2007 Yamaha XV1900 Roadliner & Stratoliner Service Manual

2007 Yamaha XV1900 Roadliner & Stratoliner Service Manual
Yamaha Service Manual
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XV19SW(C)
XV19W(C)
XV19MW(C)
XV19CTSW(C)
XV19CTW(C)
XV19CTMW(C)
SERVICE MANUAL
LIT-11616-20-40
1D7-28197-11
EAS20050
XV19SW(C)/XV19W(C)/XV19MW(C)/
XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C)
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First edition, July 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-20-40
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.
EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
1
2
3
4
5
6
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10. Gear oil
11. Molybdenum-disulfide oil
12. Wheel-bearing grease
13. Lithium-soap-based grease
14. Molybdenum-disulfide grease
15. Apply locking agent (LOCTITE®)
16. Replace the part
T.
R
7
8
9
10
E
12
11
13
B
15
M
G
14
M
LS
16
LT
New
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
FUEL SYSTEM
6
ELECTRICAL SYSTEM
7
TROUBLESHOOTING
8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER..................................................... 1-1
MODEL LABEL ......................................................................................... 1-1
FEATURES ..................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM................................................................. 1-2
FI SYSTEM ............................................................................................... 1-3
INSTRUMENT FUNCTIONS..................................................................... 1-4
IMPORTANT INFORMATION ......................................................................... 1-8
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-8
REPLACEMENT PARTS .......................................................................... 1-8
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-8
BEARINGS AND OIL SEALS.................................................................... 1-9
CIRCLIPS.................................................................................................. 1-9
CHECKING THE CONNECTIONS................................................................ 1-10
SPECIAL TOOLS.......................................................................................... 1-11
1
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
1
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame under
the rider seat. This information will be needed to
order spare parts.
1
1-1
FEATURES
EAS20170
FEATURES
ET1D71017
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum airfuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1
2
21 20 16
3
4 5 6 7 8
19 18
9 10
17 16 15
11
12
14 13
15. Lean angle sensor
16. Spark plug
17. Injector #1
18. Crankshaft position sensor
19. Injector #2
20. Cylinder-#2 right ignition coil
21. Cylinder-#2 left ignition coil
1. Air temperature sensor
2. ISC (idle speed control) unit
3. Cylinder-#2 intake air pressure sensor
4. Engine temperature sensor
5. Cylinder-#1 right ignition coil
6. Throttle position sensor
7. Cylinder-#1 left ignition coil
8. Cylinder-#1 intake air pressure sensor
9. Fuel pump
10. ECU (electronic control unit)
11. Relay unit (fuel pump relay)
12. EXUP servo motor
13. Speed sensor
14. O2 sensor
1-2
FEATURES
ET1D71018
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor,
engine temperature sensor, speed sensor and O2 sensor enable the ECU to determine the injection
duration. The injection timing is determined through the signals from the crankshaft position sensor. As
a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with
the driving conditions.
Illustration is for reference only.
6
7
1
A
8
C
2
5
3
#2 #1
4
9
10
15
B
14
13
11
12
13. Intake air pressure sensor
14. Throttle body
15. Air filter case
1. Pressure regulator
2. Fuel pump
3. Fuel injector
4. Ignition coil
5. ECU (electronic control unit)
6. Air temperature sensor
7. ISC (idle speed control) unit
8. Throttle position sensor
9. O2 sensor
10. Catalytic converter
11. Engine temperature sensor
12. Crankshaft position sensor
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
ET1D71036
INSTRUMENT FUNCTIONS
Multi-function meter unit
EW1D71008
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
1
2
4
3
1. Speedometer
2. Fuel gauge
3. Odometer/tripmeter/fuel reserve
tripmeter/clock
4. Tachometer
1. “SELECT” switch
2. “RESET” switch
Speedometer
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding speed)
• a tachometer (which shows the engine speed)
• a fuel gauge
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance traveled since they were last set to zero)
• a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve)
• a clock
• a self-diagnosis device
• a brightness control mode
1
1. Speedometer
The speedometer shows the riding speed.
When the key is turned to “ON”, the speedometer needle will sweep once across the speed
range and then return to zero in order to test the
electrical circuit.
NOTE:
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” switches, except for
setting the brightness control mode.
• To switch the odometer, the tripmeters and the
fuel reserve tripmeter displays between kilometers and miles, press the “SELECT” switch
for at least two seconds. (For USA and California only)
1-4
FEATURES
Tachometer
• The fuel gauge does not indicate the correct
fuel level for the first 5 km/h (3 mi/h) after refueling.
Odometer, tripmeter, and clock modes
1
2
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal
power range.
When the key is turned to “ON”, the tachometer
needle will sweep once across the r/min range
and then return to zero r/min in order to test the
electrical circuit.
1
1. Odometer/tripmeter/fuel reserve
tripmeter/clock
Push the “SELECT” switch to switch the display
between the odometer mode “ODO”, the tripmeter modes “TRIP 1” and “TRIP 2” and the clock
mode in the following order:
ODO → TRIP 1 → TRIP 2 → Clock → ODO
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
point. In that case, push the “SELECT” switch to
switch the display between the various tripmeter, odometer, and clock modes in the following
order:
F-TRIP → TRIP 1 → TRIP 2 → Clock → ODO →
F-TRIP
To reset a tripmeter, select it by pushing the “SELECT” switch, and then push the “RESET”
switch for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically, and the display will return to
the prior mode after refueling and traveling 5 km
(3 mi).
EC1D71017
CAUTION:
Do not operate the engine in the tachometer
red zone.
Red zone: 5000 r/min and above
Fuel gauge
1
1. Fuel gauge
The fuel gauge indicates the amount of fuel in
the fuel tank. The needle moves towards “E”
(Empty) as the fuel level decreases. When the
needle reaches “E”, approximately 3.0 L (0.79
US gal) (0.66 Imp.gal) remain in the fuel tank. If
this occurs, refuel as soon as possible.
When the key is turned to “ON”, the fuel gauge
needle will sweep once across the fuel level
range and then return to the current amount in
order to test the electrical circuit.
Clock mode
NOTE:
• Do not allow the fuel tank to empty itself completely.
1. Clock
1-5
FEATURES
Select the brightness control mode as follows.
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” switch.
3. Turn the key to “ON”, and then release the
“SELECT” switch after five seconds.
Item number “1” is displayed.
To set the clock:
1. Push the “SELECT” switch to change the display to the clock mode.
2. Push the “SELECT” and “RESET” switches
together for at least two seconds.
3. When the hour digits start flashing, push the
“RESET” switch to set the hours.
4. Push the “SELECT” switch, and the minute
digits will start flashing.
5. Push the “RESET” switch to set the minutes.
6. Push the “SELECT” switch and then release
it to start the clock.
1
2
Self-diagnosis device
This model is equipped with a self-diagnosis device for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
odometer/tripmeter/clock display will indicate a
two-digit error code (e.g., 12, 13, 14).
If the odometer/tripmeter/clock display indicates
any error codes, note the code number, and
then check the vehicle. Refer to “FUEL INJECTION SYSTEM” on page 7-27.
3
1. Multi-function meter unit panel
2. Item number
3. Brightness level
4. Adjust the multi-function meter unit panel
brightness level by pushing the “RESET”
switch.
5. Push the “SELECT” switch to select the LCD.
Item number “2” is displayed.
Adjust the LCD brightness level by pushing
the “RESET” switch.
EC1D71018
CAUTION:
If the display indicates an error code, the vehicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
1
1
3
3
4
5
1. LCD
2. Item number
3. Brightness level
2
1.
2.
3.
4.
5.
2
6. Push the “SELECT” switch to select the
speedometer, tachometer, and the fuel
gauge needles.
Item number “3” is displayed.
Adjust the brightness level of the speedometer, tachometer, and the fuel gauge needles
by pushing the “RESET” switch.
Multi-function meter unit panel
LCD
Speedometer needle
Tachometer needle
Fuel gauge needle
The brightness can be adjusted for the following:
• the multi-function meter unit panel (item number “1”)
• the LCD (item number “2”)
• the speedometer, tachometer, and the fuel
gauge needles (item number “3”)
1-6
FEATURES
1
2
3
4
5
1.
2.
3.
4.
5.
Speedometer needle
Tachometer needle
Fuel gauge needle
Item number
Brightness level
7. Push the “SELECT” switch.
The odometer/tripmeter/clock display will return to the prior mode.
1-7
IMPORTANT INFORMATION
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-11.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mated” through normal wear. Mated parts must
always be reused or replaced as an assembly.
1.
2.
3.
4.
Oil
Lip
Spring
Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-8
IMPORTANT INFORMATION
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-9
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
3. Check:
• All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
1-10
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No.
Illustration
Reference
pages
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-10, 5-79,
7-73, 7-74,
7-75, 7-79,
7-80, 7-81,
7-82, 7-83,
7-84, 7-85,
7-86, 7-87,
7-88, 7-89,
7-90, 7-91
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3-6, 5-61
Tappet adjusting tool (4 mm)
90890-04133
Valve adjustment wrench 3 mm & 4 mm
YM-08035-A
3-6, 3-7
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
3-7
YU-44456
1-11
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-10
Oil filter wrench
90890-01426
YU-38411
3-12
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
3-24
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
3-26, 4-71
Damper rod holder
90890-01460
4-64, 4-66
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-64, 4-66
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
4-66, 4-67
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
5-12
Valve spring compressor
90890-04019
YM-04019
5-39, 5-44
1-12
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
5-40
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
5-40
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-40
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-46
YU-01304
Universal clutch holder
90890-04086
YM-91042
5-60, 5-65
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-60, 5-64,
5-74, 5-75
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
5-66, 5-76,
5-93
1-13
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Rotor puller
90890-01080
Stator rotor puller
YM-01080-A
5-74
Vacuum/pressure pump gauge set
90890-06756
6-12
Pressure gauge
90890-03153
6-12
Fuel pressure adapter
90890-03176
YM-03176
6-12
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
6-12
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
7-83
1-14
SPECIAL TOOLS
1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS............................................................................ 2-2
CHASSIS SPECIFICATIONS........................................................................ 2-10
ELECTRICAL SPECIFICATIONS................................................................. 2-13
TIGHTENING TORQUES.............................................................................. 2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16
ENGINE TIGHTENING TORQUES......................................................... 2-17
CHASSIS TIGHTENING TORQUES....................................................... 2-22
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-27
ENGINE .................................................................................................. 2-27
CHASSIS ................................................................................................ 2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS ................................... 2-31
ENGINE OIL LUBRICATION CHART ..................................................... 2-31
LUBRICATION DIAGRAMS .................................................................... 2-33
CABLE ROUTING......................................................................................... 2-45
2
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model
XV19SW 1D74 (USA)
XV19SW 1D76 (CDN)
XV19SWC 1D75 (California)
XV19W 4D45 (USA)
XV19W 4D47 (CDN)
XV19WC 4D46 (California)
XV19MW 4D54 (USA)
XV19MW 4D56 (CDN)
XV19MWC 4D55 (California)
XV19CTSW 2C54 (USA)
XV19CTSW 2C56 (CDN)
XV19CTSWC 2C55 (California)
XV19CTW 4P04 (USA)
XV19CTW 4P06 (CDN)
XV19CTWC 4P05 (California)
XV19CTMW 4P14 (USA)
XV19CTMW 4P16 (CDN)
XV19CTMWC 4P15 (California)
Dimensions
Overall length
Overall width
Overall height
2580 mm (101.6 in)
1100 mm (43.3 in)
XV19S(C)/XV19(C)/XV19M(C):
1100 mm (43.3 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
1515 mm (59.6 in)
735 mm (28.9 in)
1715 mm (67.5 in)
155 mm (6.10 in)
3480 mm (137.0 in)
Seat height
