.
The resistance does not change or it
changes abruptly → Replace the throttle
position sensor.
The slot is worn or broken → Replace
the throttle position sensor.
NOTE:
Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.
Throttle position sensor resistance
0 ~ 5 ± 1.0 kΩ at 20 ˚C
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 13
CARBURETORS
CARB
3. Adjust:
• throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. Disconnect the throttle position sensor coupler.
c. Reconnect the throttle position sensor coupler.
NOTE:
After reconnecting the throttle position
sensor coupler, the tachometer switches
to the throttle position sensor adjustment mode.
d. Loosen the throttle position sensor
screws 1.
e. Adjust the throttle position sensor
angle according to the following
table.
NOTE:
The angle of the throttle position sensor
is indicated by the r/min which are displayed on the tachometer.
Tachometer reading
Throttle position
sensor angle
0 r/min
Too small
5,000 r/min 2
Correct
10,000 r/min
Too large
f. After adjusting the throttle position
sensor angle, tighten the throttle
position sensor screws.
NOTE:
To exit the throttle position sensor
adjustment mode, start the engine or set
the main switch to “OFF”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 14
CARBURETORS
CARB
EB600090
CHECKING THE FUEL PUMP
1. Check:
• fuel pump 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel tank.
Refer to “FUEL TANK” in chapter 3.
b. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor.
c. Connect the fuel-tank-to-fuel-pump
fuel hose to the fuel tank and then set
the fuel cock to “ON”.
d. Place a container under the end of the
fuel hose 2.
e. Start the engine and check if fuel
flows from the fuel hose 2.
Fuel flows.
Fuel pump is OK.
Fuel does not
flow.
Replace the fuel
pump.
f. Stop the engine and check if the fuel
stops flowing from the fuel hose 2.
Fuel stops flowing.
Fuel pump is OK.
Fuel flows.
Replace the fuel
pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 15
CARB
6 - 16
CHAS
7
CHAS
CHAPTER 7.
CHASSIS
FRONT WHEEL AND BRAKE DISCS ............................................................7-1
REMOVING THE FRONT WHEEL .........................................................7-3
DISASSEMBLING THE FRONT WHEEL ..............................................7-3
CHECKING THE FRONT WHEEL ..........................................................7-4
CHECKING THE BRAKE DISCS ............................................................7-5
ASSEMBLING THE FRONT WHEEL ....................................................7-6
INSTALLING THE FRONT WHEEL .......................................................7-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE .......................7-7
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET ................7-10
REMOVING THE REAR WHEEL .........................................................7-13
CHECKING THE REAR WHEEL ..........................................................7-13
CHECKING THE REAR WHEEL DRIVE HUB ......................................7-14
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ........7-14
INSTALLING THE REAR WHEEL .......................................................7-15
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................7-15
FRONT AND REAR BRAKES ......................................................................7-16
REPLACING THE FRONT BRAKE PADS ............................................7-18
REPLACING THE REAR BRAKE PADS ..............................................7-20
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ..........7-28
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER .............7-28
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS .....................................................................7-28
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER .......................................................................7-29
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ...................7-31
DISASSEMBLING THE FRONT BRAKE CALIPERS ...........................7-37
DISASSEMBLING THE REAR BRAKE CALIPER ................................7-38
CHECKING THE FRONT AND REAR BRAKE CALIPERS ...................7-39
ASSEMBLING AND INSTALLING
THE FRONT BRAKE CALIPERS ......................................................7-40
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER ......7-42
FRONT FORK ..............................................................................................7-44
REMOVING THE FRONT FORK LEGS ...............................................7-47
DISASSEMBLING THE FRONT FORK LEGS .....................................7-47
CHECKING THE FRONT FORK LEGS ................................................7-49
ASSEMBLING THE FRONT FORK LEGS ...........................................7-50
INSTALLING THE FRONT FORK LEGS .............................................7-55
CHAS
HANDLEBARS .............................................................................................7-56
REMOVING THE HANDLEBARS ........................................................7-58
CHECKING THE HANDLEBARS .........................................................7-58
INSTALLING THE HANDLEBARS ......................................................7-59
STEERING HEAD ........................................................................................7-61
REMOVING THE LOWER BRACKET ..................................................7-63
CHECKING THE STEERING HEAD .....................................................7-63
INSTALLING THE STEERING HEAD ..................................................7-64
REAR SHOCK ABSORBER ASSEMBLY .....................................................7-66
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER ......................................................................7-67
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER ......................................................................7-67
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ................7-68
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
AND GAS CYLINDER ......................................................................7-68
CHECKING THE RELAY ARM AND CONNECTING ARM .................7-69
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..............7-69
SWINGARM AND DRIVE CHAIN ...............................................................7-70
REMOVING THE SWINGARM ...........................................................7-72
REMOVING THE DRIVE CHAIN .........................................................7-73
CHECKING THE SWINGARM .............................................................7-73
CHECKING THE DRIVE CHAIN ...........................................................7-74
INSTALLING THE SWINGARM ..........................................................7-76
6
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700002
CHASSIS
FRONT WHEEL AND BRAKE DISCS
Order
Job/Part
Q’ty
Remarks
Removing the front wheel and brake
Remove the parts in the order listed.
discs
NOTE:
Place the motorcycle on a suitable
stand so that the front wheel is elevated.
1
2
3
4
5
6
7
8
Brake hose holder (left and right)
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collar (left and right)
Oil seal cover (left and right)
Brake disc (left and right)
2
2
1
1
1
2
2
2
Loosen.
For installation, reverse the removal
procedure.
7-1
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700010
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
Q’ty
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
7-2
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700102
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
2. Remove:
• left brake caliper
• right brake caliper
NOTE:
Do not squeeze the brake lever when
removing the brake calipers.
3. Elevate:
• front wheel
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
EB700110
DISASSEMBLING THE FRONT WHEEL
1. Remove:
• oil seals
• wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel
hub.
b. Remove the oil seals 1 with a flathead screwdriver.
NOTE:
To prevent damaging the wheel, place a
rag 2 between the screwdriver and the
wheel surface.
c. Remove the wheel bearings with a
general bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-3
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700400
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
wheel axle.
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Max. radial wheel runout
1.0 mm
Max. lateral wheel runout
0.5 mm
4. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
5. Replace:
• wheel bearings
• oil seals New
New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel
hub.
b. Remove the oil seals 1 with a flathead screwdriver.
NOTE:
To prevent damaging the wheel, place a
rag 2 between the screwdriver and the
wheel surface.
7-4
FRONT WHEEL AND BRAKE DISCS
CHAS
c. Remove the wheel bearings 3 with a
general bearing puller.
d. Install the new wheel bearings and oil
seals in the reverse order of disassembly.
CAUTION:
ACHTUNG:
Do not contact the wheel bearing center
race 4 or balls 5. Contact should be
made only with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of the wheel bearing outer race and
oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB700416
CHECKING THE BRAKE DISCS
The following procedure applies to both of
the brake discs.
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the
brake disc deflection or replace the
brake disc.
Max. brake disc deflection
Front: 0.1 mm
Rear: 0.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable
stand so that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the
left or right to ensure that the front
wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 2 ~ 3 mm
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-5
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specification → Replace.
Min. brake disc thickness
Front: 4.5 mm
Rear: 4.5 mm
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt
hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages
and in a crisscross pattern.
T.
R.
Brake disc bolt
18 Nm (1.8 m • kg)
LOCTITE
d. Measure the brake disc deflection.
e. If out of specification, repeat the
adjustment steps until the brake disc
deflection is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace
the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB700711
ASSEMBLING THE FRONT WHEEL
1. Install:
• wheel bearings
• oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil
seals in the reverse order of disassembly.
CAUTION:
ACHTUNG:
Do not contact the wheel bearing center
race 1 or balls 2. Contact should be
made only with the outer race 3.
NOTE:
Use a socket 4 that matches the diameter of the wheel bearing outer race and
oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-6
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700725
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium soap base grease
18 Nm (1.8 m · kg)
T.
R.
2. Install:
• brake discs
NOTE:
• Apply LOCTITE 648 to the threads of
the brake disc bolts.
• Tighten the brake disc bolts in stages
and in a crisscross pattern.
T.
3. Tighten:
72 Nm (7.2 m · kg)
• wheel axle 1
• wheel axle pinch bolt 2
R.
T.
R.
23 Nm (2.3 m · kg)
CAUTION:
ACHTUNG:
Before tightening the wheel axle nut,
push down hard on the handlebars several times and check if the front fork
rebounds smoothly.
T.
R.
4. Install:
• brake calipers
40 Nm (4.0 m · kg)
WARNING
WARNING
Make sure that the brake hose is routed
properly.
EB700901
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the front wheel static balance should
be adjusted.
• Adjust the front wheel static balance
with the brake discs installed.
7-7
FRONT WHEEL AND BRAKE DISCS
CHAS
1. Remove:
• balancing weight(-s)
2. Find:
• front wheel’s heavy spot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the front wheel on a suitable
balancing stand.
b. Spin the front wheel.
c. When the front wheel stops, put an
“X1” mark at the bottom of the wheel.
d. Turn the front wheel 90˚ so that the
“X1” mark is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an
“X2” mark at the bottom of the wheel.
g. Repeat steps (a) through (d) several
times until all the marks come to rest
at the same spot.
h. The spot where all the marks come to
rest is the front wheel’s heavy spot
“X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the
rim exactly opposite the heavy spot
“X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90˚ so that the
heavy spot is positioned as shown.
c. If the heavy spot does not stay in that
position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
FRONT WHEEL AND BRAKE DISCS
CHAS
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure
that it stays at each position shown.
b. If the front wheel does not remain
stationary at all of the positions,
rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EB701000
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the rear wheel
Q’ty
Brake caliper
Locknut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Washer
Rear wheel axle
Left adjusting block
Right adjusting block
Rear wheel
Brake caliper bracket
1
2
2
2
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable
stand so that the rear wheel is elevated.
Loosen.
Loosen.
NOTE:
Make sure that the tapered side of the
right adjusting block faces the wheel.
For installation, reverse the removal
procedure.
7 - 10
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EB701010
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the brake disc and rear
wheel sprocket
Brake disc
Rear wheel sprocket
Oil seal cover (left and right)
Spacer (left and right)
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Rear wheel
Q’ty
Remarks
Remove the parts in the order listed.
1
1
2
2
1
1
1
6
1
For installation, reverse the removal
procedure.
7 - 11
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear wheel
Spacer
Bearing
Spacer
Oil seal
Circlip
Bearing
Q’ty
CHAS
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7 - 12
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EB701100
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
2. Remove:
• brake caliper
NOTE:
Do not depress the brake pedal when
removing the brake caliper.
3. Remove:
• wheel axle nut
• washer
• wheel axle
• adjusting blocks
• rear wheel
NOTE:
Push the rear wheel forward and
remove the drive chain from the rear
wheel sprocket.
EB701400
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
• brake disc
Refer to “FRONT WHEEL”.
2. Check:
• tire
• rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7 - 13
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
3. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL”.
Over the specified limits → Replace.
Max. radial wheel runout
1.0 mm
Max. lateral wheel runout
0.5 mm
EB701430
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
Cracks/damage → Replace.
• rear wheel drive hub dampers 2
Damage/wear → Replace.
EB701440
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1/4 tooth a wear → Replace
the rear wheel sprocket.
Bent teeth → Replace the rear wheel
sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
• rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the
rear wheel sprocket.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces
that contact the sprocket.
c. Install the new rear wheel sprocket.
T.
R.
Rear wheel sprocket self-locking nut
150 Nm (15.0 m • kg)
NOTE:
Tighten the self-locking nuts in stages
and in a crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 14
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EB701710
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
Recommended lubricant
Lithium soap base grease
2. Adjust:
• drive chain slack a
Drive chain slack
40 ~ 50 mm
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
T.
R.
3. Tighten:
• wheel axle nut
• brake caliper bolts
150 Nm (15.0 m · kg)
T.
R.
40 Nm (4.0 m · kg)
WARNING
WARNING
Make sure that the brake hose is routed
properly.
EB701900
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the rear wheel static balance should be
adjusted.
• Adjust the rear wheel static balance
with the brake disc and rear wheel
drive hub installed.
1. Adjust:
• rear wheel static balance
Refer to “FRONT WHEEL”.
7 - 15
FRONT AND REAR BRAKES
CHAS
EB702001
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Q’ty
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim
Bleed screw
Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
2
1
1
2
2
1
For installation, reverse the removal
procedure.
7 - 16
FRONT AND REAR BRAKES
CHAS
EB702002
Order
1
2
3
4
5
6
Job/Part
Removing the rear brake pads
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
4
2
1
2
2
2
For installation, reverse the removal
procedure.
7 - 17
FRONT AND REAR BRAKES
CHAS
EB702100
CAUTION:
ACHTUNG:
Disc brake components rarely require
disassembly.
Therefore, always follow these preventive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic
brake system is disconnected, the
entire brake system must be disassembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the
eyes:
• Flush with water for 15 minutes and
get immediate medical attention.
EB702112
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake hose holder bolt 1
• brake caliper 2
7 - 18
FRONT AND REAR BRAKES
CHAS
2. Remove:
• brake pad clips 1
• brake pad pin 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
3. Measure:
• brake pad wear limit a
Out of specification → Replace the
brake pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
T.
Bleed screw
6 Nm (0.6 m • kg)
R.
d. Install a new brake pad shim onto
each new brake pads.
e. Install new brake pads and a new
brake pad spring.
NOTE:
The arrow a on the brake pad spring
must point in the direction of disc rotation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 19
FRONT AND REAR BRAKES
T.
R.
5. Install:
• brake pad pin
• brake pad clips
• brake caliper
CHAS
40 Nm (4.0 m · kg)
6. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EB702113
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake caliper 1
• brake pad cover
2. Remove:
• brake pad clips 1
• brake pad pins 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
7 - 20
FRONT AND REAR BRAKES
CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the
brake pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
T.
Bleed screw
6 Nm (0.6 m • kg)
R.
d. Install a new brake pad shim onto
each new brake pad.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 21
FRONT AND REAR BRAKES
T.
R.
5. Install:
• brake pad pins
• brake pad clips
• brake pad cover
• brake caliper
CHAS
40 Nm (4.0 m · kg)
6. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 22
FRONT AND REAR BRAKES
CHAS
EB702200
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the front brake master
cylinder and brake fluid reservoir
Brake fluid
Brake fluid reservoir cap stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm
holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Circlip
Hose joint
Brake lever
Front brake switch connector
Union bolt
Copper washer
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
1
1
1
1
2
1
3
7 - 23
Disconnect.
FRONT AND REAR BRAKES
Order
13
14
15
16
Job/Part
Brake hose
Brake master cylinder holder
Brake master cylinder
Front brake switch
Q’ty
2
1
1
1
CHAS
Remarks
For installation, reverse the removal
procedure.
