Yamaha YZF-R1 1998 Service manual

Yamaha YZF-R1 1998 Service manual
YZF-R1
’98
4XV1-AE1
SERVICE MANUAL
EB000000
YZF - R1
SERVICE MANUAL
1997 by Yamaha Motor Co., Ltd.
First edition, October 1997
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
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
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
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ELEC
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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
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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
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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
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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
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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
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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
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CHECKING THE BULBS AND BULB SOCKETS
ELEC
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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
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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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