Wheelbase
Ground clearance
Minimum turning radius
Weight
With oil and fuel
XV19S(C)/XV19(C)/XV19M(C):
340.0 kg (750 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
364.0 kg (802 lb)
XV19S(C)/XV19(C)/XV19M(C):
210 kg (463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
186 kg (410 lb)
Maximum load
2-1
ENGINE SPECIFICATIONS
EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Starting system
Air cooled 4-stroke, OHV
1854.0 cm³
V-type 2-cylinder
100.0 × 118.0 mm (3.94 × 4.65 in)
9.48 :1
Electric starter
Fuel
Recommended fuel
Fuel tank capacity
Fuel reserve amount
Premium unleaded gasoline only
17.0 L (4.49 US gal) (3.74 Imp.gal)
3.0 L (0.79 US gal) (0.66 Imp.gal)
Engine oil
Lubrication system
Type
Recommended engine oil grade
Dry sump
YAMALUBE 4 (20W40) or SAE20W40
API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount
Engine
Oil tank
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
5.20 L (5.50 US qt) (4.58 Imp.qt)
3.2 L (3.38 US qt) (2.82 Imp.qt)
2.0 L (2.11 US qt) (1.76 Imp.qt)
4.10 L (4.33 US qt) (3.61 Imp.qt)
4.90 L (5.18 US qt) (4.31 Imp.qt)
60.0 kPa/900 r/min (8.7 psi/900 r/min) (0.60
kgf/cm²/900 r/min)
Transfer gear oil
Type
Quantity (disassembled)
Quantity
SAE80 API GL-4 Hypoid gear oil
0.60 L (0.63 US qt) (0.53 Imp.qt)
0.55 L (0.58 US qt) (0.48 Imp.qt)
Oil filter
Oil filter type
Cartridge (paper)
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Bypass valve opening pressure
Trochoid
Less than 0.12 mm (0.0047 in)
0.20 mm (0.0079 in)
0.09–0.19 mm (0.0035–0.0075 in)
0.26 mm (0.0102 in)
0.06–0.13 mm (0.0024–0.0051 in)
0.20 mm (0.0079 in)
80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20
kgf/cm²)
600.0 kPa (87.0 psi) (6.00 kgf/cm²)
Relief valve operating pressure
Transfer gear oil pump
Oil pump type
Trochoid
2-2
ENGINE SPECIFICATIONS
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Less than 0.12 mm (0.0047 in)
0.20 mm (0.0079 in)
0.10–0.15 mm (0.0039–0.0059 in)
0.22 mm (0.0087 in)
0.04–0.09 mm (0.0016–0.0035 in)
0.160 mm (0.0063 in)
Spark plug (s)
Manufacturer/model
Manufacturer/model
Spark plug gap
NGK/DPR8EA-9
DENSO/X24EPR-U9
0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume
Warpage limit
80.90–84.90 cm³ (4.94–5.18 cu.in)
0.03 mm (0.0012 in)
Camshaft
Drive system
Crankcase hole inside diameter
Camshaft journal diameter (crankcase side)
Camshaft to crankcase clearance
Camshaft cover hole inside diameter
Camshaft journal diameter (camshaft cover side)
Camshaft to camshaft cover clearance
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
2-3
Gear drive
25.000–25.021 mm (0.9843–0.9851 in)
24.957–24.980 mm (0.9826–0.9835 in)
0.020–0.064 mm (0.0008–0.0025 in)
28.000–28.021 mm (1.1024–1.1032 in)
27.957–27.980 mm (1.1007–1.1016 in)
0.020–0.064 mm (0.0008–0.0025 in)
42.532–42.632 mm (1.6745–1.6784 in)
42.432 mm (1.6705 in)
35.950–36.050 mm (1.4154–1.4193 in)
35.850 mm (1.4114 in)
42.530–42.630 mm (1.6744–1.6783 in) (cylinder
#1)
42.531–42.631 mm (1.6744–1.6784 in) (cylinder
#2)
42.430 mm (1.6705 in) (cylinder #1)
42.431 mm (1.6705 in) (cylinder #2)
35.950–36.050 mm (1.4154–1.4193 in)
35.850 mm (1.4114 in)
ENGINE SPECIFICATIONS
A
B
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Limit
Rocker arm shaft outside diameter
Rocker-arm-to-rocker-arm-shaft clearance
Limit
18.000–18.018 mm (0.7087–0.7094 in)
18.036 mm (0.7101 in)
17.976–17.991 mm (0.7077–0.7083 in)
0.009–0.042 mm (0.0004–0.0017 in)
0.080 mm (0.0032 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A (intake)
Valve head diameter A (exhaust)
0.00–0.04 mm (0.0000–0.0016 in)
0.00–0.04 mm (0.0000–0.0016 in)
35.90–36.10 mm (1.4134–1.4213 in)
30.90–31.10 mm (1.2165–1.2244 in)
A
Valve seat width C (intake)
Limit
Valve seat width C (exhaust)
Limit
1.10–1.30 mm (0.0433–0.0512 in)
2.0 mm (0.08 in)
1.10–1.30 mm (0.0433–0.0512 in)
2.0 mm (0.08 in)
C
Valve margin thickness D (intake)
Limit
Valve margin thickness D (exhaust)
Limit
1.15–1.45 mm (0.0453–0.0571 in)
0.4 mm (0.02 in)
1.15–1.45 mm (0.0453–0.0571 in)
0.4 mm (0.02 in)
D
Valve stem diameter (intake)
Limit
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
5.975–5.990 mm (0.2352–0.2358 in)
5.945 mm (0.2341 in)
5.960–5.975 mm (0.2346–0.2352 in)
5.920 mm (0.2331 in)
6.000–6.012 mm (0.2362–0.2367 in)
6.050 mm (0.2382 in)
2-4
ENGINE SPECIFICATIONS
Valve guide inside diameter (exhaust)
Limit
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide clearance (exhaust)
Limit
Valve stem runout
Valve spring
Free length (intake)
Limit
Free length (exhaust)
Limit
Installed length (intake)
Installed length (exhaust)
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Installed compression spring force (intake)
6.000–6.012 mm (0.2362–0.2367 in)
6.050 mm (0.2382 in)
0.010–0.037 mm (0.0004–0.0015 in)
0.080 mm (0.0032 in)
0.025–0.052 mm (0.0010–0.0020 in)
0.100 mm (0.0039 in)
0.010 mm (0.0004 in)
Spring tilt (intake)
Spring tilt (exhaust)
46.71 mm (1.84 in)
44.71 mm (1.76 in)
46.71 mm (1.84 in)
44.71 mm (1.76 in)
32.66 mm (1.29 in)
32.66 mm (1.29 in)
16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)
21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)
16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)
21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)
217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)
217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)
2.5 °/2.0 mm
2.5 °/2.0 mm
Winding direction (intake)
Winding direction (exhaust)
Clockwise
Clockwise
Installed compression spring force (exhaust)
Valve lifter
Valve lifter outside diameter (intake)
Valve lifter outside diameter (exhaust)
Valve lifter hole inside diameter (intake)
Valve lifter hole inside diameter (exhaust)
Valve-lifter-to-valve-lifter-hole clearance
22.962–22.974 mm (0.9040–0.9045 in)
22.962–22.974 mm (0.9040–0.9045 in)
23.000–23.021 mm (0.9055–0.9063 in)
23.000–23.021 mm (0.9055–0.9063 in)
0.026–0.059 mm (0.0010–0.0023 in)
Valve push rod
Valve push rod 1 length
Valve push rod 2 length
286.5 mm (11.280 in)
288.5 mm (11.358 in)
2-5
ENGINE SPECIFICATIONS
Valve push rod runout
0.3 mm (0.012 in)
Cylinder
Bore
Taper limit
Out of round limit
100.000–100.010 mm (3.9370–3.9374 in)
0.050 mm (0.0020 in)
0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance
Limit
Diameter D
Height H
0.025–0.050 mm (0.0010–0.0020 in)
0.15 mm (0.0059 in)
99.960–99.975 mm (3.9354–3.9360 in)
10.0 mm (0.39 in)
H
D
Offset
Piston pin bore inside diameter
Limit
Piston pin outside diameter
Limit
Piston-pin-to-piston-pin-bore clearance
Limit
0.50 mm (0.0197 in)
23.004–23.015 mm (0.9057–0.9061 in)
23.045 mm (0.9073 in)
22.991–23.000 mm (0.9052–0.9055 in)
22.971 mm (0.9044 in)
0.004–0.024 mm (0.00016–0.00094 in)
0.074 mm (0.00291 in)
Piston ring
Top ring
Ring type
Dimensions (B × T)
Barrel
1.20 × 3.80 mm (0.05 × 0.15 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
2nd ring
Ring type
Dimensions (B × T)
0.20–0.35 mm (0.0079–0.0138 in)
0.55 mm (0.0217 in)
0.030–0.080 mm (0.0012–0.0032 in)
0.120 mm (0.0047 in)
Taper
1.20 × 4.00 mm (0.05 × 0.16 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
0.45–0.60 mm (0.0177–0.0236 in)
0.95 mm (0.0374 in)
0.030–0.070 mm (0.0012–0.0028 in)
0.120 mm (0.0047 in)
2-6
ENGINE SPECIFICATIONS
Oil ring
Dimensions (B × T)
2.50 × 3.40 mm (0.10 × 0.13 in)
B
T
End gap (installed)
0.20–0.70 mm (0.0079–0.0276 in)
Connecting rod
Oil clearance (using plastigauge®)
Bearing color code
0.050–0.074 mm (0.0020–0.0029 in)
1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Crankshaft
Width A
Runout limit C
Big end side clearance D
Big end radial clearance E
Limit
105.80–106.20 mm (4.165–4.181 in)
0.040 mm (0.0016 in)
0.320–0.474 mm (0.0126–0.0187 in)
0.037–0.074 mm (0.0015–0.0029 in)
0.09 mm (0.0035 in)
Journal oil clearance (using plastigauge®)
Limit
0.030–0.060 mm (0.0012–0.0024 in)
0.10 mm (0.0039 in)
Clutch
Clutch type
Clutch release method
Operation
Friction plate 1, 3 thickness
Wear limit
Plate quantity
Friction plate 2 thickness
Wear limit
Plate quantity
Clutch plate thickness
Plate quantity
Warpage limit
Clutch spring free length
Minimum length
Spring quantity
Clutch housing thrust clearance
Clutch housing radial clearance
Wet, multiple-disc
Hydraulic inner push
Left hand operation
2.90–3.10 mm (0.114–0.122 in)
2.80 mm (0.110 in)
10 pcs
2.92–3.08 mm (0.115–0.121 in)
2.82 mm (0.111 in)
1 pcs
1.90–2.10 mm (0.075–0.083 in)
10 pcs
0.20 mm (0.0079 in)
6.78 mm (0.27 in)
6.28 mm (0.25 in)
1 pcs
0.100–0.110 mm (0.0039–0.0043 in)
0.020–0.066 mm (0.0008–0.0026 in)
Transmission
Transmission type
Constant mesh 5-speed
2-7
ENGINE SPECIFICATIONS
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratio
1st
2nd
3rd
4th
5th
Main axle runout limit
Drive axle runout limit
Spur gear
72/51 (1.412)
Belt drive
70/31 (2.258)
Left foot operation
38/16 (2.375)
33/21 (1.571)
29/25 (1.160)
26/28 (0.929)
24/30 (0.800)
0.08 mm (0.0032 in)
0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type
Shift fork guide bar bending limit
Shift fork thickness
Guide bar
0.025 mm (0.0010 in)
6.26–6.39 mm (0.2465–0.2516 in)
Air filter
Air filter element
Oil-coated paper element
Fuel pump
Pump type
Model/manufacturer
Maximum consumption amperage
Output pressure
Electrical
1D7/MITSUBISHI
5.5 A
441.0–637.0 kPa (63.9–92.4 psi) (4.41–6.37
kgf/cm²)
Fuel injection
Model/quantity
Manufacturer
INP-101/2
NIPPON INJECTOR
Throttle body
Type/quantity
Manufacturer
ID mark
AC43/2
MIKUNI
XV19M/XV19S/XV19/XV19CTM/
XV19CTS/XV19CT:
1D71 00
XV19MC/XV19SC/XV19C/XV19CTMC/
XV19CTSC/XV19CTC:
1D72 10
#100
Throttle valve size
Throttle position sensor
Resistance
Output voltage (at idle)
4.0–6.0 kΩ/blue-black
0.63–0.73 V
Fuel injection sensor
Crankshaft position sensor resistance
Intake air pressure sensor output voltage
Engine temperature sensor resistance
248–372 Ω
3.75–4.25 V
0.90–1.10 kΩ at 100 °C (212 °F)
2-8
ENGINE SPECIFICATIONS
Idling condition
Engine idling speed
Intake vacuum
850–950 r/min
31.3–35.3 kPa (9.3–10.4 inHg) (235–265
mmHg)
80.0–90.0 °C (176.00–194.00 °F)
4.0–6.0 mm (0.16–0.24 in)
Oil temperature
Throttle cable free play
2-9
CHASSIS SPECIFICATIONS
EAS20300
CHASSIS SPECIFICATIONS
Chassis
Frame type
Caster angle
Trail
Double cradle
31.20 °
152.0 mm (5.98 in)
Front wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Cast wheel
18M/C × MT4.00
Aluminum
130.0 mm (5.12 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
Rear wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Cast wheel
17M/C × MT5.50
Aluminum
110.0 mm (4.33 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
Front tire
Type
Size
Manufacturer/model
Manufacturer/model
Wear limit (front)
Tubeless
130/70R18M/C 63H
DUNLOP/D251F
BRIDGESTONE/G851 RADIAL G
1.0 mm (0.04 in)
Rear tire
Type
Size
Manufacturer/model
Manufacturer/model
Wear limit (rear)
Tubeless
190/60R17M/C 78H
DUNLOP/D251
BRIDGESTONE/G850 RADIAL G
1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)
Loading condition
Front
Rear
Loading condition
0–90 kg (0–198 lb)
250 kPa (36 psi) (2.50 kgf/cm²)
280 kPa (41 psi) (2.80 kgf/cm²)
XV19S(C)/XV19(C)/XV19M(C):
90–210 kg (198–463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
90–186 kg (198–410 lb)
250 kPa (36 psi) (2.50 kgf/cm²)
280 kPa (41 psi) (2.80 kgf/cm²)
Front
Rear
High-speed riding
Front
Rear
250 kPa (36 psi) (2.50 kgf/cm²)
280 kPa (41 psi) (2.80 kgf/cm²)
2-10
CHASSIS SPECIFICATIONS
Front brake
Type
Operation
Front disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Dual disc brake
Right hand operation
298.0 × 5.0 mm (11.73 × 0.20 in)
4.5 mm (0.18 in)
0.10 mm (0.0039 in)
5.5 mm (0.22 in)
0.5 mm (0.02 in)
5.5 mm (0.22 in)
0.5 mm (0.02 in)
14.00 mm (0.55 in)
27.00 mm (1.06 in)
30.23 mm (1.19 in)
DOT 4
Rear brake
Type
Operation
Brake pedal position
Rear disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
320.0 × 6.0 mm (12.60 × 0.24 in)
5.5 mm (0.22 in)
0.15 mm (0.0059 in)
5.8 mm (0.23 in)
0.8 mm (0.03 in)
5.8 mm (0.23 in)
0.8 mm (0.03 in)
12.7 mm (0.50 in)
41.30 mm (1.63 in)
DOT 4
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Taper roller bearing
35.0 °
35.0 °
Front suspension
Type
Spring/shock absorber type
Front fork travel
Fork spring free length
Limit
Collar length
Installed length
Spring rate K1
Spring stroke K1
Spring rate K2
Spring stroke K2
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Telescopic fork
Coil spring/oil damper
130.0 mm (5.12 in)
273.9 mm (10.78 in)
268.4 mm (10.57 in)
230.0 mm (9.06 in)
268.9 mm (10.59 in)
10.0 N/mm (57.1 lb/in) (1.02 kgf/mm)
0.0–30.0 mm (0.00–1.18 in)
12.0 N/mm (68.5 lb/in) (1.22 kgf/mm)
30.0–130.0 mm (1.18–5.12 in)
46.0 mm (1.81 in)
0.2 mm (0.01 in)
No
Single disc brake
Right foot operation
110.0 mm (4.33 in)
2-11
CHASSIS SPECIFICATIONS
Recommended oil
Quantity
Level
Fork oil 10WT
571.0 cm³ (19.31 US oz) (20.10 Imp.oz)
124.0 mm (4.88 in)
Rear suspension
Type
Spring/shock absorber type
Rear shock absorber assembly travel
Spring free length
Limit
Installed length
Swingarm (link suspension)
Coil spring/gas-oil damper
50.0 mm (1.97 in)
180.0 mm (7.09 in)
176.4 mm (6.94 in)
XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in)
176.50 N/mm (1007.82 lb/in) (18.00 kgf/mm)
0.0–50.0 mm (0.00–1.97 in)
No
0.98 MPa (139.4 psi) (9.8 kgf/cm²)
Installed spring length
162.0 mm (6.38 in)
XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in)
171.0 mm (6.73 in)
Spring rate K1
Spring stroke K1
Optional spring available
Enclosed gas/air pressure (STD)
Spring preload adjusting positions
Minimum
Standard
Maximum
Swingarm
Swingarm end free play limit (radial)
Swingarm end free play limit (axial)
1.0 mm (0.04 in)
1.0 mm (0.04 in)
Drive belt
Model/manufacturer
Drive belt slack (on the sidestand)
Drive belt slack (on a suitable stand)
UBD-0732/GATES CORPORATION
7.5–13 mm (0.30–0.51 in)
14–21 mm (0.55–0.83 in)
2-12
ELECTRICAL SPECIFICATIONS
EAS20310
ELECTRICAL SPECIFICATIONS
Voltage
System voltage
12 V
Ignition system
Ignition system
Advancer type
Ignition timing (B.T.D.C.)