7 - 24
FRONT AND REAR BRAKES
CHAS
EB702201
Order
1
2
3
4
Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
7 - 25
FRONT AND REAR BRAKES
CHAS
EB702202
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder and brake fluid reservoir
Brake fluid
Drain.
Brake fluid reservoir cap stopper
1
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm
1
holder
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Hose joint
1
Union bolt
1
Copper washer
2
Brake hose
1
Brake master cylinder
1
For installation, reverse the removal
procedure.
7 - 26
FRONT AND REAR BRAKES
CHAS
EB702203
Order
1
2
Job/Part
Disassembling the rear brake master cylinder
Brake master cylinder kit
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
1
1
For assembly, reverse the disassembly
procedure.
7 - 27
FRONT AND REAR BRAKES
CHAS
EB702210
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake
master cylinder, drain the brake fluid
from the entire brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hoses 3
NOTE:
To collect any remaining brake fluid,
place a container under the master cylinder and the end of the brake hose.
EB702220
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
To collect any remaining brake fluid,
place a container under the master cylinder and the end of the brake hose.
EB702243
Å
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of
the brake master cylinders.
1. Check:
• brake master cylinder
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
ı
Å Front
ı Rear
7 - 28
FRONT AND REAR BRAKES
CHAS
2. Check:
• brake master cylinder kit
Damage/scratches/wear → Replace.
Å
Å Front
ı Rear
ı
Å
3. Check:
• brake fluid reservoir 1
Cracks/damage → Replace.
• brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
ı
4. Check:
• brake hoses
Cracks/damage/wear → Replace.
EB702283
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
WARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
7 - 29
FRONT AND REAR BRAKES
CHAS
1. Install:
• brake master cylinder 1
T.
R.
13 Nm (1.3 m · kg)
NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the brake master cylinder holder with the punch mark a in
the right handlebar.
• First, tighten the upper bolt, then the
lower bolt.
New
T.
R.
2. Install:
• copper washers
• brake hose
• union bolt
30 Nm (3.0 m · kg)
WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
NOTE:
• While holding the brake hose, tighten
the union bolt as shown.
• Turn the handlebars to the left and to
the right to make sure that the brake
hose does not touch other parts (e.g.,
wire harness, cables, leads). Correct if
necessary.
3. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reservoir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
7 - 30
FRONT AND REAR BRAKES
CHAS
CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EB702290
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
New
T.
R.
1. Install:
• copper washers
• brake hoses
• union bolt
30 Nm (3.0 m · kg)
WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake master cylinder, make sure that
the brake pipe touches the projection a
as shown.
7 - 31
FRONT AND REAR BRAKES
CHAS
2. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.
CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
5. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.
Brake pedal position (from the
top of the brake pedal to the
bottom of the rider footrest
bracket)
35 ~ 40 mm
6. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH” in chapter 3.
7 - 32
FRONT AND REAR BRAKES
CHAS
EB702301
Order
1
2
3
4
Job/Part
Removing the front brake calipers
Q’ty
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
7 - 33
FRONT AND REAR BRAKES
CHAS
EB702303
Order
Job/Part
Disassembling the front brake calipers
Q’ty
Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
1
2
3
4
5
6
7
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
2
1
1
2
4
8
1
For assembly, reverse the disassembly
procedure.
7 - 34
FRONT AND REAR BRAKES
CHAS
EB702304
Order
1
2
3
4
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
7 - 35
FRONT AND REAR BRAKES
CHAS
EB702305
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Disassembling the rear brake caliper
Remove the parts in the order listed.
Brake pad clip
4
Brake pad pin
2
Brake pad spring
1
Brake pad
2
Brake caliper piston
2
Brake caliper piston seal
4
Bleed screw
2
For assembly, reverse the disassembly
procedure.
7 - 36
FRONT AND REAR BRAKES
CHAS
EB702317
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of
the brake calipers.
NOTE:
Before disassembling either brake caliper, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a container and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper
pistons with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side pistons from the brake caliper.
WARNING
WARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side pistons from the brake
caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 37
FRONT AND REAR BRAKES
CHAS
EB702322
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a container and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper
piston with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side piston from the brake caliper.
WARNING
WARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolt 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side piston from the brake
caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 38
FRONT AND REAR BRAKES
CHAS
EB702343
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every two years
Brake fluid
Every two years
and whenever the
brake is disassembled
1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the
brake caliper.
• brake caliper cylinders 2
Scratches/wear → Replace the brake
caliper.
• brake calipers
Cracks/damage → Replace.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
Å
WARNING
WARNING
Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Å Front
ı Rear
ı
2. Check:
• rear brake caliper bracket 1
Cracks/damage → Replace.
7 - 39
FRONT AND REAR BRAKES
CHAS
EB702376
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of
the brake calipers.
WARNING
WARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components as they will cause the piston seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
New
T.
R.
1. Install:
• brake caliper 1
(temporarily)
• copper washers
• brake hose 2
• union bolt 3
30 Nm (3.0 m · kg)
WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake caliper 1, make sure that the
brake pipe a touches the projection b
on the brake caliper.
2. Remove:
• brake caliper
T.
3. Install:
• brake pads
• brake pad spring
40 Nm (4.0 m · kg)
• brake caliper
• brake hose holder
7 Nm (0.7 m · kg)
Refer to “REPLACING THE FRONT
BRAKE PADS”.
R.
T.
R.
7 - 40
FRONT AND REAR BRAKES
CHAS
4. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reservoir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 41
FRONT AND REAR BRAKES
CHAS
EB702378
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNING
WARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components as they will cause the piston seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
New
T.
R.
1. Install:
• brake caliper 1
(temporarily)
• copper washers
• brake hose 2
• union bolt 3
30 Nm (3.0 m · kg)
WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake caliper 1, make sure that the
brake pipe a touches the projection b
on the brake caliper.
2. Remove:
• brake caliper
T.
3. Install:
• brake pads
• brake pad springs
• brake caliper
40 Nm (4.0 m · kg)
7 Nm (7.0 m · kg)
• brake hose holder
Refer to “REPLACING THE REAR
BRAKE PADS”.
R.
T.
R.
7 - 42
FRONT AND REAR BRAKES
CHAS
4. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reservoir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
• brake fluid level
Below the minimum level mark a →
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 43
FRONT FORK
CHAS
EB703001
FRONT FORK
Order
Job/Part
Removing the front fork legs
Q’ty
Front wheel
1
2
3
4
5
6
Front cowling inner panels
Front fender
Upper bracket pinch bolt
Cap bolt
Handlebar pinch bolt
Lower bracket pinch bolt
Front fork leg
Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “COWLINGS” in chapter 3.
1
1
1
1
2
1
For installation, reverse the removal
procedure.
7 - 44
FRONT FORK
CHAS
EB703002
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the front fork legs
Q’ty
Cap bolt
O-ring
Spacer
Nut
Spring seat
Fork spring
Damper adjusting rod
Outer tube
Dust seal
Oil seal clip
Oil seal
Washer
1
1
1
1
1
1
1
1
1
1
1
1
7 - 45
Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
FRONT FORK
Order
C
D
E
F
Job/Part
Damper rod assembly bolt
Copper washer
Damper rod assembly
Inner tube
Q’ty
1
1
1
1
CHAS
Remarks
For assembly, reverse the disassembly
procedure.
7 - 46
FRONT FORK
CHAS
EB703100
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
2. Loosen:
• upper bracket pinch bolt 1
• cap bolt 2
• handlebar boss pinch bolt 3
• lower bracket pinch bolts
WARNING
WARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
3. Remove:
• front fork leg
EB703113
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Remove:
• cap bolt 1
(from the damper adjusting rod)
• spacer 2
• nut 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Press down on the spacer with the
fork spring compressor 4.
b. Install the rod holder 5 between the
nut 3 and the spacer 2.
Fork spring compressor
90890-01441
Rod holder
90890-01434
7 - 47
FRONT FORK
CHAS
NOTE:
Use the side of the rod holder that is
marked “B”.
c. Loosen the nut.
d. Remove the cap bolt.
e. Remove the rod holder and fork
spring compressor
WARNING
WARNING
The fork spring is compressed.
f. Remove the spacer and nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Drain:
• fork oil
NOTE:
Stroke the damper rod 1 several times
while draining the fork oil.
3. Remove:
• dust seal
• oil seal clip 1
• oil seal
• washer
(with a flat-head screwdriver)
4. Remove:
• damper rod assembly bolt
• copper washer
NOTE:
While holding the damper rod with the
damper rod holder 1, loosen the
damper rod assembly bolt.
Damper rod holder
90890-01423
7 - 48
FRONT FORK
CHAS
EB703401
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
inner tube as this may dangerously
weaken it.
2. Measure:
• spring free length a
Out of specification → Replace.
Spring free length limit
255 mm
3. Check:
• damper rod 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil
passages with compressed air.
CAUTION:
ACHTUNG:
• The front fork leg has a built-in
damper adjusting rod and a very
sophisticated internal construction,
which are particularly sensitive to foreign material.
• When disassembling and assembling
the front fork leg, do not allow any foreign material to enter the front fork.
7 - 49
FRONT FORK
CHAS
4. Check:
• cap bolt O-ring
Damage/wear → Replace.
EB703702
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNING
WARNING
• Make sure that the oil levels in both
front fork legs are equal.
• Uneven oil levels can result in poor
handling and a loss of stability.
NOTE:
• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg,
make sure that all of the components
are clean.
1. Install:
• damper rod assembly 1
WARNING
WARNING
Always use new copper washers.
CAUTION:
ACHTUNG:
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it
protrudes from the bottom of the inner
tube. Be careful not to damage the inner
tube.
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil
01 or equivalent
7 - 50
FRONT FORK
CHAS
3. Tighten:
• damper rod assembly bolt 1
T.
R.
40 Nm (4.0 m · kg)
NOTE:
While holding the damper rod with the
damper rod holder 2, tighten the
damper rod assembly bolt.
Damper rod holder
90890-01423
4. Install:
• dust seal 1
• oil seal clip 2
• oil seal 3
• washer 4
CAUTION:
ACHTUNG:
Make sure that the numbered side of
the oil seal faces up.
NOTE:
• Before installing the oil seal, lubricate
its lips with lithium soap base grease.
• Lubricate the outer surface of the inner
tube with fork oil.
• Before installing the oil seal, cover the
top of the front fork leg with a plastic
bag 5 to protect the oil seal during
installation.
5. Install:
• outer tube
(onto the inner tube)
6. Install:
• washer
• oil seal 1
(with the fork seal driver 2)
Fork seal driver
90890-01442
7. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into
the outer tube’s groove.
7 - 51
FRONT FORK
CHAS
8. Install:
• dust seal 1
(with the fork seal driver 2)
9. Install:
• rod puller 1
• adapter 2
(onto the damper rod 3)
Rod puller
90890-01437
Adapter
90890-01436
10.Fully compress the front fork leg.
11.Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
477 cm3
Recommended oil
Yamaha fork and shock oil
01 or equivalent
CAUTION:
ACHTUNG:
• Be sure to use the recommended fork
oil. Other oils may have an adverse
effect on front fork performance.
• When disassembling and assembling
the front fork leg, do not allow any foreign material to enter the front fork.
12.After filling the front fork leg, slowly
stroke the damper rod 1 up and down
(at least ten times) to distribute the fork
oil.
NOTE:
Be sure to stroke the damper rod slowly
because the fork oil may spurt out.
7 - 52
FRONT FORK
CHAS
13.Slowly stroke the outer tube 1 up and
down to distribute the fork oil once
more (1 stroke = about 100 mm).
NOTE:
Be careful not to stroke the inner tube
over 100 mm as this will cause air to
enter. If the inner tube is stroked more
than 100 mm, repeat steps (12) and (13).
14.Before measuring the fork oil level, wait
ten minutes until the oil has settled and
the air bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any
residual air.
15.Measure:
• front fork leg oil level a
Out of specification → Correct.
Front fork leg oil level (from
the top of the inner tube, with
the inner tube fully compressed, and without the
spring)
78 mm
16.Install:
• nut 1
• fork spring 2
• spring seat 3
• spacer 4
• damper adjusting rod 5
• cap bolt 6
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rod puller and adapter.
b. Install the nut.
7 - 53
FRONT FORK
CHAS
c. Install the rod puller and adapter onto
the damper rod.
Rod puller
90890-01437
Adapter
90890-01436
d. Install the fork spring, spring seat,
and spacer.
NOTE:
Install the spring with the smaller
pitch a facing up Å.
e. Press down on the spacer with the
fork spring compressor 7.
f. Pull up the rod puller and install the
rod holder 8 between the nut 1 and
the spacer 4.
NOTE:
Use the side of the rod holder that is
marked “B”.
Fork spring compressor
90890-01441
Rod holder
90890-01434
g. Remove the rod puller and adapter.
h. Install the nut 1 and position it as
specified b.
Distance b
11 mm
i. Install the damper adjusting rod and
cap bolt, and then finger tighten the
cap bolt.
j. Hold the cap bolt and tighten the nut
to specification.
T.
Nut
15 Nm (1.5 m • kg)
R.
k. Remove the rod holder and fork
spring compressor.
WARNING
WARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 54
FRONT FORK
CHAS
17.Install:
• outer tube
(onto the inner tube)
NOTE:
Temporarily tighten the cap bolt.
EB703710
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Install:
• front fork leg
Temporarily tighten the upper and
lower bracket pinch bolts.
NOTE:
Make sure that the inner fork tube is
flush with the top of the handlebar
holder.
2. Tighten:
• lower bracket pinch bolt
T.
R.
23 Nm (2.3 m · kg)
• handlebar pinch bolt 1
T.
R.
17 Nm (1.7 m · kg)
T.
• cap bolt 2
23 Nm (2.3 m · kg)
• upper bracket pinch bolt 3
R.
T.
R.
23 Nm (2.3 m · kg)
WARNING
WARNING
Make sure that the brake hoses are
routed properly.
3. Adjust:
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE FRONT
FORK LEGS” in chapter 3.
7 - 55
HANDLEBARS
CHAS
EB704001
HANDLEBARS
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the handlebars
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Starter cable
Starter lever
Clutch cable
Clutch lever
Right grip end
Throttle cable housing
Throttle cable
Throttle grip
Q’ty
1
1
2
1
1
1
1
1
1
1
2
1
7 - 56
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
HANDLEBARS
Order
13
14
15
16
17
18
19
20
21
22
23
Job/Part
Front brake switch connector
Right handlebar switch
Brake master cylinder holder
Brake master cylinder
Handlebar pinch bolt
Upper bracket bolt
Upper bracket pinch bolt
Steering stem nut
Upper bracket
Left handlebar
Right handlebar
CHAS
Q’ty
Remarks
2
Disconnect.
1
1
1
2
2
2
1
1
1
1
For installation, reverse the removal
procedure.
7 - 57
HANDLEBARS
CHAS
EB704101
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the left
handlebar and the handlebar grip, and
gradually push the grip off the handlebar.