Transistorized coil ignition (digital)
Electrical
10.0 °/900 r/min
Engine control unit
Model/manufacturer
F008T83271/MITSUBISHI
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
2JN/MORIC
6.0 mm (0.24 in)
2.16–2.64 Ω
8.64–12.96 kΩ
Spark plug cap
Material
Resistance
Resin
10.0 kΩ
AC magneto
Model/manufacturer
Standard output
Stator coil resistance
F4T38971/MITSUBISHI
14.0 V 32.0 A 5000 r/min
0.112–0.168 Ω
Rectifier/regulator
Regulator type
Model/manufacturer
No load regulated voltage
Rectifier capacity
Withstand voltage
Semi conductor-short circuit
FH012AA/SHINDENGEN
14.2–14.8 V
50.0 A
40.0 V
Battery
Model
Voltage, capacity
Manufacturer
Ten hour rate amperage
GT14B-4
12 V, 12.0 Ah
GS YUASA
1.20 A
Headlight
Bulb type
Halogen bulb
Bulb voltage, wattage × quantity
Low beam headlight
High beam headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
License plate light
Meter lighting
12 V, 51.0 W × 1
12 V, 55.0 W × 1
LED
12 V, 23 W/8.0 W × 2
12 V, 21.0 W × 2
12 V, 5.0 W
LED
2-13
ELECTRICAL SPECIFICATIONS
Indicator light
Neutral indicator light
Turn signal indicator light
High beam indicator light
Fuel level warning light
Engine trouble warning light
LED
LED
LED
LED
LED
Electric starting system
System type
Constant mesh
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Commutator diameter
Limit
Mica undercut (depth)
1D7/MORIC
0.90 kW
0.0081–0.0099 Ω
9.8 mm (0.39 in)
5.00 mm (0.20 in)
7.36–11.04 N (26.49–39.74 oz) (750–1126 gf)
28.5 mm (1.12 in)
27.5 mm (1.08 in)
1.50 mm (0.06 in)
Starter relay
Model/manufacturer
Amperage
Coil resistance
2768079-A/JIDECO
180.0 A
4.18–4.62 Ω
Horn
Horn type
Quantity
Model/manufacturer
Maximum amperage
Coil resistance
Performance
Eddy
2 pcs
YP-12/NIKKO
2.0 A
0.94–0.98 Ω
95–115 dB/2m
Turn signal relay
Relay type
Model/manufacturer
Built-in, self-canceling device
Turn signal blinking frequency
Wattage
Semi transistor
FB246H/DENSO
Yes
75.0–95.0 cycles/min
21(23) W × 2 + LED × 2
Fuel gauge
Model/manufacturer
Sender unit resistance (full)
Sender unit resistance (empty)
1D7/YAMAHA
9–11 Ω
213–219 Ω
Starting circuit cut-off relay
Model/manufacturer
Coil resistance
G8R-30Y-V3/OMRON
162–198 Ω
Headlight relay
Model/manufacturer
ACM33211M05/MATSUSHITA
2-14
ELECTRICAL SPECIFICATIONS
Fuel pump relay
Model/manufacturer
Coil resistance
G8R-30Y-V3/OMRON
162–198 Ω
Thermo unit
Model/manufacturer
Resistance at 100°C
5PX/DENSO
898.4–1098.0 Ω
Fuses
Main fuse
Headlight fuse
Taillight fuse
Signaling system fuse
Ignition fuse
Auxiliary DC connector fuse
ECU fuse
Fuel injection system fuse
Backup fuse
Reserve fuse
Reserve fuse
Reserve fuse
Reserve fuse
Reserve fuse
50.0 A
20.0 A
10.0 A
10.0 A
25.0 A
3.0 A
10.0 A
15.0 A
10.0 A
25.0 A
20.0 A
15.0 A
10.0 A
3.0 A
2-15
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require clean, dry threads. Components should be
at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt)
General tightening
torques
Nm
m·kg
ft·lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
2-16
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Cylinder head nut
M12
8
60 Nm (6.0 m·kg, 43 ft·lb)
Cylinder head stud bolt (exhaust
pipe)
M8
4
15 Nm (1.5 m·kg, 11 ft·lb)
Spark plug
M12
4
18 Nm (1.8 m·kg, 13 ft·lb)
Engine temperature sensor
—
1
20 Nm (2.0 m·kg, 14 ft·lb)
Rocker arm base bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rocker arm base bolt
M8
8
24 Nm (2.4 m·kg, 17 ft·lb)
Cylinder head cover bolt
M6
28
10 Nm (1.0 m·kg, 7.2 ft·lb)
Connecting rod bolt (1st)
M8
4
15 Nm (1.5 m·kg, 11 ft·lb)
Remarks
E
See
NOTE.
M
Connecting rod bolt (final)
M8
4
Specified angle 125–135°
See
NOTE.
M
Right balancer driven gear bolt
M10
1
40 Nm (4.0 m·kg, 29 ft·lb)
E
Left balancer drive gear bolt
M10
1
40 Nm (4.0 m·kg, 29 ft·lb)
E
Left balancer driven gear housing
screw
M6
6
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Left balancer weight bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Left balancer idle gear shaft bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft driven gear bolt
M10
1
60 Nm (6.0 m·kg, 43 ft·lb)
E
Camshaft drive gear bolt
M10
1
60 Nm (6.0 m·kg, 43 ft·lb)
E
Front cylinder camshaft gear bolt
M10
1
40 Nm (4.0 m·kg, 29 ft·lb)
E
Locknut (rocker arm adjusting
screw)
M7
4
20 Nm (2.0 m·kg, 14 ft·lb)
Valve lifter case bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil filter bolt
M18
1
70 Nm (7.0 m·kg, 50 ft·lb)
Oil filter cartridge
M20
1
17 Nm (1.7 m·kg, 12 ft·lb)
Oil pipe 1 union bolt
M10
2
21 Nm (2.1 m·kg, 15 ft·lb)
Oil pipe 1 union bolt
M8
1
18 Nm (1.8 m·kg, 13 ft·lb)
Oil filter bracket bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil pipe bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil delivery pipe 2 bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil pump driven gear
stopper bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pipe 3 bolt
M6
5
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump bolt (crankcase)
M8
3
24 Nm (2.4 m·kg, 17 ft·lb)
2-17
LT
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Oil pipe 2 bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pipe 4 bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump housing cover 1 screw
(crankcase)
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Oil pump housing cover 2 screw
(crankcase)
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Throttle body joint clamp screw
M5
2
3 Nm (0.3 m·kg, 2.2 ft·lb)
Pressure regulator bolt
M5
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Intake manifold assembly bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel pipe bolt
M12
2
30 Nm (3.0 m·kg, 22 ft·lb)
Rear exhaust pipe joint nut
M8
2
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe, rear exhaust
pipe joint cover and rear exhaust
pipe joint nut
M8
2
24 Nm (2.4 m·kg, 17 ft·lb)
Front exhaust pipe nut
M8
2
20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear exhaust pipe bolt
M8
1
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe and muffler
bolt
M8
1
20 Nm (2.0 m·kg, 14 ft·lb)
Locknut (EXUP cable)
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
EXUP valve pulley cover bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear exhaust pipe joint cover bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Muffler and muffler bracket bolt
M8
3
29 Nm (2.9 m·kg, 21 ft·lb)
Muffler bracket and frame bolt
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
O2 sensor
M18
1
44 Nm (4.4 m·kg, 32 ft·lb)
Crankcase stud bolt
M12
8
See NOTE.
Crankcase bolt
M6
21
10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt
M8
3
24 Nm (2.4 m·kg, 17 ft·lb)
Oil baffle plate bolt (left crankcase)
M6
6
10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase stud bolt
M10
1
See NOTE.
Nozzle
M6
4
0.5 Nm (0.05 m·kg, 0.36 ft·lb)
Oil gallery screw
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Bearing housing bolt (torque limiter)
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil gallery bolt
M8
4
20 Nm (2.0 m·kg, 14 ft·lb)
LT
Engine oil drain bolt (crankcase)
M14
2
43 Nm (4.3 m·kg, 31 ft·lb)
Stator coil lead holder screw
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Crankshaft position sensor lead
holder screw
M6
6
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
2-18
LT
E
LT
E
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Clutch cover damper plate screw
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft cover bolt
M6
8
10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator damper cover bolt
M5
3
5 Nm (0.5 m·kg, 3.6 ft·lb)
Engine oil filler plug
M20
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft sprocket cover plate
bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil baffle plate bolt (right crankcase)
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Clutch cover plate bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Generator cover bolt
M6
10
10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft sprocket cover bolt
M6
8
10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch cover bolt
M6
18
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil gallery bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch damper cover plate bolt
M5
3
5 Nm (0.5 m·kg, 3.6 ft·lb)
Clutch damper cover bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter clutch bolt
M8
6
24 Nm (2.4 m·kg, 17 ft·lb)
Generator rotor bolt
M12
1
80 Nm (8.0 m·kg, 58 ft·lb)
Starter motor bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Primary drive gear bolt
M12
1
100 Nm (10.0 m·kg, 72 ft·lb)
Clutch boss nut
M20
1
105 Nm (10.5 m·kg, 75 ft·lb)
Clutch spring plate retainer bolt
M6
6
8 Nm (0.8 m·kg, 5.8 ft·lb)
Bleed screw (clutch release cylinder)
M8
1
6 Nm (0.6 m·kg, 4.3 ft·lb)
Clutch release cylinder bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive axle bearing retainer screw
M8
2
20 Nm (2.0 m·kg, 14 ft·lb)
Main axle bearing retainer screw
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil drain bolt (oil tank)
M14
1
43 Nm (4.3 m·kg, 31 ft·lb)
Transfer gear oil drain bolt
M8
1
18 Nm (1.8 m·kg, 13 ft·lb)
Middle drive gear nut
M22
1
140 Nm (14.0 m·kg, 100 ft·lb)
LT
LT
LT
E
E
Stake
E
Stake
LT
Stake
E
Transfer gear case oil pump assembly nut
M10
1
40 Nm (4.0 m·kg, 29 ft·lb)
Transfer gear case oil pump assembly bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump housing screw (transfer
gear case)
M5
2
4 Nm (0.4 m·kg, 2.9 ft·lb)
Transfer gear oil check bolt
M6
1
8 Nm (0.8 m·kg, 5.8 ft·lb)
Transfer gear case bolt
M10
4
50 Nm (5.0 m·kg, 36 ft·lb)
2-19
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Dipstick joint bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive pulley case bolt
M10
8
70 Nm (7.0 m·kg, 50 ft·lb)
Oil strainer bolt (oil tank)
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil pipe 5 bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Transfer gear case cover plate
bolt
M6
3
5 Nm (0.5 m·kg, 3.6 ft·lb)
Transfer gear case cover bolt
M6
12
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil tank cover bolt
M6
15
10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil tank bracket bolt
M8
2
28 Nm (2.8 m·kg, 20 ft·lb)
Shift shaft spring stopper bolt
M8
1
22 Nm (2.2 m·kg, 16 ft·lb)
LT
Stopper lever bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Crankshaft position sensor screw
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Neutral switch screw
M6
2
4 Nm (0.4 m·kg, 2.9 ft·lb)
LT
Stator coil screw
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Neutral switch lead clamp screw
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Speed sensor bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Oil cooler bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Oil cooler bracket bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Oil cooler hose bolt
M6
8
7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch hose union bolt
M10
2
30 Nm (3.0 m·kg, 22 ft·lb)
Clutch pipe union bolt
M10
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch pipe holder bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch pipe joint nut
M10
1
19 Nm (1.9 m·kg, 13 ft·lb)
LT
NOTE:
• Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach
the specified angle 125–135°.
• Install the crankcase stud bolts (M12) so that their installed length is 141.5 mm (5.57 in).
• Install the crankcase stud bolts (M10) so that their installed length is 70.5 mm (2.78 in).
2-20
TIGHTENING TORQUES
Cylinder head tightening sequence:
B
A
1
3
2
1
4
3
A. Front cylinder
B. Rear cylinder
2-21
4
2
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Engine mounting bolt (left upper
side)
M12
2
66 Nm (6.6 m·kg, 48 ft·lb)
Engine mounting bolt (right upper
side)
M12
2
59 Nm (5.9 m·kg, 43 ft·lb)
Engine mounting nut (rear upper
side)
M12
1
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting spacer bolt
M18
1
18 Nm (1.8 m·kg, 13 ft·lb)
Engine bracket bolt (left upper
side)
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
Engine bracket bolt (right upper
side)
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
Engine bracket nut (rear upper
side)
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
Engine mounting nut (front upper
side)
M12
1
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting nut (rear lower
side)
M12
1
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting nut (front lower
side)
M12
1
105 Nm (10.5 m·kg, 75 ft·lb)
Engine bracket nut (front upper
side)
M10
4
53 Nm (5.3 m·kg, 38 ft·lb)
Engine cross-member bracket
bolt
M10
2
30 Nm (3.0 m·kg, 22 ft·lb)
Engine bracket nut (left rear lower side)
M10
3
58 Nm (5.8 m·kg, 42 ft·lb)
Engine bracket bolt (right rear
lower side)
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
Transfer gear case bracket and
transfer gear case bolt
M10
2
63 Nm (6.3 m·kg, 45 ft·lb)
Transfer gear case bracket and
frame bolt
M10
2
53 Nm (5.3 m·kg, 38 ft·lb)
Cylinder-#1 ignition coil bolt
M6
4
7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder-#2 ignition coil bolt
M6
4
7 Nm (0.7 m·kg, 5.1 ft·lb)
Lean angle sensor bolt
M4
2
2 Nm (0.2 m·kg, 1.4 ft·lb)
Horn bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
ISC (idle speed control) unit bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
ISC (idle speed control) unit
bracket bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Pivot shaft nut
M18
1
125 Nm (12.5 m·kg, 90 ft·lb)
Relay arm nut (relay arm and
swingarm)
M12
1
59 Nm (5.9 m·kg, 43 ft·lb)
2-22
Remarks
LT
E
LT
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Relay arm nut (relay arm and
connecting arm)
M12
1
59 Nm (5.9 m·kg, 43 ft·lb)
Rear shock absorber assembly
nut (rear side)
M10
1
40 Nm (4.0 m·kg, 29 ft·lb)
Rear shock absorber assembly
nut (front side)
M12
1
59 Nm (5.9 m·kg, 43 ft·lb)
Upper drive belt cover bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Lower drive belt cover bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose guide bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Upper bracket pinch bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Headlight cover bolt
M6
4
7 Nm (0.7 m·kg, 5.1 ft·lb)
Headlight bracket and throttle cable guide bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Headlight body bolt
M6
3
7 Nm (0.7 m·kg, 5.1 ft·lb)
Steering stem nut
M28
1
115 Nm (11.5 m·kg, 85 ft·lb)
Upper handlebar holder bolt
M8
4
28 Nm (2.8 m·kg, 20 ft·lb)
Lower ring nut (initial tightening
torque)
M30
1
52 Nm (5.2 m·kg, 37 ft·lb)
See
NOTE.
Lower ring nut (final tightening
torque)
M30
1
18 Nm (1.8 m·kg, 13 ft·lb)
See
NOTE.
Hose guide and lower handlebar
holder nut
M10
2
32 Nm (3.2 m·kg, 23 ft·lb)
Front brake master cylinder holder bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Front brake hose union bolt (front
brake master cylinder side)
M10
2
30 Nm (3.0 m·kg, 22 ft·lb)
Clutch master cylinder holder bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Grip end
M16
2
23 Nm (2.3 m·kg, 17 ft·lb)
Lower handlebar holder nut
M10
2
50 Nm (5.0 m·kg, 36 ft·lb)
LT
Upper bracket cover bolt
M8
2
19 Nm (1.9 m·kg, 13 ft·lb)
LT
Upper bracket cover bolt
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
LT
Front brake hose guide and front
brake hose guide bracket bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Front brake hose guide and lower
bracket bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Front brake hose joint bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Bolt (lower bracket hole)
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Front fender stay bolt
M6
4
7 Nm (0.7 m·kg, 5.1 ft·lb)
LT
Front fender bolt
M8
6
16 Nm (1.6 m·kg, 11 ft·lb)
LT
Fuel sender bolt
M5
4
4 Nm (0.4 m·kg, 2.9 ft·lb)
2-23
LT
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Fuel tank bracket bolt (front side)
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Fuel tank bracket nut (rear side)
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Sub-fuel tank bolt
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rider seat bracket bolt
M8
2
23 Nm (2.3 m·kg, 17 ft·lb)
Fuel tank and fuel tank bracket
bolt (front side)
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank and fuel tank bracket
bolt (rear side)
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Meter cover bolt
M6
3
7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel pump bolt
M5
6
5 Nm (0.5 m·kg, 3.6 ft·lb)
Fuel return pipe holder bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Air filter case bracket bolt
M8
3
16 Nm (1.6 m·kg, 11 ft·lb)
Canister bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Front wheel axle
M18
1
72 Nm (7.2 m·kg, 52 ft·lb)
Front wheel axle pinch bolt
M8
1
23 Nm (2.3 m·kg, 17 ft·lb)
Rear wheel axle nut
M18
1
150 Nm (15.0 m·kg, 110 ft·lb)
Locknut (drive belt adjusting bolt)
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Front brake caliper bolt
M10
4
40 Nm (4.0 m·kg, 29 ft·lb)
Front brake hose union bolt (front
brake caliper side)
M10
2
32 Nm (3.2 m·kg, 23 ft·lb)
Rear brake caliper bolt
M10
2
27 Nm (2.7 m·kg, 19 ft·lb)
Front brake disc bolt
M6
12
23 Nm (2.3 m·kg, 17 ft·lb)
LT
Rear brake disc bolt
M6
6
18 Nm (1.8 m·kg, 13 ft·lb)
LT
Bleed screw (front brake caliper)
M8
2
6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (rear brake caliper)
M7
1
6 Nm (0.6 m·kg, 4.3 ft·lb)
Rear wheel pulley nut
M12
5
95 Nm (9.5 m·kg, 68 ft·lb)
Left side cover and sub-fuel tank
bracket bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Left side cover bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Seat lock cable assembly bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Lead holder bracket bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Right side cover bolt
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter motor lead bolt (starter
relay side)
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Positive battery lead bolt (starter
relay side)
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear fender bracket and frame
bolt
M10
4
40 Nm (4.0 m·kg, 29 ft·lb)
2-24
LT
For California
only
LS
LT
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Rear fender bracket and frame
bolt
M10
2
40 Nm (4.0 m·kg, 29 ft·lb)
Rear fender bracket and rear
fender bolt
M8
4
23 Nm (2.3 m·kg, 17 ft·lb)
Passenger seat bolt
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Rider seat bracket assembly and
seat lock assembly bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Tool kit and battery box bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Pressure regulator bracket bolt
M6
2
13 Nm (1.3 m·kg, 9.4 ft·lb)
Cylinder-#1 ignition coil cover
bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder-#1 ignition coil bracket
bolt
M6
2
7 Nm (0.7 m·kg, 5.1 ft·lb)
License plate bolt
M8
3
16 Nm (1.6 m·kg, 11 ft·lb)
Sidestand bolt
M10
2
63 Nm (6.3 m·kg, 45 ft·lb)
LT
Rider footrest assembly bolt (left
and right)
M10
4
48 Nm (4.8 m·kg, 35 ft·lb)
LT
Passenger footrest bolt (left and
right)
M10
4
48 Nm (4.8 m·kg, 35 ft·lb)
LT
Rear brake master cylinder
bracket and rear brake master
cylinder bolt
M8
2
23 Nm (2.3 m·kg, 17 ft·lb)
Rear brake master cylinder
bracket and frame bolt
M8
2
23 Nm (2.3 m·kg, 17 ft·lb)
Rear brake master cylinder cover
bolt
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Brake fluid reservoir and frame
bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose union bolt
M10
2
30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake hose holder bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
Shift pedal shaft bracket bolt
M8
2
16 Nm (1.6 m·kg, 11 ft·lb)
Locknut (shift rod)
M8
2
12 Nm (1.2 m·kg, 8.7 ft·lb)
Shift arm bolt
M6
1
12 Nm (1.2 m·kg, 8.7 ft·lb)
Shift pedal bolt (toe side)
M6
1
18 Nm (1.8 m·kg, 13 ft·lb)
Shift pedal bolt (heel side)
M6
1
13 Nm (1.3 m·kg, 9.4 ft·lb)
Lower bracket pinch bolt
M8
4
23 Nm (2.3 m·kg, 17 ft·lb)
Cap bolt
M43
2
23 Nm (2.3 m·kg, 17 ft·lb)
Damper rod assembly
M12
2
40 Nm (4.0 m·kg, 29 ft·lb)
LT
Lower front fork cover bolt
M6
4
7 Nm (0.7 m·kg, 5.1 ft·lb)
LT
Drive pulley nut
M22
1
140 Nm (14.0 m·kg, 100 ft·lb)
Drive pulley cover damper plate
screw
M6
3
10 Nm (1.0 m·kg, 7.2 ft·lb)
2-25
LT
LT
Stake
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Drive pulley cover bolt
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rectifier/regulator cover bolt
M6
6
10 Nm (1.0 m·kg, 7.2 ft·lb)
Lead cover bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rectifier/regulator bolt
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive pulley cover plate bolt
M6
3
5 Nm (0.5 m·kg, 3.6 ft·lb)
Wire harness guide bolt
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
LT
Throttle cable guide bolt (upper
side)
M6
1
7 Nm (0.7 m·kg, 5.1 ft·lb)
LT
Throttle cable guide bolt (lower
side)
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rear shock absorber locknut
M50
1
30 Nm (3.0 m·kg, 22 ft·lb)
Windshield holder bracket assembly bolt*
M8
4
30 Nm (3.0 m·kg, 22 ft·lb)
Windshield holder nut*
M8
4
23 Nm (2.3 m·kg, 17 ft·lb)
Windshield bracket brace nut*
M6
4
10 Nm (1.0 m·kg, 7.2 ft·lb)
Windshield brace nut*
M6
6
10 Nm (1.0 m·kg, 7.2 ft·lb)
Windshield lock nut*
M24
1
12 Nm (1.2 m·kg, 8.7 ft·lb)
Windshield lock cover nut*
M6
1
8 Nm (0.8 m·kg, 5.8 ft·lb)
Backrest upper bracket and backrest lower bracket bolt*
M8
4
23 Nm (2.3 m·kg, 17 ft·lb)
Backrest pad and backrest upper bracket bolt*
M6
1
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Backrest pad and backrest upper bracket stay bolt*
M6
2
10 Nm (1.0 m·kg, 7.2 ft·lb)
LT
Backrest lock nut*
M24
1
12 Nm (1.2 m·kg, 8.7 ft·lb)
Passenger footrest and sidebag
bracket bolt (left and right)*
M10
4
47 Nm (4.7 m·kg, 34 ft·lb)
Sidebag bracket bolt*
M8
4
23 Nm (2.3 m·kg, 17 ft·lb)
Sidebag bracket brace nut*
M8
2
23 Nm (2.3 m·kg, 17 ft·lb)
LT
* For XV19CTS(C), XV19CT(C) and XV19CTM(C)
NOTE:
1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then
loosen the lower ring nut completely.
2. Retighten the lower ring nut to 18 Nm (1.8 m·kg, 13 ft·lb) with a torque wrench.
2-26
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20370
ENGINE
Lubrication point
Lubricant
Oil seal lips
LS
O-rings
LS
Bearings
E
Cylinder head nuts and washers
E
Connecting rod small end and big end
E
Crankshaft journals
M
Piston surfaces
E
Piston pins
E
Connecting rod bolts
M
Balancer idle gear inner surface and balancer idle gear shaft
E
Left balancer driven gear inner surface
M
Right balancer
M
Gasket (left balancer driven gear housing)
LS
Flange bolts (left balancer drive gear and right balancer driven gear)
E
Camshaft cam lobes and camshaft journals
M
Flange bolt (camshaft gear)
E
Valve push rod end balls
E
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
E
Valve lifters
E
Rocker arms
E
Rocker arm shafts
E
Camshaft (front and rear cylinders)
E
Oil pump rotors (inner and outer) and oil pump housing
LS
Oil pump driven gear shaft
E
Crankcase stud bolt ends
E
Starter clutch idle gear shaft
E
Starter clutch idle gear inner surface
E
Starter clutch gear inner surface and outer surface
E
Generator shaft journal
E
2-27
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Primary driven gear inner surface
E
Clutch push rods and ball
LS
Clutch boss nut and washer
E
Transmission gears (wheel and pinion) and collar
M
Drive pulley nut and washer
E
Shift forks and shift fork guide bars
E
Shift drum
E
Shift shaft and shift shaft oil seal
LS
Shift fork pawl
M
Crankcase mating surface
Yamaha bond
No.1215 (Three Bond
No.1215®)
Stator coil lead grommet
Yamaha bond
No.1215 (Three Bond
No.1215®)
Crankshaft position sensor lead grommet
Yamaha bond
No.1215 (Three Bond
No.1215®)
2-28
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20380
CHASSIS
Lubrication point
Lubricant
Steering bearings and upper bearing dust cover lip
LS
Lower bearing dust seal lip
LS
Front wheel oil seal lips (left and right)
LS
Rear wheel oil seal lips
LS
Rear wheel drive hub oil seal lip
LS
Rear wheel drive hub mating surface
LS
Tube guide (throttle grip) inner surface and throttle cables
LS
Brake lever pivoting point and metal-to-metal moving parts
LS
Clutch lever pivoting point and metal-to-metal moving parts
LS
Brake pedal shaft pivoting point
LS
Shift pedal pivoting point
LS
Passenger footrest pivoting point and ball
LS
Sidestand pivoting point and metal-to-metal moving parts
LS
Dowel pins (rear fender stay)
LS
Pivot shaft
LS
Swingarm pivoting point, collar flange circumference, and oil seal inner
surface
LS
Rear shock absorber bushings and O-rings
LS
Swingarm, relay arm bearings, and oil seal lips
LS
Connecting arm bushings and O-rings
LS
Rear wheel axle
LS
Clutch master cylinder push rod pin and contact surface
LS
2-29
LUBRICATION POINTS AND LUBRICANT TYPES
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20400
ENGINE OIL LUBRICATION CHART
22
21
20
23
19
18
17
16
15
9
8
14
11
14
9
12
10
13
7
8
6
5
4
2
3
1
2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil strainer (transfer gear case)
2. Oil pump
3. Oil tank
4. Drive axle
5. Main axle
6. Oil strainer (crankcase)
7. Balancer
8. Front cylinder head cover
9. Rear cylinder head cover
10. Rear cylinder camshaft
11. Front cylinder camshaft
12. Rear valve lifter case
13. Front valve lifter case
14. Push rod
15. Crankshaft
16. Camshaft sprocket cover
17. Generator shaft
18. Generator cover
19. Left crankcase
20. Oil filter cartridge bracket
21. Oil filter cartridge
22. Right crankcase
23. Oil cooler
2-32
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20410
LUBRICATION DIAGRAMS
9
2
10
A-A
B-B
A
3
4
B
D
A
1
B
8
E
E
C
D
7
5
6
8
4
5
D-D
11
E-E
2-33
C
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil tank
2. Dipstick
3. Oil pipe 2
4. Oil delivery pipe 1
5. Oil filter cartridge
6. Oil delivery pipe 2
7. Oil pipe 3
8. Oil pipe 4
9. Oil pipe 5
10. Oil strainer (oil tank)
11. Oil delivery pipe 3
2-34
LUBRICATION SYSTEM CHART AND DIAGRAMS
3
3
A
A
4
2
6
7
D
C
C
B
D
1
B-B
5
B
6
7
D-D
2-35
C-C
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
6.
7.
Valve lifter
Push rod
Rocker arm shaft
Oil pipe 1
Crankshaft
Oil pipe (“F” mark)
Oil pipe (“R” mark)
2-36
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
A
A
2
3
4
A-A
2-37
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
Oil pipe 1
Oil pump
Oil strainer (crankcase)
Joint pipe
2-38
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
2
A
4
3
2-39
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
A.
Main axle
Drive axle
Oil strainer (crankcase)
Oil pump
To the oil filter cartridge
2-40
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
5
B
B-B
5
B
A
A
1
A
2
4
3
2-41
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
A.
Oil pipe 5
Transfer gear oil pump
Oil strainer (transfer gear case)
Middle drive shaft
Oil strainer (oil tank)
From the oil pump
2-42
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
2
2-43
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Transfer gear oil pump
2. Middle driven shaft
2-44
CABLE ROUTING
EAS20430
CABLE ROUTING
1
5
5
6
7
B-B
C
D-D
C-C
2
A
3
D
4
5
1
1
A
A
5
E
6
C
B
D
E
C
B
7
D B
F
5
F
1
6
7
6
7
F-F
G
E
F
11
8
10
9
2-45
CABLE ROUTING
1. Clutch hose
2. Right handlebar switch lead
3. Main switch
4. Left handlebar switch lead
5. Front brake hose
6. Throttle cable (decelerator cable)
7. Throttle cable (accelerator cable)
8. Horn 1 lead
9. Horn 1
10. Rear brake light switch
11. Rear brake light switch lead
A. Cross the left and right handlebar switch leads.
Either lead can be routed on top.
B. 70 mm (2.76 in)
C. 5–25°
D. 10–30°
E. Fasten the rear brake light switch lead with the
plastic locking tie. Face the end of the plastic
locking tie inward, and then cut off the excess end
of the tie.
F. Make sure that there is no slack in the rear brake
light switch lead in the area shown in the illustration.
G. Fasten the rear brake light switch lead with the
plastic locking tie. Face the end of the plastic
locking tie downward, and then cut off the excess
end of the tie.