3. Remove:
• throttle cable housing 1
• throttle grip 2
NOTE:
Pull back the rubber cover 3 when
removing the throttle cable housing.
EB704401
CHECKING THE HANDLEBARS
1. Check:
• left handlebar
• right handlebar
Bends/cracks/damage → Replace.
WARNING
WARNING
Do not attempt to straighten bent handlebars as this may dangerously
weaken them.
7 - 58
HANDLEBARS
CHAS
EB704704
INSTALLING THE HANDLEBARS
1. Install:
• right handlebar switch 1
NOTE:
Align the projection a on the right handlebar switch with the hole b in the
right handlebar.
2. Install:
• brake master cylinder holder 1
CAUTION:
ACHTUNG:
• Install the brake master cylinder
holder with the “UP” mark facing up.
• First, tighten the upper bolt, then the
lower bolt.
NOTE:
• Align the mating surfaces of the brake
master cylinder holder with the punch
mark a in the right handlebar.
• There should be 2 mm of clearance
between the right handlebar switch
and the brake master cylinder holder.
3. Install:
• throttle grip 1
• throttle cable housing 2
• throttle cables
NOTE:
Align the projection a on the throttle
cable housing with the hole b in the
right handlebar.
4. Install:
• clutch lever holder 1
NOTE:
Align the slit in the clutch lever holder
with the punch mark a in the left handlebar.
7 - 59
HANDLEBARS
CHAS
5. Install:
• left handlebar switch 1
NOTE:
Align the projection a on the left handlebar switch with the hole b in the left
handlebar.
6. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive
onto the end of the left handlebar.
b. Slide the handlebar grip over the end
of the left handlebar.
c. Wipe off any excess rubber adhesive
with a clean rag.
WARNING
WARNING
Do not touch the handlebar grip until
the rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play (at the
end of the clutch lever)
10 ~ 15 mm
8. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
7 - 60
STEERING HEAD
CHAS
EB705001
STEERING HEAD
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the lower bracket
Front wheel
Q’ty
Front fork legs
Main switch coupler
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Upper bracket
Lower bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut
Rubber washer
2
2
1
1
1
1
1
2
1
1
1
7 - 61
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT FORK”.
Disconnect.
STEERING HEAD
Order
12
13
14
15
16
17
18
19
Job/Part
Lower ring nut
Lower bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race
Q’ty
1
1
1
2
1
1
1
2
CHAS
Remarks
For installation, reverse the removal
procedure.
7 - 62
STEERING HEAD
CHAS
EB705100
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• lower ring nut 1
(with the special tool 2)
Ring nut wrench
90890-01403
WARNING
WARNING
Securely support the lower bracket so
that there is no danger of it falling.
EB705401
CHECKING THE STEERING HEAD
1. Wash:
• bearing balls
• bearing races
Recommended cleaning solvent
Kerosine
2. Check:
• bearing balls 1
• bearing races 2
Damage/pitting → Replace.
3. Replace:
• bearing balls
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the
steering head pipe with a long rod 1
and hammer.
7 - 63
STEERING HEAD
CHAS
b. Remove the bearing race from the
lower bracket with a floor chisel 2
and hammer.
c. Install a new dust seal and new bearing races.
CAUTION:
ACHTUNG:
If the bearing race is not installed properly, the steering head pipe could be
damaged.
NOTE:
• Always replace the bearing balls and
bearing races as a set.
• Whenever the steering head is disassembled, replace the dust seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EB705700
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium soap base grease
2. Install:
• lower ring nut 1
• rubber washer 2
• upper ring nut 3
• lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
7 - 64
CHAS
STEERING HEAD
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem
nut.
4. Install:
• front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts, and handlebar pinch
bolts.
5. Tighten:
• steering stem nut
T.
R.
115 Nm (11.5 m · kg)
• lower bracket pinch bolt
T.
R.
23 Nm (2.3 m · kg)
• upper bracket pinch bolt
T.
R.
23 Nm (2.3 m · kg)
• upper bracket bolt
T.
R.
13 Nm (1.3 m · kg)
• handlebar pinch bolt
T.
R.
7 - 65
17 Nm (1.7 m · kg)
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the rear shock absorber
assembly
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt/spacer
Rear shock absorber assembly
Spacer/oil seal/bearing
Self-locking nut/bolt
Relay arm
Spacer/oil seal/bearing
Self-locking nut/bolt/spacer
Connecting arm
Spacer/oil seal/bearing
Q’ty
Remarks
Remove the parts in the order listed.
1/1
1/1
1/1/1
1
1/2/1
1/1
1
1/2/2
1/1/1
1
2/4/2
Bolt R= 54 mm
Bolt R = 80 mm
Bolt R = 65 mm
Bolt R = 54 mm
Bolt R = 65 mm
For installation, reverse the removal
procedure.
7 - 66
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EB706101
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
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.
EB706111
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
WARNING
Wear eye protection to prevent eye
damage from released gas or metal
chips.
7 - 67
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EB706204
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
2. Remove:
• rear shock absorber assembly lower
bolt 1
• relay-arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber
assembly lower bolt, hold the swingarm
so that it does not drop down.
3. Remove:
• rear shock absorber assembly upper
bolt 1
• rear shock absorber assembly
NOTE:
Raise the swingarm and then remove
the rear shock absorber assembly from
between the swingarm.
EB706401
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear
shock absorber assembly.
• rear shock absorber
Gas leaks/oil leaks → Replace the rear
shock absorber assembly.
• spring
Damage/wear → Replace the rear
shock absorber assembly.
• gas cylinder
Damage/gas leaks → Replace.
• bushings
Damage/wear → Replace.
• dust seals
Damage/wear → Replace.
• bolts
Bends/damage/wear → Replace.
7 - 68
REAR SHOCK ABSORBER ASSEMBLY
CHAS
CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
Damage/wear → Replace.
• bearings
• oil seals
Damage/pitting → Replace.
• spacers
Damage/scratches → Replace.
EB706701
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
• bearings
• oil seals
• spacers
Recommended lubricant
Lithium soap base grease
2. Install:
• connecting arm
• relay arm
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
3. Tighten:
• connecting-arm-to-frame nut
T.
R.
40 Nm (4.0 m · kg)
• relay-arm-to-connecting-arm nut
T.
R.
40 Nm (4.0 m · kg)
• relay-arm-to-swingarm nut
T.
R.
40 Nm (4.0 m · kg)
• rear shock absorber assembly upper nut
T.
R.
40 Nm (4.0 m · kg)
• rear shock absorber assembly lower nut
T.
R.
7 - 69
40 Nm (4.0 m · kg)
SWINGARM AND DRIVE CHAIN
CHAS
EB707000
SWINGARM AND DRIVE CHAIN
Order
Job/Part
Removing the swingarm and drive
chain
Drive sprocket
Rear wheel
Q’ty
Refer to “ENGINE” in chapter 4.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Rear shock absorber assembly
1
2
3
4
5
6
7
Adjusting bolt/locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut/washer
Pivot shaft
Swingarm
Remarks
Remove the parts in the order listed.
2/2
1
1
2
1/1
1
1
7 - 70
SWINGARM AND DRIVE CHAIN
Order
8
9
10
11
12
13
Job/Part
Drive chain
Dust cover
Drive chain guide
Spacer
Left bearing
Right bearing
Q’ty
1
2
1
1
1
1
CHAS
Remarks
For installation, reverse the removal
procedure.
7 - 71
SWINGARM AND DRIVE CHAIN
CHAS
EB707100
NOTE:
Before removing the drive sprocket,
drive chain, and rear wheel, measure the
drive chain slack and the length of a tenlink section of the drive chain.
EB707111
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
2. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the
pivot shaft nut.
T.
Pivot shaft nut
125 Nm (12.5 m • kg)
R.
b. Measure the swingarm side play Å
by moving the swingarm from side to
side.
c. If the swingarm side play is out of
specification, check the spacers, bearings, washers, and dust covers.
Swingarm side play (at the
end of the swingarm)
1.0 mm
d. Check the swingarm vertical movement ı by moving the swingarm up
and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust
covers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 72
SWINGARM AND DRIVE CHAIN
CHAS
EB707120
REMOVING THE DRIVE CHAIN
1. Remove:
• drive chain
(with the drive chain cutter)
Drive chain cutter
90890-01286
NOTE:
Only cut the drive chain if it or the swingarm is to be replaced.
EB707400
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
NOTE:
If the swingarm must be replaced, the
drive chain must be cut with a drive
chain cutter.
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
pivot shaft.
3. Wash:
• pivot shaft
• dust covers
• spacer
• bearings
Recommended cleaning solvent
Kerosine
7 - 73
SWINGARM AND DRIVE CHAIN
CHAS
4. Check:
• dust covers
• spacer
• oil seals
Damage/wear → Replace.
• bearings
Damage/pitting → Replace.
EB707410
CHECKING THE DRIVE CHAIN
1. Measure:
• ten-link section a of the drive chain
Out of specification → Replace the
drive chain.
Max. ten-link drive chain section
150.1 mm
NOTE:
• While measuring the ten-link section,
push down on the drive chain to
increase its tension.
• Measure the length between drive
chain roller 1 and A as shown.
• Perform this measurement at two or
three different places.
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 kerosine and
remove any remaining dirt.
7 - 74
SWINGARM AND DRIVE CHAIN
CHAS
c. Remove the drive chain from the kerosine and completely dry it.
CAUTION:
ACHTUNG:
This motorcycle has a drive chain with
small rubber O-rings 1 between the
drive chain side plates. Never use highpressure water or air, steam, gasoline,
certain solvents (e.g., benzine), or a
coarse brush to clean the drive chain.
High-pressure methods could force dirt
or water into the drive chain’s internals,
and solvents will deteriorate the Orings. A coarse brush can also damage
the O-rings. Therefore, use only kerosine to clean the drive chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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
6. Check:
• drive sprocket
• rear wheel 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
7 - 75
CHAS
SWINGARM AND DRIVE CHAIN
EB707700
INSTALLING THE SWINGARM
1. Lubricate:
• bearings
• spacers
• dust covers
• pivot shaft
Recommended lubricant
Lithium soap base grease
T.
R.
2. Install:
• swingarm
• pivot shaft
• washer
• pivot shaft nut
125 Nm (12.5 m · kg)
3. Install:
• rear shock absorber assembly
• rear wheel
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” and “REAR WHEEL”.
4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
Drive chain slack
40 ~ 50 mm
7 - 76
–
ELEC
+
8
ELEC
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS .......................................................................8-1
INSTRUMENT FUNCTIONS .........................................................................8-2
INDICATOR LIGHTS .............................................................................8-2
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT .................8-2
COMBINATION METER ........................................................................8-3
SWITCHES ....................................................................................................8-5
CHECKING SWITCH CONTINUITY ......................................................8-5
CHECKING THE SWITCHES .........................................................................8-6
CHECKING THE BULBS AND BULB SOCKETS ..........................................8-8
TYPES OF BULBS .................................................................................8-8
CHECKING THE CONDITION OF THE BULBS ....................................8-8
CHECKING THE CONDITION OF THE BULB SOCKETS ...................8-10
CHECKING THE LEDs .........................................................................8-10
IGNITION SYSTEM .....................................................................................8-11
CIRCUIT DIAGRAM .............................................................................8-11
TROUBLESHOOTING .........................................................................8-12
ELECTRIC STARTING SYSTEM .................................................................8-16
CIRCUIT DIAGRAM .............................................................................8-16
STARTING CIRCUIT CUTOFF SYSTEM OPERATION ......................8-17
TROUBLESHOOTING .........................................................................8-18
STARTER MOTOR ......................................................................................8-22
CHECKING THE STARTER MOTOR ...................................................8-24
ASSEMBLING THE STARTER MOTOR .............................................8-25
CHARGING SYSTEM ..................................................................................8-26
CIRCUIT DIAGRAM .............................................................................8-26
TROUBLESHOOTING .........................................................................8-27
LIGHTING SYSTEM ....................................................................................8-29
CIRCUIT DIAGRAM .............................................................................8-29
TROUBLESHOOTING .........................................................................8-30
CHECKING THE LIGHTING SYSTEM ................................................8-31
–
+
ELEC
SIGNALING SYSTEM .................................................................................8-35
CIRCUIT DIAGRAM .............................................................................8-35
TROUBLESHOOTING .........................................................................8-37
CHECKING THE SIGNALING SYSTEM .............................................8-38
COOLING SYSTEM .....................................................................................8-44
CIRCUIT DIAGRAM .............................................................................8-44
TROUBLESHOOTING .........................................................................8-45
FUEL PUMP SYSTEM .................................................................................8-48
CIRCUIT DIAGRAM .............................................................................8-48
FUEL PUMP CIRCUIT OPERATION ...................................................8-49
TROUBLESHOOTING .........................................................................8-50
CHECKING THE FUEL PUMP .............................................................8-52
EXUP SYSTEM ...........................................................................................8-53
CIRCUIT DIAGRAM .............................................................................8-53
TROUBLESHOOTING .........................................................................8-54
SELF-DIAGNOSIS .......................................................................................8-57
TROUBLESHOOTING .........................................................................8-58
–
+
ELECTRICAL COMPONENTS
ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Wire harness
2 Main switch
3 Front brake light switch
4 Ignition coils
5 Clutch switch
6 EXUP servomotor
7 Relay unit
8 Fuse box
9 Turn signal relay
0 Ignitor unit
A Starter relay
B Main fuse
C Oil level relay
D Battery
E Rectifier/regulator
F Rear brake light switch
G Neutral switch
H Speed sensor
I Sidestand switch
J Stator coil assembly
8-1
K Oil level switch
L Pickup coil
M Radiator fan
N Horn
O Temperature sender
P Thermo switch
Q Headlight relay
–
+
INSTRUMENT FUNCTIONS
ELEC
–
+
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
1 Neutral indicator light “ ”
2 High beam indicator light “
3 Turn indicator light “
”
4 Fuel indicator light “ ”
Turn indicator light “
”
This indicator flashes when the turn
switch is moved to the left or right.
Neutral indicator light “ ”
This indicator comes on when the transmission is in neutral.
High beam indicator light “
”
This indicator comes on when the headlight high beam is used.
Fuel indicator light “ ”
When the fuel level drops below approximately 5.5 L, this light will come on.
When this light comes on, fill the fuel
tank at the first opportunity.
”
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT
This warning light has two functions.
• The light will come on and symbol
“
” will flash if the engine oil level is
low. If this symbol flashes, stop the
engine immediately and fill it with oil
to the specified level.
• The light will come on and symbol
“
” will flash if the coolant temperature is too high. The following chart
shows the conditions of the indicator
light, symbol and temperature display
in accordance with the coolant temperature.
1 Oil level/coolant temperature warning light
“
”
2 Oil level symbol “
”
3 Coolant temperature symbol “
”
CAUTION:
ACHTUNG:
• Do not run the motorcycle until you
know it has sufficient engine oil.