2-46
CABLE ROUTING
A
1
5
4
9
G
2
10
B
C
E
3
D
I
G
E
F
6
G
8
F
J
H
F
7
11
E
A
2
B
B
1
D
C
B-B
D
4
A
1
2
C
8
6
2
12
3
1
2
K
3
G-G
F-F
D-D
L
E-E
2-47
CABLE ROUTING
1. Main switch lead
2. Right handlebar switch lead
3. Wire harness
4. Left handlebar switch lead
5. Air temperature sensor lead
6. Front left turn signal/position light lead
7. Headlight lead
8. Front right turn signal/position light lead
9. Headlight coupler (high beam)
10. Headlight coupler (low beam)
11. Air temperature sensor
12. Main switch
A. View with headlight lens unit removed.
B. Place the joint coupler behind the leads.
C. Place the sections of the handlebar switch leads
that are not covered by their protective sleeves in
the rear of the headlight housing.
D. Fasten the headlight leads, front turn
signal/position light leads, and accessory light lead
with the holders along the side of the headlight
housing.
E. Place the headlight leads, front turn signal/position
light leads, and accessory light lead near the base
of the holder.
F. 30 mm (1.18 in)
G. View from rear of headlight lens unit
H. Less than 20 mm (0.79 in). Fasten the headlight
lead (low beam) with the holder, making sure to
fasten the protective sleeve of the lead, not the lead
itself.
I. Route the headlight lead (high beam) between the
headlight coupler (low beam) and the stay.
J. Route the headlight lead (high beam) behind the
headlight lead (low beam).
K. Secure the plastic band by inserting the projection
on the band into the hole in the headlight housing.
L. Face the end of the plastic band downward.
2-48
CABLE ROUTING
R
T
R
3
A-A
U
S
S
4
B-B
T
R
3
20 21
U
T
R
3
C-C
10
4
8
7
11
T
4
3
D-D
G
9
C D
A B
5
4
6 B C
A
3
E
D
F
D
C
B
2
A
E
Q
12
M
J
J
J
K
L
1
F
F
N
13
14
H
19
18
H
I
I
G
P
H
G
O
17
16 15
O
24
22 23
V
14
14
14
G-G
H-H
W
AE
F-F
V
X
25 Y
AF
K
26
AD
27 Y
AH
K
J-J
Z AC AB
14
AG
28
I
2-49
E
AA
Z
CABLE ROUTING
J. Fasten the wire harness and the cylinder-#2 left
and right spark plug leads with a plastic locking tie,
making sure to install the tie just past the end of the
protective tube of the wire harness. Face the end of
the plastic locking tie inward, and then cut off the
excess end of the tie.
K. To the throttle position sensor
L. To the fuel injector and engine temperature sensor
M. To the neutral switch
N. To the speed sensor
O. Fasten the stator coil lead with the plastic locking
ties. Face the end of each plastic locking tie
outward, and then cut off the excess end of the tie.
P. To the rear brake caliper
Q. Install the O2 sensor coupler completely onto the
O2 sensor bracket.
1. EXUP servo motor
2. Fuse box
3. Wire harness
4. Fuel outlet hose
5. Cylinder-#1 right spark plug cap
6. Cylinder-#1 right ignition coil
7. Cylinder-#2 intake air pressure sensor coupler
8. Fuel sender (fuel tank) coupler
9. Meter assembly coupler
10. Throttle cable
11. Front brake hose
12. Cylinder-#2 right spark plug cap
13. Cylinder-#1 left ignition coil
14. Clutch pipe
15. Neutral switch lead
16. Stator coil lead
17. Speed sensor lead
18. O2 sensor lead
R. Outside of the frame
S. Position the buckle of the plastic locking tie to the
inside of the frame. Face the end of the plastic
locking tie upward, and then cut off the excess end
of the tie.
T. Inside of the frame
U. Position the buckle of the plastic locking tie to the
inside of the frame.
V. To the wire harness
W. To the cylinder-#2 right spark plug
X. Right side
Y. Position the sub-wire harness 3 coupler and the
sub-wire harness 4 coupler between the cylinder#2 right spark plug lead and the cylinder-#1 ISC
unit outlet hose.
Z. Face the ends of the hose clamp outward, angled
45° downward.
AA.Route the cylinder-#2 right spark plug lead under
the sub-wire harness 4.
AB.Face the ends of the hose clamp downward.
AC.Route the cylinder-#2 left spark plug lead under the
cylinder-#2 ISC unit outlet hose.
AD.Left side
AE.To the cylinder-#2 left spark plug
AF. Install the clutch pipe onto the clutch release
cylinder, making sure that the pipe contacts the
projection on the cylinder.
AG.To the O2 sensor
19. EXUP cable
20. Cylinder-#1 right spark plug lead
21. Cylinder-#1 left spark plug lead
22. ISC (idle speed control) unit inlet hose
23. Cylinder-#2 ISC (idle speed control) unit outlet
hose
24. Cylinder-#1 ISC (idle speed control) unit outlet
hose
25. Sub-wire harness 3 coupler
26. Cylinder-#2 right spark plug lead
27. Sub-wire harness 4 coupler
28. Cylinder-#2 left spark plug lead
A. Fasten the cylinder-#1 left and right spark plug
leads, fuel outlet hose, wire harness and the fuel
tank damper with the plastic locking tie. Install the
plastic locking tie in the rear slot of the fuel tank
damper.
B. Fasten the fuel outlet hose, wire harness, and fuel
tank damper with the plastic locking tie. Install the
plastic locking tie in the front slot of the fuel tank
damper and make sure that the end of the damper
is aligned with the edge of the flat section on the
outside of the frame.
C. Fasten the cylinder-#1 left and right ignition coil
leads, engine temperature sensor lead, and throttle
position sensor lead to the guide on the engine
bracket (right upper side) with the plastic locking tie.
Face the end of the plastic locking tie rearward, and
then cut off the excess end of the tie.
D. Fasten sub-wire harness 2 with the plastic locking
tie.
E. Align the positioning tape on the wire harness with
the top of the frame.
F. 0–15 mm (0–0.59 in)
G. Route the throttle cables behind the front brake
hose.
H. Make sure that the wire harness is not twisted
between the fuel tank and the headlight assembly.
I. Position the cylinder-#2 left and right spark plug
leads, sub-wire harness 2 coupler and sub-wire
harness 4 coupler on top of the guide.
AH.Align the cutout in the clutch pipe union bolt cap
with the projection on the clutch release cylinder.
2-50
CABLE ROUTING
1
D
C
A
A B 2 3 4
B
A
5
E
B
F
6 G
H
21
G
C
C
G
F
20
22
19
7
18 U
8
T
17
I
J
D
9
S
P
R 16 Q
26
27
28
29
D
30
E
L 11
O N 14 N M 13 12
15
31
K
32
10
24
18
AB
15
25
16
23
33
AA
D-D
H
H
24
AC
W
X
AA
V
A-A
3
2
AD
1
Y
Z
E
F
36
B-B
34
16
1
15
D
35
S
R
Q
D
18
G-G
C-C
O
2-51
CABLE ROUTING
K. Fasten the stator coil lead and rectifier/regulator
lead with the plastic locking tie. Face the end of the
plastic locking tie outward, and then cut off the
excess end of the tie.
L. Fasten the lean angle sensor lead, starter motor
lead, horn 1 lead, rear brake light switch lead, and
sidestand switch lead with the holder.
M. Route the starter motor lead, horn 1 lead, rear
brake light switch lead, and sidestand switch lead to
the inside of the frame boss.
N. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, and sidestand switch lead
with the plastic locking tie. Face the end of the
plastic locking tie outward, and then cut off the
excess end of the tie.
O. Fasten the starter motor lead, horn 1 lead, and rear
brake light switch lead with the plastic locking tie,
and then face the end of the tie outward. Be sure to
install the plastic locking tie behind the frame cross
member and to fasten the rear brake light switch
lead at the white tape.
P. Route the starter motor lead, horn 1 lead, and rear
brake light switch lead along the frame in the area
shown in the illustration, making sure not to cross
the leads.
Q. Align the positioning tape on the starter motor lead
with the engine mounting bolt (front lower side).
R. Pass the fuel tank breather/overflow hose through
the horn 1 bracket, making sure to position the end
of the hose as shown in the illustration.
S. Fasten the starter motor lead, horn 1 lead, and rear
brake light switch lead with the plastic locking tie,
and then face the end of the tie inward.
T. Fasten the horn 1 lead, rear brake light switch lead,
and starter motor lead with the plastic locking tie.
Face the end of the plastic locking tie inward, and
then cut off the excess end of the tie.
U. Route the horn 1 lead to the rear of the starter
motor lead.
V. Pass the throttle cables through the cable guides
as shown in the illustration.
W. Install the lead cover, making sure not to pinch the
stator coil lead and rectifier/regulator lead.
X. Pass the plastic locking tie through the hole in the
battery box projection, and then fasten the wire
harness with the tie.
Y. Fasten the stator coil lead at the white tape with the
plastic locking tie.
Z. Fasten the stator coil lead with the plastic locking
ties.
AA.Pass the plastic locking tie through the hole in the
battery box projection, and then fasten the wire
harness with the tie.
AB.Route the wire harness along the side of the fuse
box/starter relay bracket.
AC.For California only
AD.Route the horn 1 lead to the rear of the canister.
1. Clutch hose
2. Throttle cable (decelerator cable)
3. Throttle cable (accelerator cable)
4. Cylinder-#2 left spark plug cap
5. Cylinder-#1 left spark plug cap
6. Sub-wire harness 1
7. Rectifier/regulator
8. Crankshaft position sensor lead
9. Stator coil lead
10. Rectifier/regulator lead
11. Lean angle sensor
12. Horn 2 lead
13. Horn 2
14. Sidestand switch
15. Horn 1 lead
16. Rear brake light switch lead
17. Horn 1
18. Starter motor lead
19. Clutch pipe
20. Fuel tank breather/overflow hose
21. Rollover valve
22. Front brake hose
23. Headlight assembly
24. Front fork
25. Frame
26. Main fuse
27. Diode 1
28. Relay unit
29. Turn signal relay
30. Headlight relay
31. Starter relay
32. EXUP servo motor
33. EXUP cable
34. Speed sensor lead
35. Wire harness
36. Canister
A. Route the throttle cables to the inside of the clutch
hose.
B. Pass the cylinder-#2 left spark plug lead through
the guide.
C. 30–40 mm (1.18–1.57 in)
D. Position the buckle of the plastic locking tie to the
inside of the frame.
E. Fasten the crankshaft position sensor lead, neutral
switch lead, and sidestand switch lead with the
holders.
F. Fasten the starter motor lead, speed sensor lead,
and wire harness with the holders.
G. Route sub-wire harness 1 to the inside of the
frame.
H. To the tail/brake light
I. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, sidestand switch lead, and
crankshaft position sensor lead with the plastic
locking tie.
J. Make sure that there is no slack in the stator coil
lead and rectifier/regulator lead in the area shown
in the illustration.
2-52
CABLE ROUTING
2-53
CABLE ROUTING
L. Fasten the air filter case damper with the plastic
locking tie so that the rubber part of the damper
contacts the frame. Be sure to pass the plastic
locking tie between the air filter case damper and
the frame.
M. Route the crankshaft position sensor lead,
sidestand switch lead, neutral switch lead, starter
motor lead, and speed sensor lead under the fuel
outlet hose.
N. Inside of frame
O. Outside of frame
P. View with tray removed
Q. Route the negative battery lead under the starter
motor lead and battery positive lead.
R. Route the positive battery lead (main fuse to starter
relay) over the tray.
S. Route the negative battery lead towards the front of
the vehicle.
T. Route the positive battery lead (battery to starter
relay) under the tray.
U. View with tray installed
V. To the tail/brake light
W. View with ECU removed
X. Wrap the protective covering around the couplers
(crankshaft position sensor coupler, auxiliary DC
jack coupler, neutral switch coupler, sub-wire
harness 1 coupler, speed sensor coupler, and
sidestand switch coupler) and the wire harness.
Y. When installing the ECU, be sure not to pinch the
leads in the areas shown in the illustration with
oblique lines.
1. Meter assembly coupler
2. Cylinder-#2 intake air pressure sensor coupler
3. Cylinder-#1 right spark plug cap
4. Wire harness
5. Negative battery lead
6. EXUP servo motor
7. Fuse box
8. Starter motor lead
9. Positive battery lead
10. Sub-wire harness 1
11. ECU (electronic control unit)
12. Cylinder-#1 left spark plug cap
13. Cylinder-#1 intake air pressure sensor coupler
14. Fuel sender (fuel tank) coupler
15. Neutral switch lead
16. Sidestand switch lead
17. Crankshaft position sensor lead
18. Speed sensor lead
19. Fuel hose (fuel tank to fuel hose joint)
20. Fuel return hose (fuel return pipe to sub-fuel tank)
21. Air vent hose (fuel pump to fuel hose joint)
22. Fuel outlet hose
23. Frame
24. Oil tank
25. Sub-fuel tank
26. Battery
27. Main fuse
28. Fuel pump lead
A. Do not pinch the leads between the fuel tank
bracket and the frame when installing the bracket.
B. Pass the plastic locking ties through the holes in
the frame damper, and then fasten the wire harness
and damper with the ties. Face the end of each
plastic locking tie upward, and then cut off the
excess end of the tie.
C. Align the white tape on the wire harness with the
frame cross member.
D. 20 mm (0.79 in)
E. Fasten the wire harness with the plastic locking tie.
Face the end of the plastic locking tie upward, and
then cut off the excess end of the tie.
F. Route the wire harness along the frame.
G. Fasten the wire harness with the plastic locking tie,
making sure to align the tie with the line on the
rubber damper. Face the end of the plastic locking
tie upward, and then cut off the excess end of the
tie.
H. Connect the ECU couplers, and then fasten the
ECU with the band.
I. Fasten the fuel return hose (fuel return pipe to subfuel tank) with the plastic locking tie. Face the end
of the plastic locking tie inward, and then cut off the
excess end of the tie.
J. Route the cylinder-#1 intake air pressure sensor
lead so that it does not protrude past the top of the
frame.
K. Fasten the fuel tank damper with the plastic locking
tie. Install the plastic locking tie in the middle slot of
the fuel tank damper.
2-54
CABLE ROUTING
2
1
3
F
4
5
6
7
A
17
23
C B
18
19
A
9
D
15
16
22
8
12
11
10
E
G
13
14
21
H
20
8
I
B
6
H
K
L
M
J
T
U
S
24
V
N
R
25
5
Q
4
P
6
5
L
11
G
W
7
O
4
A
F
7
21
X
11
26
8
24
27
C
C
C-C
B
28
2-55
CABLE ROUTING
Q. Install the fuel hose (fuel tank to fuel hose joint)
with its white paint mark facing downward.
R. To the pressure regulator
S. Install the air vent hose (fuel hose joint to fuel tank)
with its white paint mark facing downward.