• Do not run the motorcycle if the
engine is overheated.
NOTE:
Even if the oil is filled to the specified
level, the warning light may flicker when
riding on a slope or during sudden
acceleration or deceleration, but this is
normal.
8-2
INSTRUMENT FUNCTIONS
Coolant
temperature
Display
Conditions
ELEC
–
+
What to do
0 ˚C ~ 40 ˚C
Symbol is on and
Go ahead with riding.
“LO” is displayed.
41 ˚C ~ 117 ˚C
Symbol is on and
temperature is dis- Go ahead with riding.
played.
118 ˚C ~ 140 ˚C
Stop the motorcycle
and allow it to idle until
Symbol and tem- the coolant temperature
perature flashes
goes down.
and indicator light If the temperature does
comes on.
not go down, stop the
engine. Refer to “OVERHEATING” in chapter 9.
141 ˚C ~
Symbol flashes,
“HI” is displayed
and flashes, and
the indicator light
comes on.
Stop the engine and
allow it to cool. Refer to
“OVERHEATING”
in
chapter 9.
COMBINATION METER
This combination meter is equipped with
the following.
• A speedometer
• An odometer
• Two trip odometers
• A fuel reserve tripmeter
• A clock
For GB and USA models only:
To change the speedometer display from
kilometers to miles, press the “SELECT”
button for at least two seconds.
1 Speedometer
2 Clock, odometer
3 “SELECT” button
4 “RESET” button
Odometer and trip meters
Use the trip meters to estimate how far you
can ride on a tank of fuel.
Use the fuel reserve trip meter to see the
distance traveled from when the fuel level
dropped to the reserve level.
Push the “SELECT” button to change
between the odometer mode “ODO” and
the trip odometer modes “TRIP 1” and
“TRIP 2” in the following order:
“ODO” → “TRIP 1” → “TRIP 2” → “ODO”
8-3
INSTRUMENT FUNCTIONS
ELEC
–
+
When the fuel level indicator light comes on
the odometer display will automatically
change to the fuel reserve trip meter mode
“TRIP F” and start counting the distance
traveled from that point. Push the
“SELECT” button to change between the
fuel odometer, trip odometer and odometer
modes in the following order:
“TRIP F” → “TRIP 1” → “TRIP 2” → “ODO”
→ “TRIP F”
To reset a trip odometer to 0.0, select it by
pushing the “SELECT” button and push the
“RESET” button for at least one second. To
reset the fuel reserve trip meter, select it by
pushing the “SELECT” button and push the
“RESET” button for at least one second.
The display will return to “TRIP 1”. If you do
not reset the fuel reserve trip meter manually, it will automatically reset and return to
“TRIP 1” after refueling and the motorcycle
has traveled both 5 km and for approximately 3 minutes.
Clock
To change the display to the clock mode,
push both the “SELECT” and “RESET” buttons.
To set the clock:
1. Push both the “SELECT” and “RESET”
buttons for at least two seconds.
2. When the hour digits start flashing,
push the “RESET” button to set the
hours.
3. Push the “SELECT” button to change
the minutes.
4. When the minute digits start flashing,
push the “RESET” button to set the
minutes.
5. Push the “SELECT” button to start the
clock.
NOTE:
After setting the clock, be sure to push
the “SELECT” button before turning the
main switch to “OFF”, otherwise the
clock will not be set.
8-4
SWITCHES
ELEC
–
+
EB801000
SWITCHES
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:
ACHTUNG:
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
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 blue/red
and red when the switch is set to “
”.
There is continuity between blue/red
and blue, between brown/blue and red,
and between blue/yellow and blue/black
when the switch is set to “ON”.
8-5
CHECKING THE SWITCHES
ELEC
–
+
EB801010
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 the switch.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
8-6
CHECKING THE SWITCHES
1 Main switch
2 Pass switch
3 Dimmer switch
4 Turn signal switch
5 Horn switch
6 Clutch switch
7 Light switch
8 Engine stop switch
9 Start switch
0 Front brake light switch
A Fuse
B Sidestand switch
C Rear brake light switch
D Neutral switch
E Oil level switch
8-7
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EB801020
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.
Incorrect continuity reading → Repair
or replace the bulb, bulb socket or
both.
TYPES OF BULBS
The bulbs used on this motorcycle are
shown in the illustration on the left.
• Bulbs A and B are used for headlights
and usually use a bulb holder which
must be detached before removing the
bulb. The majority of these bulbs can
be removed from their respective
socket by turning them counterclockwise.
• Bulb C is used for turn signal and tail/
brake lights and can be removed from
the socket by pushing and turning the
bulb counterclockwise.
• Bulbs D and E are used for meter and
indicator lights and can be removed
from their respective socket by carefully pulling them out.
CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of
the bulbs.
1. Remove:
• bulb
8-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
WARNING
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
ACHTUNG:
• 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
NOTE:
Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1”
range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the tester positive probe to
terminal 1 and the tester negative
probe to terminal 2, and check the
continuity.
b. Connect the tester positive probe to
terminal 1 and the tester negative
probe to terminal 3, and check the
continuity.
c. If either of the readings indicate no
continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-9
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
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE LEDs
The following procedure applies to all of
the LEDs.
1. Check:
LED (for proper operation)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the meter assembly coupler (meter assembly side).
b. Connect two jumper leads 1 from the
battery terminals to the respective
coupler terminals as shown.
WARNING
WARNING
• A wire that is used as a jumper lead
must have at least the same capacity
of the battery lead, otherwise the
jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable gas or fluid is in the vicinity.
c. When the jumper leads are connected
to the terminals the respective LED
should illuminate.
Does not light → Replace the meter
assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 10
8 - 11
L
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
B
B
B
L
j
k
l
(Option)
m
n
B
L
B
B
L
i
h
Br
B
B
B
B
B
B
B
(BLACK)
R/Y
Br
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
3
L/Y L/B
L L/R
Br
L
B
R
W W W
Br
Y
(BLACK)
B
B
R/Y
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
f
A
L/R
L/B
u
B
A
L/R
B
Br
G
e
L/R
B
d
B/W
L/R
B/L
B/Y
B
B/Y
Br
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
c
B
B
Ch
Ch
]
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
B/L
B
L/R R/B L/W
L/B L/Y Sb B/Y B
L/R
L/B
B/Y
Sb L/Y
0A
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
•
(BLUE)
G/Y
Br
s
t
L/W
R/W
(BLUE)
g
B
B
6
8
7
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
r
B
B
B
R
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
(BROWN) (BROWN)
W
W
W
1 Main switch
A
5 Battery
6 Main fuse
C Sidestand switch
G Ignitor unit
H Ignition coils
I Spark plugs
J Pickup coil
K Neutral switch
n Ignition fuse
u Engine stop switch
P
OFF
ON
1
R
R
R/G
2
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
Y
A
A
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Sb
A
L/Y
Y/B
B
B/L
G/R
L/Y
W
B/L
B
Y/B Sb
W
A
A
W
B
G
R/W
R/B
IGNITION COIL SUB-WIRE HARNESS
B
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
L
B
B
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
K
Gy
B
H
H
J
Sb
R/B
R/B
O
Gy
B/L
I
I
IGNITION SYSTEM
ELEC
–
+
EB802001
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
ELEC
–
+
EB802401
EB802011
TROUBLESHOOTING
2.Battery
The ignition system fails to operate (no
spark or intermittent spark).
• 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. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. engine stop switch
10. neutral switch
11. sidestand switch
12. relay unit
13. wiring
(of the entire ignition system)
Min. open-circuit voltage
12.8 V or more at 20 ˚C
• Is the battery OK?
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) ignition coil plate and ignition coils
5) front cowling inner panel (left)
6) windshield
• Troubleshoot with the following special tool(-s).
EB802403
3.Spark plugs
The following procedure applies to all of
the spark plugs.
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK
PLUGS” in chapter 3.
Ignition checker
90890-06754
Pocket tester
90890-03112
Standard spark plug
CR9E (NGK)
U27ESR-N (DENSO)
Spark plug gap
0.7 ~ 0.8 mm
• Is the spark plug in good condition, is it
of the correct type, and its gap within
specification?
EB802400
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
YES
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(-s).
8 - 12
IGNITION SYSTEM
ELEC
–
+
EB802405
Spark plug cap resistance
10 kΩ at 20 ˚C
4.Ignition spark gap
•
•
•
•
•
•
The following procedure applies to all of
the spark plugs.
Disconnect the spark plug cap from the
spark plug.
Connect the ignition checker 1 as
shown.
2Spark plug cap
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 cap OK?
NO
YES
Replace the spark
plug cap.
EB802409
6.Ignition coil resistance
The following procedure applies to all of
the ignition coils.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Tester positive probe → red/black
Tester negative probe → orange (gray)
Min. ignition spark gap
6 mm
• Is there a spark and is the spark gap
within specification?
NO
YES
The ignition system
is OK.
• Measure the primary coil resistance.
EB802407
Primary coil resistance
1.87 ~ 2.53 Ω at 20 ˚C
5.Spark plug cap resistance
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
• Measure the secondary coil resistance.
The following procedure applies to all of
the spark plug caps.
• Disconnect the spark plug cap from the
spark plug.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.
Tester positive probe →
spark plug lead 1
Tester positive probe →
spark plug lead 2
8 - 13
IGNITION SYSTEM
–
ELEC
+
EB802411
8.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch.
Secondary coil resistance
12 ~ 18 kΩ at 20 ˚C
• Is the ignition coil OK?
EB802412
9.Engine stop switch
NO
YES
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
Replace the ignition
coil.
YES
EB802410
NO
7.Pickup coil resistance
Replace the right
handlebar switch.
• Disconnect the pickup coil coupler from
the wire harness.
• Connect the pocket tester (Ω × 100) to
the pickup coil terminal.
EB802413
Tester positive probe → gray 1
Tester negative probe → black 2
10.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
NO
YES
Replace the neutral
switch.
EB802414
• Measure the pickup coil resistance.
11.Sidestand switch
Pickup coil resistance
248 ~ 372 Ω at 20 ˚C
(between gray and black)
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
• Is the pickup coil OK?
YES
NO
NO
YES
Replace the pickup
coil.
Replace the
stand switch.
8 - 14
side-
IGNITION SYSTEM
ELEC
–
+
EB802416
EB802415
12.Relay unit
13.Wiring
• Remove the relay unit from the wire harness.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Check the starting circuit cutoff relay for
continuity.
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
NO
Tester positive probe →
sky blue 1 Continuity
Tester negative probe →
blue/yellow 2
Properly
connect
or repair the ignition system’s wiring.
Tester positive probe →
blue/yellow 2 No continuity
Tester negative probe →
sky blue 1
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the
above chart will be reversed.
• Are the tester readings correct?
NO
YES
Replace
unit.
the
relay
8 - 15
YES
Replace the ignitor
unit.
8 - 16
L
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
B
B
j
k
l
(Option)
m
n
B
L
B
B
Br
B
B
B
B
B
B
B
L
i
(BLACK)
R/Y
Br
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
3
L/Y L/B
L L/R
Br
L
B
R
W W W
Br
Y
B
B
L
(BLACK)
B
R/Y
Y
L Y
B
B
R/Y
Y L/R
R/Y
R/Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
L/R
L/B
u
B
A
L/R
B
Br
G
e
L/R
B
d
B/W
L/R
B/L
B/Y
B
B/Y
Br
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
c
B
B
Ch
Ch
]
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
B/L
B
L/R R/B L/W
L/B L/Y Sb B/Y B
L/R
L/B
B/Y
Sb L/Y
0A
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
A
f
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
•
(BLUE)
G/Y
Br
s
t
L/W
R/W
(BLUE)
g
B
B
6
8
7
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
r
B
B
B
R
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
(BROWN) (BROWN)
W
W
W
1 Main switch h
5 Battery
A
A
6 Main fuse
7 Starter relay
8 Starter motor
0 Starting circuit cutoff relay
C Sidestand switch
K Neutral switch
] Clutch switch
n Ignition fuse
u Engine stop switch
v Start switch
P
OFF
ON
1
R
R
R/G
2
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
Y
A
A
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Sb
A
L/Y
Y/B
B
B/L
G/R
L/Y
W
B/L
B
Y/B Sb
W
A
A
W
B
G
R/W
R/B
IGNITION COIL SUB-WIRE HARNESS
B
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
L
B
B
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
R/B
O
Sb
K
Gy
B
H
H
J
Sb
R/B
Gy
B/L
I
I
ELECTRIC STARTING SYSTEM
ELEC
–
+
EB803000
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EB803010
STARTING CIRCUIT CUTOFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and
the main switch is set to “ON” (both
switches are closed), the starter motor can
only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and
the sidestand is up (the sidestand
switch is closed).
The starting circuit cutoff relay prevents the
starter motor from operating when neither
of these conditions has been met. In this
instance, the starting circuit cutoff relay is
open so current cannot reach the starter
motor. When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the engine can be
started by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE SIDESTAND IS UP
AND THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cutoff relay
7 Diode
8 Clutch switch
9 Sidestand switch
0 Neutral switch
A Start switch
B Starter relay
C Starter motor
8 - 17
ELECTRIC STARTING SYSTEM
ELEC
–
+
EB802401
EB803020
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. starting circuit cutoff relay
5. relay unit
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. start switch
13. wiring
(of the entire starting system)
Open-circuit voltage
12.8 V or more at 20 ˚C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) front cowling inner panel (left)
5) windshield
• Troubleshoot with the following special tool(-s).
EB803400
3.Starter motor
• Connect the battery positive terminal 1
and starter motor lead 2 with a jumper
lead 3.
Pocket tester
90890-03112
EB802400
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
WARNING
WARNING
• A wire that is used as a jumper lead
must have at least the same capacity of
the battery lead, otherwise the jumper
lead may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
NO
Replace the fuse(-s).
• Does the starter motor turn?
YES
NO
Repair or replace
the starter motor.
8 - 18
ELECTRIC STARTING SYSTEM
ELEC
–
+
EB803403
EB803402
4.Starting circuit cutoff relay
5.Relay unit
• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the relay unit terminals
as shown.
• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Measure the starting circuit cutoff relay
for continuity as follows.
Battery positive terminal → red/black 1
Battery negative terminal →
black/yellow 2
Tester positive probe →
sky blue 1
Tester negative probe →
black/yellow 2 Continuity
Tester positive probe →
Tester positive probe → blue/white 3
Tester negative probe → black 4
sky blue 1
Tester negative probe →
blue/yellow 3
Tester positive probe →
black/yellow 2
Tester negative probe →
sky blue 1 No continuity
Tester positive probe →
blue/yellow 3
Tester negative probe →
sky blue 1
• Does the starting circuit cutoff relay
have continuity between black and blue/
white?
NO
YES
Replace
unit.
the
relay
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the
above chart will be reversed.
• Are the tester readings correct?