T. For California only
U. To the fuel tank
V. To the intake manifold assembly
W. Fasten the canister purge hose and fuel tank
breather/overflow hose with the holder, making sure
to align the paint mark on the breather/overflow
hose with the holder.
X. Fasten the canister purge hose and throttle cable
guide with the holder.
1. Fuel tank breather hose
2. Fuel sender (fuel tank)
3. Fuel tank
4. Fuel hose (fuel tank to fuel hose joint)
5. Fuel return hose (fuel return pipe to sub-fuel tank)
6. Air vent hose (fuel hose joint to fuel tank)
7. Fuel hose joint
8. Fuel outlet hose
9. Fuel pump
10. Sub-fuel tank
11. Fuel hose (fuel hose joint to fuel pump)
12. Fuel return pipe
13. Fuel return hose (pressure regulator to fuel return
pipe)
14. Pressure regulator
15. Rollover valve 1
16. Rollover valve 2
17. Cylinder-#2 left spark plug lead
18. Rollover valve hose 1
19. Rollover valve hose 2
20. Starter motor lead
21. Fuel tank breather/overflow hose
22. Rollover valve hose 4
23. Rollover valve hose 3
24. Air vent hose (fuel pump to fuel hose joint)
25. Fuel pump coupler
26. Canister purge hose (for California only)
27. Canister (for California only)
28. Canister breather hose (for California only)
A. Align the blue paint mark on the fuel hose (fuel
hose joint to fuel tank) with the round indentation on
the bend in the fuel hose joint.
B. Face the fastener of the clamp downward, making
sure that the projections on the clamp are
positioned as shown in the illustration.
C. Align the white paint mark on the end of the fuel
return hose (fuel return pipe to sub-fuel tank) with
the white paint mark on the fuel return pipe.
D. White paint mark
E. Align the ends of the hose clamp with the white
paint mark on the fuel return hose.
F. Align the paint marks on the hoses with the hose
joint as shown in the illustration.
G. Fasten the fuel tank breather/overflow hose to the
throttle cable guide with the holder.
H. Align the paint mark on the hose with the hose joint
as shown in the illustration.
I. Fasten the fuel tank breather/overflow hose and
starter motor lead with the holder.
J. To the fuel injector
K. Align the yellow paint mark on the air vent hose
(fuel hose joint to fuel tank) with the round
indentation on the bend in the fuel hose joint.
L. Face the fastener of the clamp to the left.
M. Face the ends of the hose clamp forward.
N. Install the air vent hose (fuel pump to fuel hose
joint) with its white paint mark facing upward.
O. Face the ends of the hose clamp upward.
P. Face the fastener of the clamp upward, making
sure that the projections on the clamp are
positioned as shown in the illustration.
2-56
CABLE ROUTING
A
5
C
4
3
7
6
8
9
10
E
D
1
2
B
A
11
12
17
13
B
H
G
14
16
13
F
15
11
18
I
C
13
13
11
C-C
11
11
C
B
J
19
4
5
A
7
20
K
21
22
2-57
CABLE ROUTING
1.
2.
3.
4.
Cylinder-#1 intake air pressure sensor
Cylinder-#1 intake air pressure sensor hose
Air filter case breather hose 1
Fuel hose (intake manifold assembly to pressure
regulator)
5. Pressure regulator
6. Air filter case breather hose 2
7. Canister purge hose (for California only)
8. ISC (idle speed control) unit inlet hose
9. Canister (for California only)
10. Fuel tank breather/overflow hose (for California
only)
11. Cylinder-#2 ISC (idle speed control) unit outlet
hose
12. ISC (idle speed control) unit
13. Cylinder-#1 ISC (idle speed control) unit outlet
hose
14. Cylinder-#2 intake air pressure sensor
15. Cylinder-#1 intake air pressure sensor hose
16. Fuel outlet hose
17. Cylinder head breather hose
18. Hose joint cover
19. Throttle position sensor
20. Cylinder-#1 injector coupler
21. Engine temperature sensor coupler
22. Sub-wire harness 2
A. Face the ends of the hose clamp to the left, angled
45° rearward.
B. Install the cylinder-#1 intake air pressure sensor
hose onto the throttle body pipe up to the bend in
the pipe, making sure to face the white paint mark
on the hose upward. Face the ends of the hose
clamp forward.
C. Fasten the canister purge hose and the air filter
case breather hose 2 with the hose clamp, making
sure to face the ends of the clamp upward (for
California only).
D. Face the ends of the hose clamp to the left.
E. Fasten the canister purge hose and fuel tank
breather/overflow hose with the holder 70 mm (2.76
in) from the hose joints on the canister (for
California only).
F. Install the cylinder-#2 intake air pressure sensor
hose onto the throttle body pipe up to the bend in
the pipe, making sure to face the white paint mark
on the hose upward. Face the ends of the hose
clamp rearward.
G. Install the canister purge hose onto the throttle
body pipe up to the bend in the pipe, making sure to
face the white paint mark on the hose upward (for
California only).
H. Face the ends of the hose clamp rearward, angled
to the left.
I. Align the white paint marks.
J. Align the yellow paint marks.
K. Route the canister purge hose over the air filter
case joint clamp screw.
2-58
CABLE ROUTING
2
A
3
A
1
4
5
16
E
15
9 10 B 11 B
10
C
14
9
8
7
D
B
6
13
12
17
9
4
H
18
10
19
I
B
8
J
8
G
9
10
A
B
2-59
F
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cylinder-#1 intake air pressure sensor
Cylinder-#2 intake air pressure sensor hose
Cylinder-#2 intake air pressure sensor
ISC (idle speed control) unit coupler
ISC (idle speed control) unit
Rollover valve 1
Rollover valve 2
ISC (idle speed control) unit inlet hose
Cylinder-#1 ISC (idle speed control) unit outlet
hose
10. Cylinder-#2 ISC (idle speed control) unit outlet
hose
11. Hose joint
12. Air filter case breather hose 2
13. Throttle position sensor
14. Throttle body assembly
15. Cylinder-#1 intake air pressure sensor hose
16. Cylinder head breather hose
17. Cylinder-#2 left ignition coil
18. Cylinder-#2 right ignition coil
19. Sub-wire harness 4
A. Face the ends of the hose clamp inward.
B. Face the ends of the hose clamps outward.
C. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold, making sure to
face the green paint mark on the hose to the left.
Face the ends of the hose clamp outward, angled
45° forward.
D. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold, making sure to
face the blue paint mark on the hose to the left.
E. Face the ends of the hose clamp upward.
F. Position the sub-wire harness 4 coupler on top of
the guide.
G. To the wire harness
H. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose onto the ISC unit pipe, making sure to
align the blue paint mark on the hose with the blue
paint mark on the pipe.
I. Install the ISC (idle speed control) unit inlet hose
onto the ISC unit pipe, making sure to align the
white paint mark on the hose with the white paint
mark on the pipe.
J. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose onto the ISC unit pipe, making sure to
align the green paint mark on the hose with the
green paint mark on the pipe.
2-60
CABLE ROUTING
2-61
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................ 3-1
INTRODUCTION....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART....................... 3-1
ENGINE ........................................................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
SYNCHRONIZING THE THROTTLE BODIES ......................................... 3-7
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-8
CHECKING THE SPARK PLUGS............................................................. 3-9
CHECKING THE IGNITION TIMING....................................................... 3-10
CHECKING THE ENGINE OIL LEVEL ................................................... 3-11
CHANGING THE ENGINE OIL ............................................................... 3-11
CHECKING THE TRANSFER GEAR OIL LEVEL................................... 3-13
CHANGING THE TRANSFER GEAR OIL .............................................. 3-14
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-14
BLEEDING THE HYDRAULIC CLUTCH SYSTEM................................. 3-15
REPLACING THE AIR FILTER ELEMENT ............................................. 3-15
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-16
CHECKING THE FUEL LINE .................................................................. 3-16
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-17
CHECKING THE OIL TANK BREATHER HOSE .................................... 3-17
CHECKING THE EXHAUST SYSTEM ................................................... 3-17
CHECKING THE CANISTER (for California only)................................... 3-18
ADJUSTING THE EXUP CABLES.......................................................... 3-18
CHASSIS....................................................................................................... 3-20
ADJUSTING THE REAR DISC BRAKE .................................................. 3-20
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-20
CHECKING THE FRONT BRAKE PADS................................................ 3-21
CHECKING THE REAR BRAKE PADS .................................................. 3-21
CHECKING THE FRONT BRAKE HOSES ............................................. 3-21
CHECKING THE REAR BRAKE HOSES ............................................... 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH................................. 3-22
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-22
ADJUSTING THE SHIFT PEDAL............................................................ 3-23
ADJUSTING THE DRIVE BELT SLACK ................................................. 3-24
CHECKING AND ADJUSTING THE STEERING HEAD......................... 3-25
CHECKING THE FRONT FORK............................................................. 3-26
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-27
CHECKING THE TIRES ......................................................................... 3-27
CHECKING THE WHEELS ..................................................................... 3-29
CHECKING AND LUBRICATING THE CABLES .................................... 3-29
LUBRICATING THE LEVERS................................................................. 3-30
LUBRICATING THE PEDAL ................................................................... 3-30
LUBRICATING THE SIDESTAND .......................................................... 3-30
LUBRICATING THE REAR SUSPENSION ............................................ 3-30
3
ELECTRICAL SYSTEM ................................................................................ 3-31
CHECKING AND CHARGING THE BATTERY....................................... 3-31
CHECKING THE FUSES ........................................................................ 3-31
REPLACING THE HEADLIGHT BULBS ................................................. 3-31
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-32
PERIODIC MAINTENANCE
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAU17600
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIAL
No.
ITEM
1 * Fuel line
2 * Spark plugs
3 * Valve clearance
4 * Crankcase
breather system
5 * Fuel injection
6 * Exhaust system
Evaporative emission control sys7 * tem (For
California only)
ROUTINE
ODOMETER READINGS
8000 mi
12000 mi 16000 mi 20000 mi
600 mi
4000 mi
(13000
(19000
(25000
(31000
(1000 km) (7000 km)
km)
km)
km)
km)
or
or
or
or
or
or
1 month 6 months
12 months 18 months 24 months 30 months
• Check fuel hoses for cracks or
damage.
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
• Replace every 8000 mi
(13000 km) or 12 months.
• Check and adjust valve clearance when engine is cold.
• Adjust if necessary.
• Check breather hose for
cracks or damage.
• Replace if necessary.
• Adjust synchronization.
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
√
√
√
√
√
√
Replace.
√
Replace.
√
Every 16000 mi (25000 km)
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Check control system for
damage.
• Replace if necessary.
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
EAU32183
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
No.
ITEM
1 * Air filter element
2 * Clutch
3 * Front brake
4 * Rear brake
5 * Brake hoses
ROUTINE
• Check condition and damage.
• Replace if necessary.
• Check operation and fluid
leakage.
• Correct if necessary.
• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if necessary.
• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if necessary.
• Check for cracks or damage.
• Replace.
ODOMETER READINGS
600 mi
4000 mi
(1000 km) (7000 km)
or
or
1 month 6 months
8000 mi
12000 mi 16000 mi 20000 mi
(13000
(19000
(25000
(31000
km)
km)
km)
km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Every 4 years
√
√
3-1
PERIODIC MAINTENANCE
INITIAL
No.
ITEM
ROUTINE
ODOMETER READINGS
8000 mi
12000 mi 16000 mi 20000 mi
600 mi
4000 mi
(13000
(19000
(25000
(31000
(1000 km) (7000 km)
km)
km)
km)
km)
or
or
or
or
or
or
1 month 6 months
12 months 18 months 24 months 30 months
• Check runout and for damage.
• Replace if necessary.
• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth
operation.
• Replace if necessary.
• Check bearing assemblies for
looseness.
• Check belt tension.
• Adjust if necessary.
• Check bearing assemblies for
looseness.
• Moderately repack with lithium-soap-based grease every
16000 mi (25000 km) or 24
months.
• Check all chassis fitting and
fasteners.
• Correct if necessary.
• Apply lithium-soap-based
grease (all-purpose grease)
lightly.
• Apply lithium-soap-based
grease (all-purpose grease)
lightly.
• Check operation.
• Apply lithium-soap-based
grease (all-purpose grease)
lightly.
• Check operation and replace
if necessary.
• Check operation and for oil
leakage.
• Replace if necessary.
• Check operation and for oil
leakage.
• Replace if necessary.
• Apply lithium-soap-based
grease lightly.
• Change (warm engine before
draining).
√
Engine oil filter
21 * cartridge
• Replace.
√
√
√
22 * Transfer case oil
• Check for leakage.
• Change at initial 600 mi (1000
km) or 1 month, and thereafter every 16000 mi (25000
km) or 24 months.
Change.
√
Change.
6 * Wheels
7 * Tires
8 * Wheel bearings
9 *
Swingarm pivot
bearings
10 * Drive belt
11 * Steering bearings
12 * Chassis fasteners
13
Brake and clutch
lever pivot shafts
14
Brake and shift
pedal pivot shafts
15
Sidestand pivot
16 * Sidestand switch
17 * Front fork
18 *
Shock absorber
assembly
19 * Rear suspension
link pivots
20
23 *
Engine oil
Front and rear
brake switches
24 * Control cables
Throttle grip
25 * housing and cable
26 *
Lights, signals
and switches
• Check operation.
• Apply Yamaha chain and cable lube or engine oil SAE
10W-30 thoroughly.
• Check operation and free
play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip
housing and cable.
• Check operation.
• Adjust headlight beam.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Every 2500 mi (4000 km)
√
√
√
Repack.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
3-2
PERIODIC MAINTENANCE
NOTE:
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
EAU38440
NOTE:
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake and clutch systems
• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder,
always change the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as
required.
• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and
clutch release cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
3-3
ENGINE
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
• Muffler
• Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
2. Disconnect:
• Spark plug caps
3. Remove:
• Spark plugs
4. Remove:
• Shift pedal assembly “1”
EAS20470
ENGINE
EAS20530
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• The valve clearance is automatically adjusted
by the hydraulic valve lifter. However, there are
times when the valve clearance needs to be
adjusted manually. If this is the case, adjust the
clearance of the two maladjusted or worn
valves using the adjusting screw on the rocker
arm.
If clearance is on the slip side “1”, loosen the
adjusting screw and bring the valve clearance
“a” within specification. Check if the valve
clearance “b” on the adjusting screw “2” side is
within specification.
1
5. Remove:
• Damper cover “1”
• Damper “2”
• Timing mark accessing screw “3”
• Crankshaft end screw “4”
If clearance is on the adjusting screw “2” side,
tighten the adjusting screw and bring the valve
clearance “b” within specification.
4
3 2
1
6. Remove:
• Camshaft sprocket cover “1”
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
7. Remove:
• Wire harness guide bolt “1”
3-4
ENGINE
3
1
2
3
8. Remove:
• Fuel tank damper “1”
• Cylinder head breather hose “2”
9. Disconnect:
• Oil tank breather hose “3”
• Fuel outlet hose “4”
11.Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake
0.00–0.04 mm (0.0000–0.0016 in)
Exhaust
0.00–0.04 mm (0.0000–0.0016 in)
1
3
4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston #1 TDC (rear cylinder)
a. Turn the crankshaft counterclockwise.