NO
YES
Replace
unit.
8 - 19
the
relay
ELECTRIC STARTING SYSTEM
–
ELEC
+
EB802412
EB803404
6.Starter relay
8.Engine stop switch
• Disconnect the starter relay from the
coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the starter relay coupler
as shown.
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
Battery positive terminal → red/white 1
Battery negative terminal →
blue/white 2
NO
Replace the right
handlebar switch.
Tester positive probe → red 3
Tester negative probe → black 4
EB802413
9.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
NO
YES
Replace the neutral
switch.
• Does the starter relay have continuity
between red and black?
YES
NO
EB802414
10.Sidestand switch
Replace the starter
relay.
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
EB802411
7.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
YES
Replace the
stand switch.
side-
NO
EB803405
11.Clutch switch
Replace the main
switch.
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
8 - 20
ELECTRIC STARTING SYSTEM
EB803406
12.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EB803408
13.Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
NO
Properly
connect
or repair the starting system’s wiring.
YES
The starting system
circuit is OK.
8 - 21
ELEC
–
+
STARTER MOTOR
ELEC
–
EB803500
STARTER MOTOR
Order
1
2
3
4
Job/Part
Removing the starter motor
Rider seat
Fuel tank
Left side cowling
EXUP servomotor
Throttle stop screw
Starter motor lead
Starter motor assembly
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
1
1
1
1
For installation, reverse the removal
procedure.
8 - 22
+
STARTER MOTOR
ELEC
–
+
EB803501
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Q’ty
Remarks
Disassembling the starter motor
Remove the parts in the order listed.
Starter motor front cover
1
Lock washer
1
Oil seal
1
Bearing
1
Washer set
1
Starter motor rear cover
1
Washer set
1
Armature assembly
1
Brush seat (along with the brushes)
1
Brush holder (along with the brushes)
1
O-ring
2
Starter motor yoke
1
For assembly, reverse the disassembly
procedure
8 - 23
STARTER MOTOR
ELEC
–
+
EB803511
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.
Min. commutator diameter
27 mm
3. Measure:
• mica undercut a
Out of specification → Scrape the mica
to the proper measurement with a
hacksaw blade which has been
grounded to fit the commutator.
Mica undercut
0.7 mm
NOTE:
The mica 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
Armature assembly
Commutator resistance 1
0.025 ~ 0.035 Ω at 20 ˚C
Insulation resistance 2
Above 1 MΩ at 20 ˚C
b. If any resistance is out of specification, replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 24
STARTER MOTOR
ELEC
–
+
5. Measure:
• brush length a
Out of specification → Replace the
brushes as a set.
Min. brush length
5 mm
6. Measure:
• brush spring force
Out of specification → Replace the
brush springs as a set.
Brush spring force
7.03 ~ 10.63 N (717 ~ 1,084 gf)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(-s).
EB803701
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush seat 1
NOTE:
Align the tab a on the brush seat with
the slot b in the starter motor rear
cover.
T.
2. Install:
• starter motor yoke 1
New
• O-rings 2
• starter motor front cover 3
• starter motor rear cover 4
• bolts
5 Nm (0.5 m · kg)
R.
NOTE:
Align the match marks a on the starter
motor yoke with the match marks b on
the front and rear covers.
8 - 25
–
ELEC
CHARGING SYSTEM
+
EB804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
R/G
R/G
R
W
W
W
W
W
W
R
R R R
R
R
R R
L/W R/W
6
5
R/W
B
B
R
W W W
R
3
P
OFF
ON
L/R Br/L L/Y
L
Br/L
L/Y L/B
L L/R
B L/Y
L/R L
R
Br/L
R
Br/L
W W
W
W
4
B
1
W W
B
n
8
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
W R/L
Br B
(BLACK)
R/L
r
Br
o
W
(BROWN)
Br/R
L
L/B
B
B
B
B
(BROWN)
(BLACK)
l
Br R/W
B R/B
B G/Y
R/W Br
R/B B
G/Y L/W
(BROWN)
s
t
•
B
(Option)
Br/L
B
R/W
m
Br/L
B
L/W
B
B
B
B
Br/L
7
B
R/Y
L
G/Y
L/B
(BROWN)
Br
G/Y
Br
W
Br/R
L
Br
k
R/Y
W
j
p
Br
Br
L
Br
i
q
L
X
3 Rectifier/regulator
4 Generator
W/Y Dg
Dg Y
5 Battery
W/G
O
6 Main fuse Ch G
L/Y B/Y
Br
8 - 26
B
B/Y L/Y
Y
—
PAS
CHARGING SYSTEM
ELEC
–
+
EB802401
EB804010
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 assembly resistance
5. wiring
(of the entire charging system)
Open-circuit voltage
12.8 V or more at 20 ˚C
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
• Troubleshoot with the following special tool(-s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
Engine tachometer
90890-03113
Pocket tester
90890-03112
EB804400
3.Charging voltage
• Connect the engine tachometer to the
spark plug lead of cylinder #1.
• Connect the pocket tester (DC 20V) to
the battery as shown.
Tester positive probe →
battery positive terminal
Tester negative probe →
battery negative terminal
EB802400
1.Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
YES
NO
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
Replace the fuse.
Charging voltage
14 V at 5,000 r/min
8 - 27
CHARGING SYSTEM
ELEC
–
+
EB804404
5.Wiring
NOTE:
Make sure that the battery is fully
charged.
• Check the wiring connections of the
entire charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
• Is the charging voltage within specification?
NO
YES
NO
The charging circuit
is OK.
Properly
connect
or repair the charging system’s wiring.
EB804401
4.Stator coil assembly resistances
• Remove the generator cover.
• Connect the pocket tester (Ω × 1) to the
stator coil assembly coupler as shown.
Tester positive probe → white 1
Tester negative probe → white 2
Tester positive probe → white 1
Tester negative probe → white 3
• Measure the stator coil assembly resistances.
Stator coil resistance
0.45 ~ 0.55 Ω at 20 ˚C
• Is the stator coil assembly OK?
YES
NO
Replace the stator
coil assembly.
8 - 28
YES
Replace the rectifier/regulator.
P
OFF
ON
1
L
8 - 29
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
R
B
B
B
L
j
k
l
(Option)
m
n
L
i
B
h
Br
B
B
B
B
B
B
B
(BLACK)
B
B
R/Y
Br
(BLACK)
B
L
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
3
L/Y L/B
L L/R
Br
L
B
R
W W W
R
Br
Y
B
R/Y
A
•
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
L/R
L/B
u
B
A
d
B
e
L/R
B
Br
G
B/W
L/R
B/L
B/Y
B
B/Y
Br
L/R
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
L/R
c
B
B
Ch
Ch
]
B/L
B
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
L/B
B/Y
Sb L/Y
0A
L/R R/B L/W
L/B L/Y Sb B/Y B
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
A
f
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
Br
s
t
L/W
(BLUE)
G/Y
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
B
B
8
7
R/W
(BLUE)
g
B
r
B
6
R
R
B
R
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R
R R R
L/W R/W
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
2
(BROWN) (BROWN)
W
W
W
R/G
A
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
A
A
L/Y
Sb
Y/B
A
Y
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
B/L
G/R
L/Y
W
B/L
B
Y/B Sb
W
A
A
W
B
R/W
R/B
L
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
Sb
R/B
R/B
O
K
Gy
B
Gy
B/L
1 Main switch
5 Battery
6 Main fuse
U High beam indicator light
B light
W Meter
Y Pass switch
Z Dimmer switch
B
d Headlight
H
I
e Auxiliary light
f HeadlightBrelay
G
g Tail/brake
light H I
k Headlight fuseJ
l Signaling system fuse
t Lights switch
IGNITION COIL SUB-WIRE HARNESS
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
B
LIGHTING SYSTEM
ELEC
–
+
EB805000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
ELEC
–
+
EB802401
EB805010
TROUBLESHOOTING
2.Battery
Any of the following fail to light: headlight, high beam indicator light, taillight,
auxiliary light or meter light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Open-circuit voltage
12.8 V or more at 20 ˚C
Check:
1. main, signaling system, and headlight
fuses
2. battery
3. main switch
4. lights switch
5. dimmer switch
6. pass switch
7. wiring
(of the entire charging system)
• Is the battery OK?
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) seats
2) fuel tank
3) air filter case
4) front cowling inner panels
5) front cowling
6) rear cowling
• Troubleshoot with the following special tool(-s).
EB802411
3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
YES
NO
Replace the main
switch.
EB802400
1.Main, signaling system, and headlight
fuses
• Check the main, signaling system, and
headlight fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, signaling system, and
headlight fuses OK?
YES
NO
EB805400
4.Lights switch
• Check the lights switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the lights switch OK?
NO
YES
Replace the fuse(-s).
NO
The lights switch is
faulty. Replace the
right handlebar
switch.
8 - 30
LIGHTING SYSTEM
EB805401
ELEC
–
+
EB805410
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator light fail to come on.
5.Dimmer switch
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
YES
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?
NO
The dimmer switch
is faulty. Replace
the left handlebar
switch.
NO
YES
Replace the headlight bulb, socket or
both.
EB805403
6.Pass switch
• Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the pass switch OK?
YES
2.High beam indicator light LED
• Check the LED of the high beam indicator light.
Refer to “CHECKING THE LEDs”.
• Is the high beam indicator light LED OK?
NO
The pass switch is
faulty. Replace the
left handlebar
switch.
NO
YES
Replace the motor
assembly.
EB805404
7.Wiring
3.Voltage
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
• Connect the pocket tester (DC 20V) to
the headlight and high beam indicator
light couplers as shown.
YES
Check the condition
of each of the lighting system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
Å When the dimmer switch is set to “
ı When the dimmer switch is set to “
NO
Headlight coupler (wire harness side)
Properly
connect
or repair the lighting system’s wiring.
8 - 31
”
”
LIGHTING SYSTEM
ELEC
–
+
Headlight
Tester positive probe →
black/yellow 1 or black/blue 2
Tester negative probe → black 3
High beam indicator light
Tester positive probe → yellow 4
Tester negative probe → black 5
Meter assembly coupler (wire harness
side)
• Does the headlight relay have continuity
between white/yellow (white/green) and
black?
NO
YES
This circuit is OK.
• Set the main switch to “ON”.
• Set the light switch to “
”.
• Set the dimmer switch to “
” or
“
”.
• Measure the voltage (12 V) of black/yellow (black/blue) 2 on the headlight coupler (headlight side).
• Is the voltage within specification?
YES
Replace the headlight relay.
EB805411
2. A meter light fails to come on.
1.Meter light bulb and socket
• Check the meter light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the meter light bulb and socket OK?
NO
The wiring circuit
from
the
main
switch to the headlight
coupler
is
faulty and must be
repaired.
NO
YES
Replace the meter
light bulb, socket or
both.
4.Headlight relay
2.Voltage
• Disconnect the headlight relay from the
coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the headlight relay terminals as shown.
• Connect the pocket tester (20 V) to the
meter assembly coupler (wire harness
side) as shown.
Tester positive probe → blue 1
Tester negative probe → black 2
Battery positive terminal →
red/yellow 1
Battery negative terminal →
black/yellow (black/blue) 2
Tester positive probe →
white/yellow (white/green) 3
Tester negative probe → black 4
8 - 32
LIGHTING SYSTEM
This circuit is OK.
–
+
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue/red 1
on the tail/brake light coupler (wire harness side).
• Is the voltage within specification?
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue 1 on
the meter assembly coupler (wire harness side).
• Is the voltage within specification?
NO
YES
ELEC
NO
YES
This circuit is OK.
The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.
The wiring circuit
from
the
main
switch to the tail/
brake light coupler
is faulty and must
be repaired.
EB805413
EB805412
3. A tail/brake light fails to come on.
4. The auxiliary light fails to come on.
1.Tail/brake light bulb and socket
1.Auxiliary light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
• Check the auxiliary light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the auxiliary light bulb and socket
OK?
YES
NO
YES
NO
Replace the auxiliary
light
bulb,
socket or both.
Replace the tail/
brake light bulb,
socket or both.
2.Voltage
2.Voltage
• Connect the pocket tester (DC 20V) to
the tail/brake light coupler (wire harness
side) as shown.
• Connect the pocket tester (DC 20V) to
the auxiliary light couplers (wire harness
side) as shown.
Tester positive probe → blue/red 1
Tester negative probe → black 2
Tester positive probe → blue/red 1
Tester negative probe → black 2
8 - 33
LIGHTING SYSTEM
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue/red 1
on the auxiliary light couplers (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from
the
main
switch to the auxiliary light connectors is faulty and
must be repaired.
8 - 34
ELEC
–
+
P
OFF
ON
1
L
8 - 35
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
R
B
B
B
L
j
k
l
(Option)
m
n
L
i
B
h
Br
B
B
B
B
B
B
B
(BLACK)
B
B
R/Y
Br
(BLACK)
B
L
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
3
L/Y L/B
L L/R
Br
L
B
R
W W W
R
Br
Y
B
R/Y
A
•
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
L/R
L/B
u
B
A
L/R
B
Br
G
e
L/R
B
d
B/W
L/R
B/L
B/Y
B
B/Y
Br
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
L/R
c
B
B
Ch
Ch
]
B/L
B
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
L/B
B/Y
Sb L/Y
0A
L/R R/B L/W
L/B L/Y Sb B/Y B
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
A
f
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
Br
s
t
L/W
(BLUE)
G/Y
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
B
B
8
7
R/W
(BLUE)
g
B
r
B
6
R
B
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
(BROWN) (BROWN)
W
W
W
R/G
2
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
A
A
L/Y
Sb
Y/B
A
Y
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
B
B/L
G/R
L/Y
W
B/L
B
Y/B Sb
W
A
A
W
B
G
R/W
R/B
IGNITION COIL SUB-WIRE HARNESS
B
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
L
B
B
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
K
Gy
B
H
H
J
Sb
R/B
R/B
O
Gy
B/L
I
I
SIGNALING SYSTEM
ELEC
–
+
EB806000
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
1 Main switch
5 Battery
6 Main fuse
D Fuel sender
K Neutral switch
O Fuel level indicator light
P Oil level/coolant temperature warning light
Q Neutral indicator light
R Tachometer
S Combination meter
V Turn signal indicator light
[ Horn switch
\ Horn
_ Turn signal switch
a Turn signal relay
b Rear turn signal light
c Front turn signal light
g Tail/brake light
l Signaling system fuse
o Oil level relay
p Oil level switch
q Rear brake light switch
s Front brake light switch
8 - 36
ELEC
–
+
SIGNALING SYSTEM
ELEC
–
+
EB802401
EB806010
TROUBLESHOOTING
2.Battery
• Any of the following fail to light: turn
signal light, brake light or an indicator
light.
• The horn fails to sound.