2
10.Remove:
• Front cylinder head cover “1”
• Rear cylinder head cover “2”
NOTE:
Due to the small clearance between the frame
and the rear cylinder head cover, the three bolts
“3” cannot be removed when the cover is in
place. Loosen the bolts, and then remove the
cylinder head cover from the right side of the vehicle, making sure that the bolts do not scratch
the rocker arms or other engine parts.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the
crankshaft position sensor rotor with the
pointer “b” on the clutch cover.
b
1
a
2
c. Check the camshaft drive gear mark “c” position and camshaft driven gear mark “d” position as shown.
If the marks are not aligned, turn the crankshaft counterclockwise 360 degrees and recheck step (b).
3-5
ENGINE
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
d
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c
12.Adjust:
• Valve clearance
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a. Loosen the locknut “1”.
d. Measure the valve clearance with a thickness
gauge.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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Piston #2 TDC (front cylinder)
a. Turn the crankshaft counterclockwise from
the piston #1 TDC by 408 degrees.
b. When piston #2 is at TDC on the compression stroke, align the TDC mark “e” on the
crankshaft position sensor rotor with the
pointer “b” on the clutch cover.
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
c. Turn the adjusting screw “3” in direction “a” or
“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
e
b
Tappet adjusting tool (4 mm)
90890-04133
Valve adjustment wrench 3 mm &
4 mm
YM-08035-A
c. Check the camshaft drive gear mark “c” position and camshaft driven gear mark “d” position as shown.
Adjusting
screw side
d
c
d. Measure the valve clearance with a thickness
gauge.
3-6
Slip side
Direction “a”
Valve clearance is increased.
Valve clearance is decreased.
Direction “b”
Valve clearance is decreased.
Valve clearance is increased.
ENGINE
4
• Cylinder-#1 ignition coil cover
Refer to “ENGINE REMOVAL” on page 5-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
3. Remove:
• Cylinder-#1 intake air pressure sensor bracket “1”
• Cylinder-#2 intake air pressure sensor bracket “2”
3 2
a
b
2
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specification.
1
T.
R
Locknut (rocker arm adjusting
screw)
20 Nm (2.0 m·kg, 14 ft·lb)
Tappet adjusting tool (4 mm)
90890-04133
Valve adjustment wrench 3 mm &
4 mm
YM-08035-A
4. Disconnect:
• Cylinder-#1 intake air pressure sensor hose
“1”
• Cylinder-#2 intake air pressure sensor hose
“2”
e. Measure the valve clearance again.
f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
2
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1
13.Install:
• All removed parts
Refer to “CAMSHAFTS” on page 5-14.
NOTE:
5. Install:
• Hose “1” (Parts No.: 5JW-24311-00)
• 3-way joint “2” (Parts No.: 90413-05014)
• Vacuum gauge hose for #1 “3”
• Vacuum gauge hose for #2 “4”
• Cylinder-#1 intake air pressure sensor hose
“5”
• Cylinder-#2 intake air pressure sensor hose
“6”
• Vacuum gauge
• Tachometer
For installation, reverse the removal procedure.
EAS20570
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition timing should be checked.
1. Stand the vehicle on a level surface.
NOTE:
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
Place the vehicle on a suitable stand.
2. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
3-7
ENGINE
NOTE:
The difference in vacuum pressure between two
throttle bodies should not exceed 1.33 kPa (10
mmHg).
4
6
2
1
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1
8. Stop the engine and remove the measuring
equipment.
9. Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
5
3
2
6. Install:
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
7. Adjust:
• Throttle body synchronization
Throttle cable free play
4.0–6.0 mm (0.16–0.24 in)
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10.Install:
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Cylinder-#1 ignition coil cover
Refer to “ENGINE REMOVAL” on page 5-1.
• Rider seat bracket assembly
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
a. Start the engine and let it warm up for several
minutes, and then let it run at specified engine idling speed.
Engine idling speed
850–950 r/min
b. With throttle body #1 as standard, adjust
throttle body #2 using the air screw “1” (for
throttle body #2).
EAS20630
ADJUSTING THE THROTTLE CABLE FREE
PLAY
1
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and throttle body synchronization should be adjusted properly.
1. Check:
• Throttle cable free play “a”
Out of specification → Adjust.
NOTE:
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If the air screw was removed, turn the screw
3/4 turn in and be sure to synchronize the throttle body.
a
ECA14900
CAUTION:
Do not use the throttle valve adjusting
screws to adjust the throttle body synchronization.
Throttle cable free play
4.0–6.0 mm (0.16–0.24 in)
2. Adjust:
• Throttle cable free play
Intake vacuum
31.3–35.3 kPa (9.3–10.4 inHg)
(235–265 mmHg)
3-8
ENGINE
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4. Check:
• Spark plug type
Incorrect → Change.
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle cable free play is
obtained.
Manufacturer/model
NGK/DPR8EA-9
Manufacturer/model
DENSO/X24EPR-U9
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
5. Check:
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
c. Tighten the locknut “1”.
2
1
a
b
EWA12910
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to the
right and to the left to ensure that this does
not cause the engine idling speed to change.
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EAS20680
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
• Spark plug cap
3. Remove:
• Spark plug
8. Install:
• Spark plug
T.
R
Spark plug
18 Nm (1.8 m·kg, 13 ft·lb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
ECA13320
CAUTION:
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from falling
into the cylinders.
3-9
ENGINE
10.Install:
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Rider seat bracket assembly
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
1
EAS20700
CHECKING THE IGNITION TIMING
5. Check:
• Ignition timing
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
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a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
1. Stand the vehicle on a level surface.
2. Remove:
• Shift pedal assembly “1”
Engine idling speed
850–950 r/min
b. Check that pointer “a” on the clutch cover is
within the firing range “b” on the crankshaft
position sensor rotor.
Incorrect firing range → Check the ignition
system.
1
a
b
3. Remove:
• Damper cover “1”
• Damper “2”
• Timing mark accessing screw “3”
NOTE:
The ignition timing is not adjustable.
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6. Install:
• Timing mark accessing screw
• Damper
• Damper cover
3 2
1
T.
4. Connect:
• Timing light “1”
• Tachometer
R
Damper cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
7. Install:
• Shift pedal assembly “1”
T.
Timing light
90890-03141
Inductive clamp timing light
YU-03141
R
3-10
Shift pedal bolt
18 Nm (1.8 m·kg, 13 ft·lb)
ENGINE
NOTE:
Type
YAMALUBE 4 (20W40) or
SAE20W40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.
1
ECA13380
CAUTION:
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives.
• Do not allow foreign materials to enter the
crankcase.
a
EAS20750
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
6. Start the engine, warm it up for several minutes, and then turn it off.
7. Check the engine oil level again.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
2. Start the engine, warm it up for approximately
15 minutes until the oil temperature rises to
60 °C (140 °F), and then turn it off.
3. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove:
• Dipstick “1”
5. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
8. Install:
• Dipstick
9. Install:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20780
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolts.
3. Remove:
• Engine oil filler cap “1”
NOTE:
1
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
b
1
a
4. Remove:
• Engine oil drain bolt (oil tank) “1”
(along with the gasket)
3-11
ENGINE
1
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
5. Remove:
• Engine oil drain bolts (crankcase) “1”
(along with the gaskets)
T.
R
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
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1
8. Check:
• Engine oil drain bolt gaskets
Damage → Replace.
9. Install:
• Engine oil drain bolt (oil tank)
(along with the gasket)
1
T.
6. Drain:
• Engine oil
(completely from the oil tank and crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
R
Engine oil drain bolt (oil tank)
43 Nm (4.3 m·kg, 31 ft·lb)
10.Install:
• Engine oil drain bolts (crankcase)
(along with the gaskets)
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a. Remove the oil filter cartridge “1” with an oil
filter wrench “2”.
T.
R
Oil filter wrench
90890-01426
YU-38411
Engine oil drain bolt (crankcase)
43 Nm (4.3 m·kg, 31 ft·lb)
11.Fill:
• Oil tank
(with the specified amount of the recommended engine oil)
Engine oil quantity
Total amount
5.20 L (5.50 US qt) (4.58 Imp.qt)
Without oil filter cartridge replacement
4.10 L (4.33 US qt) (3.61 Imp.qt)
With oil filter cartridge replacement
4.90 L (5.18 US qt) (4.31 Imp.qt)
b. Lubricate the O-ring “3” of the new oil filter
cartridge with a thin coat of engine oil.
NOTE:
ECA13390
Pour the engine oil in two stages. First, pour in
2.5 L of oil, then start the engine and rev it 3 to 5
times. Stop the engine, and then pour in the remainder of the specified amount.
CAUTION:
Make sure the O-ring “3” is positioned correctly in the groove of the oil filter cartridge.
3-12
ENGINE
EC1D71008
CAUTION:
T.
When starting the engine make sure the dipstick is securely fitted into the oil tank.
R
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12.Fill: (when engine is disassembled)
• Crankcase and oil tank
(with the specified amount of the recommended engine oil)
Engine oil quantity
Total amount
5.20 L (5.50 US qt) (4.58 Imp.qt)
Engine
3.2 L (3.38 US qt) (2.82 Imp.qt)
Oil tank
2.0 L (2.11 US qt) (1.76 Imp.qt)
Oil gallery bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
EAS20840
CHECKING THE TRANSFER GEAR OIL
LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
2. Remove:
• Transfer gear oil check bolt “1”
13.Install:
• Engine oil filler cap
14.Start the engine, warm it up for several minutes, and then turn it off.
15.Check:
• Engine
(for engine oil leaks)
16.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-11.
17.Check:
• Engine oil pressure
1
3. Check:
• Transfer gear oil level
The transfer gear oil level should be up to the
brim “1” of the hole.
Below the brim → Add the recommended
transfer gear oil to the proper level.
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a. Slightly loosen the oil gallery bolts “1”.
1
1
b. Start the engine and keep it idling until engine
oil starts to seep from the oil gallery bolts. If
no engine oil comes out after one minute, turn
the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “OIL PUMP” on page 5-95.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolts to specification.
Type
SAE80 API GL-4 Hypoid gear oil
EC1D71024
CAUTION:
Do not allow foreign materials to enter the
transfer gear case.
4. Install:
• Transfer gear oil check bolt
3-13
ENGINE
T.
R
Transfer gear oil check bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
EAS20850
CHANGING THE TRANSFER GEAR OIL
1. Remove:
• Muffler
• Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
2. Place a container under the transfer gear oil
drain bolt.
3. Remove:
• Straight plug “1”
• Transfer gear oil drain bolt “2”
8. Install:
• Straight plug
9. Check:
• Transfer gear oil level
Refer to “CHECKING THE TRANSFER
GEAR OIL LEVEL” on page 3-13.
10.Install:
• Exhaust pipes
• Muffler
Refer to “ENGINE REMOVAL” on page 5-1.
EAS20890
2
1
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
4. Drain:
• Transfer gear oil
(completely from the transfer gear case)
5. Check:
• Transfer gear oil drain bolt gasket
Damage → Replace.
6. Install:
• Transfer gear oil drain bolt
(along with the gasket)
Place the vehicle on a suitable stand.
2. Check:
• Clutch fluid level
Below the minimum level mark “a” → Add the
recommended clutch fluid to the proper level.
Recommended clutch fluid
Brake fluid DOT 4
T.
R
Transfer gear oil drain bolt
18 Nm (1.8 m·kg, 13 ft·lb)
7. Fill:
• Transfer gear case
(with the specified amount of the recommended transfer gear oil)
Quantity
0.55 L (0.58 US qt) (0.48 Imp.qt)
Quantity (disassembled)
0.60 L (0.63 US qt) (0.53 Imp.qt)
EWA13370
WARNING
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.
3-14
ENGINE
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch fluids may result in a harmful chemical reaction, leading to poor clutch performance.
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
1
2
ECA13420
CAUTION:
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
NOTE:
In order to ensure a correct reading of the clutch
fluid level, make sure the top of the reservoir is
horizontal.
EAS20900
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
EWA13000
WARNING
R
NOTE:
T.
Bleed the hydraulic clutch system whenever:
• the system was disassembled,
• a clutch hose was loosened or removed,
• the clutch fluid level is very low,
• clutch operation is faulty.
d. Place the other end of the hose into a container.
e. Slowly squeeze the clutch lever several
times.
f. Fully squeeze the clutch lever without releasing it.
g. Loosen the bleed screw. This will release the
tension and cause the clutch lever to contact
the handlebar grip.
h. Tighten the bleed screw and then release the
clutch lever.
i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the clutch fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw (clutch release cylinder)
6 Nm (0.6 m·kg, 4.3 ft·lb)
k. Add the recommended clutch fluid to the
proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” on page 3-14.
• Be careful not to spill any clutch fluid or allow
the clutch master cylinder reservoir to overflow.
• When bleeding the hydraulic clutch system,
make sure there is always enough clutch fluid
before applying the clutch lever. Ignoring this
precaution could allow air to enter the hydraulic
clutch system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to let
the clutch fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
EWA13010
WARNING
After bleeding the hydraulic clutch system,
check the clutch operation.
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EAS20960
REPLACING THE AIR FILTER ELEMENT
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
3. Remove:
• Air filter case cover “1”
1. Bleed:
• Hydraulic clutch system
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a. Add the recommended clutch fluid to the
proper level.
b. Install the clutch master cylinder reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
3-15
ENGINE
EAS21010
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the
throttle body joints and intake manifolds.
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Throttle body joints “1”
Cracks/damage → Replace.
1
4. Remove:
• Air filter element “1”
1
1
5. Check:
• Air filter element
Damage → Replace.
3. Install:
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Rider seat bracket assembly
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
NOTE:
The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
6. Install:
• Air filter case cover
EC1D71002
CAUTION:
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect the throttle
body synchronization, leading to poor engine performance and possible overheating.
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the fuel,
air vent and breather hoses.
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
2. Check:
• Fuel hoses “1”
• Air vent hose “2”
• Breather hose “3”
Cracks/damage → Replace.
Loose connection → Connect properly.
NOTE:
When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.
7. Install:
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
ECA14940
CAUTION:
Make sure the fuel tank breather hose is routed correctly.
3-16
ENGINE
1
2
1
1
3. Install:
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Rider seat bracket assembly
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
3
1
EAS21060
CHECKING THE OIL TANK BREATHER
HOSE
1. Remove:
• Right side cover
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Oil tank breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Rider seat bracket assembly
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21050
CHECKING THE CYLINDER HEAD
BREATHER HOSE
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Cylinder head breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
ECA14930
CAUTION:
Make sure the oil tank breather hose is routed correctly.
1
ECA14920
CAUTION:
3. Install:
• Right side cover
Refer to “GENERAL CHASSIS” on page 4-1.