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
Open-circuit voltage
12.8 V or more at 20 ˚C
Check:
1. main and signaling system fuses
2. battery
3. main switch
4. wiring
(of the entire signaling system)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) seats
2) fuel tank
3) air filter case
4) front cowling inner panels
5) bottom cowling
6) left side cowling
7) windshield
8) rear cowling
• Troubleshoot with the following special tool(-s).
EB802411
3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
Pocket tester
90890-03112
NO
Replace the main
switch.
EB802400
1.Main and signaling system fuses
EB806400
• Check the main and signaling system
fuses for continuity.
Refer to “CHECKING AND CHARGING
THE FUSES” in chapter 3.
• Are the main and signaling system fuses
OK?
YES
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 - 37
Properly
connect
or repair the signaling system’s wiring.
SIGNALING SYSTEM
ELEC
–
+
EB806410
3.Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
• Disconnect the black connector at the
horn terminal.
• Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?
1.Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
YES
NO
Replace the left handlebar switch.
2.Voltage
• Connect the pocket tester (DC 20V) to
the horn connector at the horn terminal
as shown.
NO
Tester positive probe → black/white 1
Tester negative probe → ground
YES
The horn is OK.
4.Voltage
• Connect the pocket tester (DC 20V) to
the horn connector at the black terminal
as shown.
Tester positive probe → black 1
Tester negative probe → ground
• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (12V) of black/white
at the horn terminal.
• Is the voltage within specification?
YES
NO
The wiring circuit
from
the
main
switch to the horn
connector is faulty
and
must
be
repaired.
• Set the main switch to “ON”.
• Measure the voltage (12V) of black 1 at
the horn terminal.
• Is the voltage within specification?
YES
Repair or replace
the horn.
8 - 38
NO
Replace the horn.
SIGNALING SYSTEM
ELEC
–
+
EB806411
• Set the main switch to “ON”.
• Pull in the brake lever or push down on
the brake pedal.
• Measure the voltage (12 V) of yellow at
the tail/brake light coupler (wire harness
side).
• Is the voltage within specification?
2. A tail/brake light fails to come on.
1.Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
YES
NO
YES
NO
This circuit is OK.
Replace the tail/
brake light bulb,
socket or both.
The wiring circuit
from
the
main
switch to the tail/
brake light coupler
is faulty and must
be repaired.
2.Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
EB806413
3. A turn signal light, turn signal indicator
light or both fail to blink.
NO
1.Turn signal light bulb and socket
• Check the turn signal light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
OK?
Replace the brake
light switch.
3.Voltage
• Connect the pocket tester (DC 20V) to
the tail/brake light coupler (wire harness
side) as shown.
NO
YES
Tester positive probe → yellow 1
Tester negative probe → black 2
Replace the turn
signal light bulb,
socket or both.
2.Turn signal indicator light LED
• Check the LED of the turn signal indicator light.
Refer to “CHECKING THE LEDs”.
• Is the turn signal indicator light LED OK?
YES
NO
Replace the meter
assembly.
8 - 39
SIGNALING SYSTEM
–
+
Tester positive probe → brown/white 1
Tester negative probe → ground
3.Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
YES
ELEC
NO
Replace the left handlebar switch.
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12V) of brown/
white at the turn signal relay coupler
(wire harness side).
• Is the voltage within specification?
4.Voltage
• Connect the pocket tester (DC 20V) to
the turn signal relay coupler (wire harness side) as shown.
Tester positive probe → brown 1
Tester negative probe → ground
NO
YES
The
turn
signal
relay is faulty and
must be replaced.
6.Voltage
• Connect the pocket tester (DC 20V) to
the turn signal light connectors or the
meter assembly coupler (wire harness
side) as shown.
• Set the main switch to “ON”.
• Measure the voltage (12V) of brown 1
at the turn signal relay coupler (wire harness side).
• Is the voltage within specification?
YES
Å Turn signal light
ı Turn signal indicator light
Left turn signal light
Tester positive probe →
chocolate (orange) 1
Tester negative probe → ground
Right turn signal light
Tester positive probe → dark green 2
Tester negative probe → ground
NO
The wiring circuit
from
the
main
switch to the turn
signal relay coupler
(turn signal relay
side) is faulty and
must be repaired.
Å
5.Voltage
• Connect the pocket tester (DC 20V) to
the turn signal relay coupler (wire harness side) as shown.
8 - 40
ı
SIGNALING SYSTEM
+
• Connect the pocket tester (DC 20V) to
the meter assembly coupler (wire harness side) as shown.
Tester positive probe → brown 1
Tester negative probe → sky blue 2
NO
YES
The wiring circuit
from the turn signal
switch to the turn
signal light connector is faulty and
must be repaired.
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and sky blue 2 at the meter assembly
coupler.
• Is the voltage within specification?
EB806414
4. The neutral indicator light fails to
come on.
1.Neutral indicator light LED
NO
YES
• Check the LED of the neutral indicator
light.
Refer to “CHECKING THE LEDs”.
• Is the neutral indicator light LED OK?
YES
–
3.Voltage
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or
“ ”.
• Measure the voltage (12V) of chocolate
(orange) 1 or dark green 2 at the turn signal light connector (wire harness side).
• Is the voltage within specification?
This circuit is OK.
ELEC
This circuit is OK.
NO
Replace the meter
assembly.
The wiring circuit
from
the
main
switch to the meter
light bulb coupler is
faulty and must be
repaired.
EB806416
5. The oil level warning light fails to
come on.
2.Neutral switch
1.Oil level warning light LED
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
• Check the LED of the oil level warning
light.
Refer to “CHECKING THE LEDs”.
• Is the oil level warning light LED OK?
NO
YES
Replace the neutral
switch.
NO
Replace the meter
assembly.
8 - 41
SIGNALING SYSTEM
ELEC
–
+
2.Oil level switch
4.Voltage
• Drain the engine oil and remove the oil
level switch from the oil pan.
• Check the oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the oil level switch OK?
• Connect the pocket tester (DC 20V) to
the meter assembly coupler (wire harness side) as shown.
YES
Tester positive probe → brown 1
Tester negative probe → black/red 2
NO
Replace the oil
level switch.
3.Oil level relay
• Disconnect the oil level relay from the
coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the oil level relay terminals as shown.
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/red at the meter assembly
coupler.
• Is the voltage within specification?
Battery positive terminal → brown 1
Battery negative terminal → white 2
NO
YES
Tester positive probe → red/blue 3
Tester negative probe → black 4
This circuit is OK.
The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.
EB806417
6. The fuel level indicator light fails to
come on.
• Does the oil level relay have continuity
between red/blue and black?
YES
1.Fuel level indicator light LED
NO
• Check the LED of the fuel level indicator
light.
Refer to “CHECKING THE LEDs”.
• Is the fuel level indicator light LED OK?
Replace the oil
level relay.
YES
NO
Replace the meter
assembly.
8 - 42
SIGNALING SYSTEM
• Disconnect the fuel sender coupler from
the wire harness.
• Drain the fuel from the fuel tank and
remove the fuel sender from the fuel
tank.
• Check the fuel sender for continuity.
YES
This circuit is OK.
Tester positive probe → green 1
Tester negative probe → black 2
• Is the fuel sender OK?
NO
Replace
sender.
the
–
+
• Set the main switch to “ON”.
• Measure the voltage (12V).
• Is the voltage within specification?
2.Fuel sender
YES
ELEC
fuel
3.Voltage
Connect the pocket tester (DC 20V) to
the meter assembly coupler (wire harness side) as shown.
Tester positive probe → brown 1
Tester negative probe → green/red 2
8 - 43
NO
The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.
P
OFF
ON
1
L
8 - 44
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
R
B
B
B
L
j
k
l
(Option)
m
n
L
i
B
h
Br
B
B
B
B
B
B
B
(BLACK)
B
B
R/Y
Br
(BLACK)
B
L
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
3
L/Y L/B
L L/R
Br
L
B
R
W W W
R
Br
Y
B
R/Y
A
•
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
f
A
L/R
L/B
u
B
A
L/R
B
Br
G
e
L/R
B
d
B/W
L/R
B/L
B/Y
B
B/Y
Br
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
L/R
c
B
B
Ch
Ch
]
B/L
B
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
L/B
B/Y
Sb L/Y
0A
L/R R/B L/W
L/B L/Y Sb B/Y B
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
Br
s
t
L/W
R/W
(BLUE)
G/Y
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
B
B
8
7
6
(BLUE)
g
B
r
B
B
R
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
2
(BROWN) (BROWN)
W
W
W
R/G
A
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
Y
A
A
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Sb
A
L/Y
Y/B
B/L
L/Y
W
B/L
B
G/R
W
Y/B Sb
G
A
A
W
B
R/B
R/W
L
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
K
Gy
B
H
J
Sb
R/B
R/B
O
Gy
B/L
I
1 Main switch
5 Battery
6 Main fuse
M Temperature sender
B
S Combination
meter
T Coolant temperature meter
h Radiator fan motor
B
i Thermo switch
H
I
j Radiator fan motor fuse
l Signaling system
fuse
B
IGNITION COIL SUB-WIRE HARNESS
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
B
COOLING SYSTEM
ELEC
–
+
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
–
ELEC
+
EB807010
• Is the battery OK?
TROUBLESHOOTING
• The radiator fan motor fails to turn.
• The coolant temperature meter needle
fails to move when the engine is warm.
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
Check:
1. main, signal system, and radiator fan
motor fuses
2. battery
3. main switch
4. radiator fan motor
5. thermo switch
6. temperature sender
7. wiring
(the entire cooling system)
EB802411
3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) bottom cowling
3) front cowling inner panels
4) left side cowling
5) windshield
• Troubleshoot with the following special tool(-s).
NO
YES
Replace the main
switch.
EB807400
4.Radiator fan motor (test 1)
• Disconnect the radiator fan motor coupler from the wire harness.
• Connect the battery (12 V) as shown.
Pocket tester
90890-03112
EB802400
Battery positive lead → blue 1
Battery negative lead → black 2
1.Main, signal system and radiator fan
motor fuses
• Check the main, signal system, and radiator fan motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, signal system, and radiator fan motor fuses OK?
NO
YES
• Does the radiator fan motor turn?
Replace the fuse(-s).
YES
EB802401
NO
2.Battery
The radiator fan
motor is faulty and
must be replaced.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Open-circuit voltage
12.8 V or more at 20 ˚C
8 - 45
COOLING SYSTEM
–
ELEC
+
EB807400
5.Radiator fan motor (test 2)
• Disconnect the thermo switch coupler.
• Set the main switch to “ON”.
• Connect the brown 1 and blue 2 terminals with a jumper lead 3 as shown.
Test
step
Coolant temperature
1
0 ~ 98 ˚C
NO
2
More than 105 ± 3 ˚C
YES
3*
105 to 98 ˚C
YES
4*
Less than 98 ˚C
NO
Continuity
Thermo switch
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
• Does the radiator fan motor turn?
YES
NO
The wiring circuit
from
the
main
switch to the radiator fan motor coupler is faulty and
must be repaired.
EB807402
6.Thermo switch
• Remove the thermo switch from the
radiator.
• Connect the pocket tester (Ω × 1) to the
thermo switch 1 as shown.
• Immerse the thermo switch in a container filled with coolant 2.
WARNING
WARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
NOTE:
Make sure that the thermo switch terminals do not get wet.
T.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool
to the specified temperature as indicated
in the table.
• Check the thermo switch for continuity
at the temperatures indicated in the
table.
R.
Thermo switch
23 Nm (2.3 m • kg)
Three bond sealock 10
Å The thermo switch circuit is open and the
radiator fan is off.
ı The thermo switch circuit is closed and
the radiator fan is on.
8 - 46
COOLING SYSTEM
ELEC
–
+
• Does the thermo switch operate properly as described above?
NO
YES
Replace the thermo
switch.
7.Temperature sender
WARNING
WARNING
• Remove the temperature sender from
the radiator.
• Connect the pocket tester (Ω × 10) to the
temperature sender 1 as shown.
• Immerse the temperature sender in a
container filled with water 2.
• Place a thermometer 3 in the water.
• Slowly heat the water, then let it cool
down to the specified temperature.
• Check the temperature sender for continuity at the temperatures indicated
below.
Handle the temperature sender with special care.
Never subject the temperature sender to
strong shocks. If the temperature sender
is dropped, replace it.
T.
R.
Temperature sender
15 Nm (1.5 m • kg)
Three bond sealock  10
YES
Temperature sender resistance
47.5 ~ 56.8 Ω at 80 ˚C
16.5 ~ 20.5 Ω at 115 ˚C
NO
Replace the temperature sender.
EB807403
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
This circuit is OK.
8 - 47
NO
Properly
connect
or repair the cooling system’s wiring.
8 - 48
L
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
R
B
B
B
L
j
k
l
(Option)
m
n
Br
L
L
i
B
h
Br
B
B
B
B
B
B
B
(BLACK)
B
B
R/Y
Br
(BLACK)
B
L
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
L/Y L/B
L L/R
3
Br
Y
B
R/Y
A
•
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
L/R
L/B
u
B
A
d
B
e
L/R
B
Br
G
B/W
L/R
B/L
B/Y
B
B/Y
Br
L/R
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
L/R
c
B
B
Ch
Ch
]
B/L
B
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
L/B
B/Y
Sb L/Y
0A
L/R R/B L/W
L/B L/Y Sb B/Y B
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
A
f
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
Br
s
t
L/W
R/W
(BLUE)
G/Y
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
B
B
8
7
6
(BLUE)
g
B
r
B
B
R
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
(BROWN) (BROWN)
W
W
W
1 Main switch
5 Battery
6 Main fuse
A Fuel pump relay
B Fuel pump
G Ignitor unit
n Ignition fuse
u Engine stop switch
P
OFF
ON
1
B
R
W W W
R
R/G
2
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
A
A
L/Y
Sb
Y/B
A
Y
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
B
B/L
G/R
L/Y
W
B/L
Y/B Sb
W
B
A
A
W
B
G
R/W
R/B
IGNITION COIL SUB-WIRE HARNESS
B
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
L
B
B
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
K
Gy
B
H
H
J
Sb
R/B
R/B
O
Gy
B/L
I
I
FUEL PUMP SYSTEM
ELEC
–
+
EB808000
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The ignitor unit includes the control unit for the fuel pump.
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Ignitor unit
7 Fuel pump relay
8 Fuel pump
8 - 49
ELEC
–
+
FUEL PUMP SYSTEM
ELEC
–
+
EB802401
EB808020
TROUBLESHOOTING
2.Battery
The fuel pump fails to operate.
• 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. engine stop switch
5. fuel pump relay
6. fuel pump
7. wiring
(the entire fuel pump system)
Open-circuit voltage
12.8 V or more at 20 ˚C
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) front cowling inner panel (left)
• Troubleshoot with the following special tool(-s).
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EB802411
3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
YES
EB802400
NO
1.Main and ignition fuses
Replace the main
switch.
• Check the main and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
EB802412
4.Engine stop switch
NO
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
Replace the fuse(-s).
YES
NO
Replace the right
handlebar switch.
8 - 50
FUEL PUMP SYSTEM
ELEC
–
+
• Measure the fuel pump resistance.
5.Fuel pump relay
Fuel pump resistance
4 ~ 30 Ω at 20 ˚C
• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the relay unit terminals
as shown.
• Is the fuel pump OK?
YES
Battery positive terminal → red/black 1
Battery negative terminal → blue/red 2
NO
Replace the fuel
pump.
Tester positive probe → red/black 1
Tester negative probe → blue/black 3
EB808401
7.Wiring
• Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the fuel pump system’s wiring properly connected and without defects?
YES
• Does the fuel pump relay have continuity between red/black and blue/black?
Replace the ignitor
unit.
NO
YES
Replace
unit.
the
relay
EB808400
6.Fuel pump resistance
• Disconnect the fuel pump coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
fuel pump coupler (fuel pump side) as
shown.
Tester positive probe → black/blue 1
Tester negative probe → black 2
8 - 51
NO
Properly
connect
or repair the fuel
pump system’s wiring.
FUEL PUMP SYSTEM
ELEC
–
+
EB808410
CHECKING THE FUEL PUMP
WARNING
WARNING
Gasoline is extremely flammable and
under certain circumstances there can
be a danger of an explosion or fire. Be
extremely careful and note the following points:
• Stop the engine before refuelling.
• Do not smoke and keep away from
open flames, sparks or any other
source of fire.
• If you do accidentally spill gasoline,
wipe it up immediately with dry rags.
• If gasoline touches the engine when it
is hot, a fire may occur. Therefore,
make sure that the engine is completely cool before performing the following test.
1. Check:
• fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose into an
open container.
c. Connect the battery (12V) to the fuel
pump coupler as shown.
Battery positive lead → blue/black 1
Battery negative lead → black 2
d. If fuel flows out of the fuel hose, the
fuel pump is OK. If fuel does not flow,
replace the fuel pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 52
8 - 53
L
Br/L
Br/L
Br/L
Br/L
L/R Br/L L/Y
R
B
B
B
L
j
k
l
(Option)
m
n
Br
L
L
i
B
h
Br
B
B
B
B
B
B
B
(BLACK)
B
B
R/Y
Br
(BLACK)
B
L
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
R/W
R
Br/L
R
Br/L
B
B L/Y
L/R L
L/Y L/B
L L/R
3
Br
Y
B
R/Y
A
•
L Y
B
R/Y
B
A
Y L/R
R/Y
R/Y
Y
B
B B/Y
W/Y R/Y
B/Y
B
R/Y
W/Y
L/R
B
A
L/R
L/B
u
B
A
d
B
e
L/R
B
Br
G
B/W
L/R
B/L
B/Y
B
B/Y
Br
L/R
B
Br
G
B/Y
B/L B/L
—
[
B
B
e
G
W/Y W/G
Y
B
B
L/W
B
B
\
L/R
c
B
B
Ch
Ch
]
B/L
B
L/B
B
B
B
Dg
L/Y
B
b
B
B
Ch
O
O
Br/W
Br
B
B
Dg
Dg
Dg
b
Br/W
a
Br
Ch
A
OFF
Dg
Dg
A
B
B
C
(BLUE) (BLUE)
`
B
L/Y
G
B
(GREEN) (GREEN)
G/W
B
(BLACK) (BLACK)
c
Ch
L/Y
B
B
B
B/L
L/B
L/B
B/Y
Sb L/Y
0A
L/R R/B L/W
L/B L/Y Sb B/Y B
B
R/G
A
L
A
B/R G/W G/Y
A A A
R/L
Br
A
D
G/W
HEADLIGHT SUB-WIRE HARNESS
WIRE HARNESS
R/B
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
9
L/B
—
v
B/Y
A
Z
R/B
R/W
B/L
B/Y
B
L/R
B/L
B
R/Y
W/G
f
R/Y
Br/R
—
PASS
Y
Br/R
L
B B/L
W/G R/Y
A
f
L/B Br/W
R/Y
Br B
Br/W L/B
Br/R
B Br
Dg Y
Ch G
B/Y L/Y
X
Br
Br
s
t
L/W
R/W
(BLUE)
G/Y
R/Y
L
G/Y
L/B
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
B
B
8
7
6
(BLUE)
g
B
r
B
B
R
R
R R
L/W R/W
B
B
Y
L/R
(BROWN)
Br/R
L
L/B
(BROWN)
Br R/W
B R/B
B G/Y
B
5
R R R
R
q
Br
o
Br
W
W W
R/G
W/Y Dg
W/G O
L/Y B/Y
p
W
W
W
W
W W
R/L
4
W R/L
Br B
(BLACK)
W
W
W
(BROWN) (BROWN)
W
W
W
1 Main switch
5 Battery
6 Main fuse
E EXUP servomotor
G Ignitor unit
n Ignition fuse
P
OFF
ON
1
B
R
W W W
R
R/G
2
L
L
Dg
Ch
Y
N
Y
B/L
E
Y/L B/R
W/B B/Y
R/B
O
Gy
W
V
U
T
S
R
Q
P
O
F
B/L
L
Y
B/L
L
Gy W
W/R Y
B/Y
B/R
L/R
G/Y
B
B/L
G/R
W
L/Y
Y/B
Sb
Y
A
A
A
B/L
L
W/R
B
L
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Sb
A
L/Y
Y/B
B
B/L
G/R
L/Y
W
B/L
Y/B Sb
W
B
A
A
W
B
G
R/W
R/B
IGNITION COIL SUB-WIRE HARNESS
B
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
G/Y
G/W
R/G
B/R
Br
B/R L
B/Y B/L
WIRE HARNESS
R/B
O
Gy
L
B
B
M
B/L
G/R
B/L
L/Y W
B/W
P O/R
O/R
P
B/W
Gy
Gy
O
R/B
Gy
B/L
Gy
Sb
K
Gy
B
H
H
J
Sb
R/B
R/B
O
Gy
B/L
I
I
EXUP SYSTEM
ELEC
–
+
EB811000
EXUP SYSTEM
CIRCUIT DIAGRAM
EXUP SYSTEM
ELEC
–
+
EB811010
TROUBLESHOOTING
When the engine speed changes, the
EXUP servomotor does not operate.
Procedure 1
Check:
1. Exup servomotor operation
(with the EXUP servomotor coupler
connected to the wire harness)
2. voltage
3. Exup servomotor operation
4. (with the EXUP servomotor coupler
disconnected from the wire harness)
5. Exup servomotor resistance
6. wiring
(the entire EXUP system)
Procedure 2
Check:
1. main and ignition fuses
2. battery
3. main switch
4. engine stop switch
5. wiring
(the entire EXUP system)
• Does the EXUP servomotor pulley turn?
NO
YES
Check
that
the
EXUP cables are
properly installed.
If OK, check the
EXUP valve and
cables. Refer to
“ENGINE” in chapter 4.
EB811401
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
3) bottom cowling
• Troubleshoot with the following special tool(-s).
2.Voltage
• Connect the pocket tester (DC 20V) to
the EXUP servomotor coupler (wire harness side) as shown.
Tester positive probe → black/red 1
Tester negative probe → black/yellow 2
Pocket tester
90890-03112
EB811400
Procedure 1
1.EXUP servomotor operation (with the
EXUP servomotor coupler connected to
the wire harness)
• Disconnect the EXUP cables from the
EXUP servomotor pulley.
• Start the engine and rev it to 2,000 r/min.
• Set the main switch to “ON”.
• Measure the voltage (12V) between
black/red 1 and black/yellow 2 (wire
harness side).
• Is the voltage within specification?
YES
NO
Go to Procedure 2.
8 - 54
EXUP SYSTEM
ELEC
–
+
EB811402
3.EXUP servomotor operation (with the
servomotor coupler disconnected from
the wire harness)
• Disconnect the EXUP cables from the
EXUP servomotor pulley.
• Disconnect the EXUP servomotor coupler from the wire harness.
• Connect the battery leads to the EXUP
servomotor coupler (servomotor side)
as shown.
• Measure the EXUP servomotor resistance.
Battery positive terminal →
black/yellow 1
Battery negative terminal → black/red 2
EXUP servomotor resistance
5.3 ~ 9.8 kΩ
(between white/black and yellow/blue)
• Connect the pocket tester (Ω × 1k) to the
EXUP servomotor coupler.
Tester positive probe → white/black 1
Tester negative probe → white/red 3
• Check that the EXUP servomotor pulley
rotates several times.
CAUTION:
ACHTUNG:
To prevent damaging the EXUP servomotor, perform this test within a few seconds of connecting the battery.
• While slowly turning the EXUP servomotor pulley by hand, measure the
EXUP servomotor resistance.
• Does the EXUP servomotor pulley turn?
NO
YES
EXUP servomotor resistance
(when the pulley is turned one
full rotation)
0 ~ approximately 7.5 kΩ
(between
white/black
and
white/red)
Replace the EXUP
servomotor.
EB811403
4.EXUP servomotor resistance
• Is the EXUP servomotor OK?
• Disconnect the EXUP servomotor coupler from the wire harness.
• Connect the pocket tester (Ω × 1k) to the
EXUP servomotor coupler.
YES
NO
The EXUP servomotor is faulty and
must be replaced.
Tester positive probe → white/black 1
Tester negative probe → yellow/blue 2
8 - 55
EXUP SYSTEM
ELEC
–
+
EB802411
EB811404
5.Wiring
3.Main switch
• Check the entire EXUP system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the EXUP system’s wiring properly
connected and without defects?
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
YES
Replace the ignitor
unit.
NO
Replace the main
switch.
Properly
connect
or repair the EXUP
system’s wiring.
EB802412
4.Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
EB811410
Procedure 2
EB802400
1.Main and ignition fuses
YES
• Check the main and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
NO
Replace the right
handlebar switch.
NO
YES
EB811411
5.Wiring
Replace the fuse(-s).
• Check the entire EXUP system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the EXUP system’s wiring properly
connected and without defects?
EB802401
2.Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
YES
Open-circuit voltage
12.8 V or more at 20 ˚C
Go to “Procedure
1”.
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
8 - 56
NO
Properly
connect
or repair the EXUP
system’s wiring.
SELF-DIAGNOSIS
ELEC
–
+
EB812000
SELF-DIAGNOSIS
The YZF-R1 features a self-diagnosing system for the following circuit(-s):
• throttle position sensor
• EXUP
• fuel level indicator light
If any of these circuits are defective, their respective condition codes will be displayed on the
tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not)
Circuit
Throttle position sensor
Defect(-s)
• Disconnected
• Short-circuit
• Locked
•
•
EXUP
• Improper connection
• Short-circuit
•
•
• Servomotor is
locked.
•
•
Fuel level indi- • Improper connec- •
tion
cator light
System response
Condition code
The ignitor unit stays set to the 3,000 r/min
wide-open throttle ignition timing. The motorcycle can be ridden.
The tachometer displays the
condition code.
The EXUP valve stays in the 7,000 r/min
open position for three seconds
and then the servomotor shuts
off. The motorcycle can be ridden.
The tachometer displays the
condition code.
The servomotor’s power supply
is constantly interrupted so that
it will not burn out. The motorcycle can be ridden.
The tachometer displays the
condition code.
The tachometer displays the 8,000 r/min
condition code.
Tachometer display sequence
When more than one item is being monitored, the tachometer needle displays the condition
codes in ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
8 - 57
SELF-DIAGNOSIS
ELEC
–
+
EB812010
1.Wire harness
TROUBLESHOOTING
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
The tachometer starts to display the selfdiagnosis sequence.
Check:
1. throttle position sensor
2. Exup
3. fuel level indicator light
Repair or replace
the wire harness.
NOTE:
• Before troubleshooting, remove the
following part(-s):
1) rider seat
2) fuel tank
3) air filter case
• Troubleshoot with the following special tool(-s).
EB812401
2.Throttle position sensor
• Check the throttle position sensor for
continuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
• Is the throttle position sensor OK?
Pocket tester
90890-03112
EB812020
YES
1. Throttle position sensor
CIRCUIT DIAGRAM
R/B
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Gy W
W/R Y
B
Replace the ignitor
unit.
R/B
R/W
R/B
B
L
O
B
L/R
G/Y
B/R L
B/Y B/L
L
E
Y
B/L
Gy
B
Gy
G
L
W/R
B/L
B/L
F
L
O
R/B
B/Y
B/R
Y/L B/R
W/B B/Y
L
Y
Y
Gy
Gy
B/L
B/L
B
NO
YES
Y/B Sb
W
B
F Throttle position sensor
G Ignitor unit
8 - 58
NO
Replace the throttle position sensor.
SELF-DIAGNOSIS
EB812030
ELEC
–
+
EB812402
2. EXUP
CIRCUIT DIAGRAM
2.EXUP servomotor
R/B
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Gy W
W/R Y
B
• Check the EXUP servomotor for continuity.
Refer to “EXUP SYSTEM”.
• Is the EXUP servomotor OK?
R/B
R/W
B
L
O
B
L/R
G/Y
B/R L
B/Y B/L
L
E
Y
Gy
B
Replace the ignitor
unit.
G
G
L
W/R
B/L
B/L
F
L
YES
L
Y
B/L
Y
Gy
G
B
B/L
B
Y/B Sb
W
B
E EXUP servomotor
G Ignitor unit
EB812400
1.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES
NO
R
B/Y
B/R
Y/L B/R
W/B B/Y
O
NO
Repair or replace
the wire harness.
8 - 59
Replace the EXUP
servomotor.
SELF-DIAGNOSIS
EB812040
–
ELEC
+
EB812403
3. Fuel level indicator light
CIRCUIT DIAGRAM
1.Fuel level indicator light LED
• Check the LED of the fuel level indicator
light.
Refer to “CHECKING THE LEDs”.
• Is the fuel level indicator light LED OK?
A
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
WIRE HARNESS
HEADLIGHT SUB-WIRE HARNESS
NO
YES
R/B
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
Gy W
W/R Y
R R/B L/W
B L/Y Sb B/Y B
B
R/B
R/W
B
L
Repair the fuel level
indicator light LED.
O
L/R
G/Y
B/R L
B/Y B/L
B/Y
B/R
Y/L B/R
W/B B/Y
L
E
B/L
B
L/B
B
G/W
G/W
B
B/L
G
B
• Disconnect the fuel sender coupler from
the wire harness.
• Connect the pocket tester (W × 1) to the
fuel sender coupler as shown.
Gy
Y
L
Y
B/L
(GREEN) (GREEN)
D
L/Y
B
B
C
B
B
2.Fuel sender
B/L
F
Y
EB812404
B/L
(BLACK) (BLACK)
L
Gy
G
L
W/R
Y/B Sb
W
B
Tester positive probe → green 1
Tester negative probe → black 2
L/Y
B
(BLUE) (BLUE)
B
N
O
Br
a
Br/W
Br
P
A
Br
A
Br/W
R/L
Q
Br
R
R/G
A A A
`
Sb
A
Sb
Y/B
A
Y/B
L/Y
A
L/Y
B/R G/W G/Y
R/G
B/R
OFF
S
G/Y
G/W
Ch
W
G/R
B/L
T
O
A
U
G/R
B/L
L
• Check the fuel sender for continuity.
• Is the fuel sender OK?
M
Dg
L
O
Dg
Dg
Ch
Dg
B
B
B
b
B
W
A
A
B
V
Ch
A
Dg
c
O/
P
B/
Dg
Y
Dg
A
L/Y
W
B/L
A
L
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
Replace
sender.
b
B
NO
YES
A
W
B
D Fuel sender
G Ignitor unit
O Fuel level indicator light
S Combination meter
8 - 60
the
fuel
SELF-DIAGNOSIS
EB812405
3.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES
Replace the ignitor
unit.
NO
Replace or replace
the wire harness.
8 - 61
ELEC
–
+
ELEC
8 - 62
–
+
TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9.
TROUBLESHOOTING
STARTING PROBLEMS ................................................................................9-1
ENGINE .................................................................................................9-1
FUEL SYSTEM ......................................................................................9-1
ELECTRICAL SYSTEMS .......................................................................9-1
INCORRECT ENGINE IDLING SPEED ..........................................................9-2
ENGINE .................................................................................................9-2
FUEL SYSTEM ......................................................................................9-2
ELECTRICAL SYSTEMS .......................................................................9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................9-2
ENGINE .................................................................................................9-2
FUEL SYSTEM ......................................................................................9-2
FAULTY GEAR SHIFTING ............................................................................9-2
SHIFTING IS DIFFICULT .......................................................................9-2
SHIFT PEDAL DOES NOT MOVE .........................................................9-2
JUMPS OUT OF GEAR .........................................................................9-2
FAULTY CLUTCH ..........................................................................................9-3
CLUTCH SLIPS ......................................................................................9-3
CLUTCH DRAGS ...................................................................................9-3
OVERHEATING .............................................................................................9-3
ENGINE .................................................................................................9-3
COOLING SYSTEM ...............................................................................9-3
FUEL SYSTEM ......................................................................................9-3
CHASSIS ...............................................................................................9-3
ELECTRICAL SYSTEMS .......................................................................9-3
OVERCOOLING .............................................................................................9-3
COOLING SYSTEM ...............................................................................9-3
POOR BRAKING PERFORMANCE ...............................................................9-4
FAULTY FRONT FORK LEGS .......................................................................9-4
LEAKING OIL .........................................................................................9-4
MALFUNCTION ....................................................................................9-4
TRBL
SHTG
UNSTABLE HANDLING ................................................................................9-4
FAULTY LIGHTING AND SIGNALING SYSTEMS ......................................9-5
HEADLIGHT DOES NOT LIGHT ...........................................................9-5
HEADLIGHT BULB BURNT OUT ..........................................................9-5
TAIL/BRAKE LIGHT DOES NOT LIGHT ...............................................9-5
TAIL/BRAKE LIGHT BULB BURNT OUT ..............................................9-5
TURN SIGNAL DOES NOT LIGHT .......................................................9-5
TURN SIGNAL BLINKS SLOWLY ........................................................9-5
TURN SIGNAL REMAINS LIT ..............................................................9-5
TURN SIGNAL BLINKS QUICKLY ........................................................9-5
HORN DOES NOT SOUND ..................................................................9-5
STARTING PROBLEMS
TRBL
SHTG
EB900000
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING PROBLEMS
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel filter
• Clogged fuel tank breather hose
• Clogged rollover valve (California only)
• Clogged
rollover-valve-to-fuel-tank
hose (California only)
• Deteriorated or contaminated fuel
Fuel pump
• Faulty fuel pump
• Faulty fuel pump relay
Fuel cock
• Clogged or damaged fuel hose
Carburetors
• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Damaged float
• Worn needle valve
• Incorrectly installed needle valve seat
• Incorrect fuel level
• Incorrectly installed pilot jet
• Clogged starter jet
• Faulty starter plunger
• Incorrectly adjusted starter cable
ENGINE
Cylinders and cylinder head(-s)
• Loose spark plug
• Loose cylinder head
• Damaged cylinder head gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Incorrectly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
Pistons and piston rings
• Incorrectly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Incorrectly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Incorrectly assembled crankcase
• Seized crankshaft
ELECTRICAL SYSTEMS
Battery
• Faulty battery
• Discharged battery
Fuses
• Blown, damaged or incorrect fuse
• Incorrectly installed fuse
Spark plugs
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coils
• Damaged ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
Ignition system
• Faulty ignitor unit
• Faulty pickup coil
Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Incorrectly grounded circuit
• Loose connections
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cutoff relay
• Faulty starter clutch
9-1
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-ANDHIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING
TRBL
SHTG
EB901000
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinders and cylinder head
• Incorrect valve clearance
• Damaged valve train components
Air filter
• Clogged air filter element
ELECTRICAL SYSTEMS
Battery
• Faulty battery
• Discharged battery
Spark plugs
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coils
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Damaged ignition coil
Ignition system
• Faulty ignitor unit
• Faulty pickup coil
FUEL SYSTEM
Carburetors
• Faulty starter plunger
• Loose or clogged pilot jet
• Loose or clogged pilot air jet
• Damaged or loose carburetor joint
• Incorrectly synchronized carburetors
• Incorrectly adjusted engine idling
speed (throttle stop screw)
• Incorrect throttle cable free play
• Flooded carburetor
EB902000
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
• Clogged air filter element
FUEL SYSTEM
Carburetors
• Faulty diaphragm
• Incorrect fuel level
• Loose or clogged main jet
Fuel pump
• Faulty fuel pump
EB903000
FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Incorrectly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Incorrectly adjusted shift rod
• Bent shift shaft.
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission
gears
• Incorrectly assembled transmission
9-2
FAULTY CLUTCH/OVERHEATING/OVERCOOLING
TRBL
SHTG
EB904000
FAULTY CLUTCH
CLUTCH SLIPS
Clutch
• Incorrectly assembled clutch
• Incorrectly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
CLUTCH DRAGS
Clutch
• Unevenly tensioned clutch spring plate
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch pull rod
• Damaged clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EB905001
OVERHEATING
ENGINE
Clogged coolant passages
Cylinder head(-s) and piston(-s)
• Heavy carbon buildup
Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
FUEL SYSTEM
Carburetors
• Incorrect main jet setting
• Incorrect fuel level
• Damaged or loose carburetor joint
Air filter
• Clogged air filter element
CHASSIS
Brakes
• Dragging brake
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
Water pump
• Damaged or faulty water pump
Thermostat
• Thermostat stays closed
Oil cooler
• Clogged or damaged oil cooler
Hoses and pipes
• Damaged hose
• Incorrectly connected hose
• Damaged pipe
• Incorrectly connected pipe
ELECTRICAL SYSTEMS
Spark plugs
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty ignitor unit
EB906000
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
9-3
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK
LEGS/UNSTABLE HANDLING
TRBL
SHTG
EB907000
POOR BRAKING PERFORMANCE
•
•
•
•
•
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper piston seal
•
•
•
•
•
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
EB908001
FAULTY FRONT FORK LEGS
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
LEAKING OIL
• Bent, damaged or rusty inner tube
• Damaged outer tube
• Incorrectly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt
copper washer
• Damaged cap bolt O-ring
EB909001
UNSTABLE HANDLING
Handlebars
• Bent or incorrectly installed right handlebar
• Bent or incorrectly installed left handlebar
Steering head components
• Incorrectly installed upper bracket
• Incorrectly installed lower bracket
(incorrectly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork legs
• Unevenoil levels (both front fork legs)
• Unevenly tensioned fork spring (both
front fork legs)
• Damaged fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
Rear shock absorber assembly
• Faulty rear shock absorber spring
• Leaking oil or gas
Tires
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheels
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Incorrectly installed bearing race
9-4
FAULTY LIGHTING AND SIGNALING SYSTEMS
TRBL
SHTG
EB910000
FAULTY LIGHTING AND
SIGNALING SYSTEMS
TURN SIGNAL BLINKS SLOWLY
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Wrong turn signal bulb
HEADLIGHT DOES NOT LIGHT
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Incorrectly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal relay
• Burnt-out turn signal bulb
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Incorrectly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
TURN SIGNAL BLINKS QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal bulb
HORN DOES NOT SOUND
• Incorrectly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
TAIL/BRAKE LIGHT DOES NOT LIGHT
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light
switch
• Tail/brake light bulb life expired
TURN SIGNAL DOES NOT LIGHT
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Incorrectly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
9-5
TRBL
SHTG
9-6
YZF-R1 WIRING DIAGRAM
A
2
R/G
R/G
R
R
B
R/Y W/Y W Br G/W
Dg R/G L G/R
R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L
G/R L R/G Dg
G/W Br W W/Y R/Y
Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y
WIRE HARNESS
HEADLIGHT SUB-WIRE HARNESS
R/B
O
Gy
R/B
O
Gy
WIRE HARNESS
IGNITION COIL SUB-WIRE HARNESS
R R
L/W R/W
R R R
R/B
B
R/B
R/B
W
W
W
R
W
W
W
R
6
5
9
B
B
R
W W W
R
3
P
OFF
ON
L/Y L/B
L L/R
B L/Y
L/R L
R
Br/L
R
Br/L
W W
W
W
4
B
1
W W
7
B
B
B/L
B/R
B Y/B O
G/Y Sb B/Y R/W
L/R Gy
L/W
B
B
B
L
Br/L
B/R L
B/Y B/L
B/Y
B/R
Y/L B/R
W/B B/Y
L
R/W
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
m
B
B
G/W
B
B
B
B
W R/L
Br B
(BLACK)
R/L
R/B
R/W
r
Br
o
Br R/W
B R/B
B G/Y
W
(BROWN)
R/W Br
R/B B
G/Y L/W
(BROWN)
t
s
u
(BROWN)
(BLACK)
R/Y
L
G/Y
L/B
(BROWN)
Br
G/Y
Br
B
Br/R
L
W
N
B
L/B
O
Br/L
R/Y
a
W
j
p
Br
W/Y Dg
W/G O
L/Y B/Y
q
B
B
Br
Y
(BROWN) (BROWN)
B
L
Y
h
(BLACK)
B
R/Y
A
R/Y
R/Y
A
P
A
Br
Br/R
L/B
A
B/Y
Br
L/Y
Br/W
R/L
Br
i
L
B
L
Br/W
Br
\
X
Br
L
Dg Y
Ch G
B/Y L/Y
(BLUE)
(BLUE)
Br/W L/B
Br/R
B Br
L/B Br/W
R/Y
Br B
Y
Z
[
—
PASS
Y
A
G/Y
G/W
Ch
B
O
Y
Ch
A
Ch
Dg
A
B/L
L
B/L B/L
B/Y
B/Y
B/L
B/Y
B
L/R
e
e
B
g
L/R
B
B
U
A
d
Br
G
L/R
B
Ch
Dg
O
Dg
Ch
Dg
Ch
Dg
B
B
B
B
c
c
B
b
B
V
A
L
R/G B L/Y W B/L G/R B/R Y/B
Br G/W G/Y Sb Y Ch Dg L
b
B
B
B
Sb ..........sky blue
W ...........white
Y ............yellow
B/L .........black/blue
B/R .........black/red
B/W........black/white
B/Y .........black/yellow
Br/L ........brown/blue
Br/R .......brown/red
Br/W ......brown/white
B/L
L/Y W
M
B/L
W
G/R........ green/red
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/R........ orange/red
R/B ........ red/black
R/G........ red/green
R/L......... red/blue
R/W ....... red/white
R/Y ........ red/yellow
W/B ....... white/black
W/G....... white/green
W/Y ....... white/yellow
Y/B ........ yellow/black
Y/L......... yellow/blue
Sb
B/W
G/R
G/R
COLOR CODE
B ............black
Br...........brown
Ch ..........chocolate
Dg..........dark green
G............green
Gy..........gray
L ............blue
O............orange
P ............pink
R ............red
P O/R
W
A
A
B
B
Br
G
A
L
B/L
L/R
B/L
B/Y
B
L/Y
O/R
P
B/W
Dg
B/L
B
B
W
G/R
A
Sb
L/Y
W
B/L
Dg
A
L/R
B
Y/B
L/Y
S
f
B/Y
B
L Y
Sb
A
R/G
B/R
G
B B/L
W/G R/Y
A
A
T
R/Y
W/G
L/R
R
R/G
Sb
Y/B
B/R G/W G/Y
OFF
f
B
`
B
]
R/Y
W/Y
Y L/R
B/W
—
R/Y
B B/Y
W/Y R/Y
Q
Br
A A A
R/Y
W/Y W/G
Y
L/R
B
L/Y
B
Br
k
Y/B Sb
W
Br
Br/L
Gy
B/L
(BLUE) (BLUE)
B
Br/R
L
L/B
I
D
B
B
B
H
Gy
J
Gy
Y
L
Y
B
—
I
B/L
C
v
•
B/L
G
B
L/Y
B
Y
B
Gy
G
L
W/R
B/L
F
L
G/W
B
(GREEN) (GREEN)
B
B
l
L/B
B
H
B/L
(BLACK) (BLACK)
B
(Option)
B
B
B/L
B
B
B
Br/L
E
O
R/B
L/B
8
B/L
B
B
B
O
L/R
G/Y
B
n
R/B
B
L
L/R
Sb L/Y
B/Y
Gy W
W/R Y
L/R R/B L/W
L/B L/Y Sb B/Y B
0A
L/W
B
L/B
L/R Br/L L/Y
R/W
R/W
K
Gy
B
Gy
B/L
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
^
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
Main switch
Backup fuse (odometer)
Rectifier/regulator
Generator
Battery
Main fuse
Starter relay
Starter motor
Relay unit
Starting circuit cutoff relay
Fuel pump relay
Fuel pump
Sidestand switch
Fuel sender
EXUP servomotor
Throttle position sensor
Ignitor unit
Ignition coil
Spark plug
Pickup coil
Neutral switch
Speed sensor
Temperature sender
Meter assembly
Fuel level indicator light
Oil level warning light
Neutral indicator light
Tachometer
Combination meter
Coolant temperature meter
High beam indicator light
Turn signal indicator light
Meter light
Left handlebar switch
Pass switch
Dimmer switch
Horn switch
Horn
Clutch switch
Turn signal switch
Turn signal relay
Rear turn signal light
Front turn signal light
Headlight
Auxiliary light
Headlight relay
Tail/brake light
Radiator fan motor
Thermo switch
Radiator fan motor fuse
Headlight fuse
Signaling system fuse
CYCLELOCK (option)
Ignition fuse
Oil level relay
Oil level switch
Rear brake light switch
Right handlebar switch
Front brake light switch
Lights switch
Engine stop switch
Start switch
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