Make sure the cylinder head breather hose is
routed correctly.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes and gaskets.
1. Check:
• Front exhaust pipe “1”
• Rear exhaust pipe “2”
3-17
ENGINE
• Muffler “3”
• Muffler bracket “4”
Cracks/damage → Replace.
• Gaskets “5”
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Front exhaust pipe nuts “6”
• Front exhaust pipe and rear exhaust pipe bolt
“7”
• Rear exhaust pipe nuts “8”
• Rear exhaust pipe and muffler bolt “9”
• Muffler and muffler bracket bolts “10”
• Muffler bracket and frame bolts “11”
EAS21090
CHECKING THE CANISTER (for California
only)
1. Remove:
• Horn 1
Refer to “THROTTLE BODIES” on page 6-6.
2. Check:
• Canister “1”
• Canister purge hose “2”
• Canister breather hose “3”
• Fuel tank breather/overflow hose “4”
Cracks/damage → Replace.
T.
Front exhaust pipe nut
20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear exhaust pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe nut
24 Nm (2.4 m·kg, 17 ft·lb)
Rear exhaust pipe and muffler
bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and muffler bracket bolt
29 Nm (2.9 m·kg, 21 ft·lb)
Muffler bracket and frame bolt
53 Nm (5.3 m·kg, 38 ft·lb)
LOCTITE®
R
3
2
4
1
3
3. Install:
• Horn 1
Refer to “THROTTLE BODIES” on page 6-6.
EAS21100
ADJUSTING THE EXUP CABLES
1. Remove:
• EXUP valve pulley cover “1”
10
1
4
2. Check:
• EXUP system operation
LT
11
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8
9
5
a. Turn the main switch to “ON”.
b. Check that the EXUP valve operates properly.
5
5
2
NOTE:
7
5
Check that the projection “a” on the EXUP valve
pulley contact the stopper “b” (fully-open position) and the stopper “c” (fully-closed position).
6
1
3-18
ENGINE
b
a
b
a
2
b
a
c
2
c. Tighten both locknuts.
d. Turn the main switch to “ON” and check that
the projection “c” on the EXUP valve pulley
contacts the stoppers (fully open and fully
closed positions), then stops between the
lines “d” on the cable holder.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• EXUP cable free play (at the EXUP valve pulley) “a” and “b”
EXUP cable free play (at the
EXUP valve pulley)
a: 3 mm (0.12 in) or less
b: 3 mm (0.12 in) or less
c
b
d
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• EXUP valve pulley cover
T.
4. Adjust:
• EXUP cable free play
R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
1
b. Turn both adjusting bolts “2” in or out until the
specification.
Turn in “a” →
Free play is increased.
Turn out “b” →
Free play is decreased.
3-19
EXUP valve pulley cover bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
CHASSIS
EAS21140
CHASSIS
2
EAS21190
1
ADJUSTING THE REAR DISC BRAKE
1. Check:
• Brake pedal position
(distance “a” from the top of the rider footrest
to the top of the brake pedal)
Out of specification → Adjust.
c
d
Brake pedal position
110.0 mm (4.33 in)
c. Tighten the locknut.
EW1D71005
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance.
a
ECA13510
CAUTION:
After adjusting the brake pedal position,
make sure there is no brake drag.
2. Adjust:
• Brake pedal position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Adjust:
• Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-22.
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake pedal position is
obtained.
EAS21240
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
EWA13070
WARNING
2. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
3. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
After adjusting the brake pedal position,
check that the end of the adjusting bolt “c” is
visible through the hole “d”.
a
1
Front brake
Recommended fluid
DOT 4
Rear brake
Recommended fluid
DOT 4
b
2
3-20
CHASSIS
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “1” almost disappeared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-31.
B
1
a
A. Front brake
B. Rear brake
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicators “1” almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-43.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
1
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• Brake hoses “1”
Cracks/damage/wear → Replace.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
4. Install:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
3-21
CHASSIS
EAS21330
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
1
NOTE:
The rear brake light switch is operated by movement of the brake pedal. The rear brake light
switch is properly adjusted when the brake light
comes on just before the braking effect starts.
1
1. Check:
• Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• Rear brake light operation timing
2. Check:
• Brake hose clamps
Loose → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the brake
several times.
4. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-31.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the rear brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
rear brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
EAS21290
CHECKING THE REAR BRAKE HOSES
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Brake hoses “1”
Cracks/damage/wear → Replace.
1
2
a
1
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21350
1
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
1
EWA13100
3. Check:
• Brake hose clamp
Loose connection → Tighten the clamp bolt.
4. Check:
• Brake hose guide
Loose → Tighten the guide bolt.
5. Hold the vehicle upright and apply the brake
several times.
6. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-43.
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
3-22
CHASSIS
NOTE:
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
Loosening the bleed screw will release the pressure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
T.
R
2. Bleed:
• Hydraulic brake system
Bleed screw (front brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (rear brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
k. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
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a. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
2
EAS21380
ADJUSTING THE SHIFT PEDAL
NOTE:
1
The shift pedal position is determined by the installed shift rod length “a”.
B
1. Measure:
• Installed shift rod length “a”
Incorrect → Adjust.
2
Installed shift rod length
312.0–316.0 mm (12.28–12.44 in)
1
A. Front
B. Rear
a
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
2. Adjust:
• Installed shift rod length
3-23
CHASSIS
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1. Stand the vehicle on a level surface.
a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” until
the specified installed shift rod length is obtained.
Direction “a”
Installed shift rod length increases.
Direction “b”
Installed shift rod length decreases.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on the sidestand and or on a
suitable stand so that the rear wheel is elevated.
2. Check:
• Drive belt slack “a”
Out of specification → Adjust.
NOTE:
Make sure that the exposed thread length “c” between the locknut and joint on both ends of the
shift rod is 10 mm or less.
1
a
c
a
b
c
2
Drive belt slack (on the sidestand)
7.5–13 mm (0.30–0.51 in)
Drive belt slack (on a suitable
stand)
14–21 mm (0.55–0.83 in)
c. Tighten both locknuts.
T.
R
Locknut (shift rod)
12 Nm (1.2 m·kg, 8.7 ft·lb)
d. Make sure the installed shift rod length is
within specification.
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21430
ADJUSTING THE DRIVE BELT SLACK
NOTE:
NOTE:
The drive belt slack must be checked at the tightest point on the belt.
• The level marks of the level window on the lower drive belt cover are in units of 5 mm (0.20 in).
Use them as a standard for measuring the
drive belt slack.
• Measure the drive belt slack when the drive
belt has been pushed with 4.5 kg (10 lbs) of
pressure using a belt tension gauge “1”.
ECA14950
CAUTION:
A drive belt that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swingarm or cause an accident. Therefore, keep
the drive belt slack within the specified limits.
NOTE:
Measure the drive belt slack when the engine is
cold, and when the drive belt is dry.
3-24
CHASSIS
NOTE:
Using the alignment marks on each side of the
swingarm, make sure that both belt pullers are in
the same position for proper wheel alignment.
d. Tighten the locknuts to specification.
T.
1
R
3. Remove:
• Muffler
Refer to “ENGINE REMOVAL” on page 5-1.
4. Adjust:
• Drive belt slack
Locknut (drive belt adjusting
bolt)
16 Nm (1.6 m·kg, 11 ft·lb)
e. Tighten the rear wheel axle nut to specification.
T.
R
Rear wheel axle nut
150 Nm (15.0 m·kg, 110 ft·lb)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
5. Install:
• Muffler
Refer to “ENGINE REMOVAL” on page 5-1.
a. Loosen the wheel axle nut “1”.
EWA12800
WARNING
Always use a new gasket.
EAS21510
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a level surface.
EWA13120
WARNING
1
b. Loosen both locknuts “2”.
c. Turn both adjusting bolts “3” in direction “a” or
“b” until the specified drive belt slack is obtained.
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
Direction “a”
Drive belt is tightened.
Direction “b”
Drive belt is loosened.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
a
b
3
2
3-25
CHASSIS
T.
3. Remove:
• Upper bracket
Refer to “FRONT FORK” on page 4-60.
4. Adjust:
• Steering head
R
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-69.
e. Install the rubber washer “3”.
f. Install the upper ring nut.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
b. Loosen the lower ring nut “4”, and then tighten it to the specified torque with a steering nut
wrench “5”.
Lower ring nut (final tightening
torque)
18 Nm (1.8 m·kg, 13 ft·lb)
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
NOTE:
Set a torque wrench at a right angle to the steering nut wrench.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
T.
R
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m·kg, 37 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Upper bracket
Refer to “FRONT FORK” on page 4-60.
EAS21530
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Inner tube
Damage/scratches → Replace.
• Oil seal
Oil leakage → Replace.
c. Loosen the lower ring nut completely, and
then tighten it to specification with a steering
nut wrench.
EWA13140
WARNING
Do not overtighten the lower ring nut.
3-26
CHASSIS
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-60.
Spring preload adjusting positions
Installed spring length
Minimum
162.0 mm (6.38 in)
Standard
XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in)
Maximum
171.0 mm (6.73 in)
1
a
b
EAS21590
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
ECA13590
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Spring preload
c. Installed spring length
c. Tighten the locknut to specification.
NOTE:
T.
Adjust the spring preload with the special
wrench “1”.
R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “2”.
b. Turn the adjusting ring “3” in direction “a” or
“b”.
Locknut (rear shock absorber
spring preload adjusting nut)
30 Nm (3.0 m·kg, 22 ft·lb)
ECA13600
CAUTION:
Always tighten the locknut against the adjusting nut and torque it to specification.
Direction “a”
Spring preload is increased (suspension is harder).
Direction “b”
Spring preload is decreased (suspension is softer).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21650
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
3-27
CHASSIS
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, replace the tire immediately.
2. Check:
• Tire surfaces
Damage/wear → Replace the tire.
Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)
EWA13180
WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and accessories) and the anticipated riding
speed.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
1. Tire tread depth
2. Side wall
3. Wear indicator
Tire air pressure (measured on
cold tires)
Loading condition
0–90 kg (0–198 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
Rear
280 kPa (41 psi) (2.80 kgf/cm²)
Loading condition
XV19S(C)/XV19(C)/XV19M(C):
90–210 kg (198–463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
90–186 kg (198–410 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
Rear
280 kPa (41 psi) (2.80 kgf/cm²)
High-speed riding
Front
250 kPa (36 psi) (2.50 kgf/cm²)
Rear
280 kPa (41 psi) (2.80 kgf/cm²)
Maximum load
XV19S(C)/XV19(C)/XV19M(C):
210 kg (463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
186 kg (410 lb)
* Total weight of rider, passenger, cargo
and accessories
EWA14080
WARNING
• Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden
deflation.
• When using a tube tire, be sure to install the
correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
• Patching a punctured tube is not recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality replacement.
3-28
CHASSIS
• Install the tire with the mark pointing in the direction of wheel rotation.
• Align the mark “2” with the valve installation
point.
A. Tire
B. Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless tire
EAS21670
EWA14090
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• Wheel
Damage/out-of-round → Replace.
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one
approved by Yamaha is used on this vehicle.
Front tire
Size
130/70R18M/C 63H
Manufacturer/model
DUNLOP/D251F
Manufacturer/model
BRIDGESTONE/G851 RADIAL G
EWA13260
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
EAS21690
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
Rear tire
Size
190/60R17M/C 78H
Manufacturer/model
DUNLOP/D251
Manufacturer/model
BRIDGESTONE/G850 RADIAL G
EWA13270
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Replace damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
EWA13210
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
Recommended lubricant
Engine oil or a suitable cable lubricant
NOTE:
For tires with a direction of rotation mark “1”:
3-29
CHASSIS
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubricating device.
EAS21700
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium-soap-based grease
EAS21710
LUBRICATING THE PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Recommended lubricant
Lithium-soap-based grease
EAS21720
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS21740
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Lithium-soap-based grease
NOTE:
Lubricate the pivoting points and contact surfaces between the connecting rod and frame and
between the swingarm and frame.
3-30
ELECTRICAL SYSTEM
5. Replace:
• Low beam headlight bulb
EAS21750
ELECTRICAL SYSTEM
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect:
• Headlight coupler “1”
b. Remove:
• Headlight bulb “2”
EAS21760
CHECKING AND CHARGING THE BATTERY
Refer to “ELECTRICAL COMPONENTS” on
page 7-67.
EWA13320
EAS21770
WARNING
CHECKING THE FUSES
Refer to “ELECTRICAL COMPONENTS” on
page 7-67.
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
EAS21790
REPLACING THE HEADLIGHT BULBS
1. Remove:
• Windshield (For XV19CTS(C)/
XV19CT(C)/XV19CTM(C))
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Headlight cover “1”
2
1
1
c. Install:
• Headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
ECA13690
CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
3. Disconnect:
• Air temperature sensor coupler “1”
1
d. Connect:
• Headlight coupler
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Replace:
• High beam headlight bulb
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Remove:
• Headlight assembly “1”
a. Remove:
• Headlight bulb cover “1”
1
3-31
ELECTRICAL SYSTEM
7. Install:
• Headlight assembly
8. Connect:
• Air temperature sensor coupler
9. Install:
• Headlight cover
T.
Headlight cover bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
R
1
10.Install:
• Windshield (For XV19CTS(C)/
XV19CT(C)/XV19CTM(C))
Refer to “GENERAL CHASSIS” on page 4-1.
b. Disconnect:
• Headlight coupler “1”
c. Detach:
• Headlight bulb holder “2”
EAS21810
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
2
1
d. Remove:
• Headlight bulb
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
a
e. Install:
b
1
• Headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
ECA13690
CAUTION:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Adjust:
• Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
Direction “a”
Headlight beam moves to the right.
Direction “b”
Headlight beam moves to the left.
f. Attach:
• Headlight bulb holder
g. Connect:
• Headlight coupler
h. Install:
• Headlight bulb cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-32
ELECTRICAL SYSTEM
b
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-33
CHASSIS
GENERAL CHASSIS ...................................................................................... 4-1
REMOVING THE WINDSHIELD ............................................................... 4-2
ASSEMBLING THE WINDSHIELD ........................................................... 4-2
INSTALLING THE WINDSHIELD.............................................................. 4-2
REMOVING THE BACKREST .................................................................. 4-5
ASSEMBLING THE BACKREST .............................................................. 4-5
INSTALLING THE BACKREST................................................................. 4-5
CHECKING THE SIDEBAG BRACKET SPRING NUTS........................... 4-8
FRONT WHEEL ............................................................................................ 4-15
REMOVING THE FRONT WHEEL ......................................................... 4-18
DISASSEMBLING THE FRONT WHEEL................................................ 4-18
CHECKING THE FRONT WHEEL .......................................................... 4-18
ASSEMBLING THE FRONT WHEEL...................................................... 4-19
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-19
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-20
REAR WHEEL............................................................................................... 4-23
REMOVING THE REAR WHEEL (DISC)................................................ 4-28
DISASSEMBLING THE REAR WHEEL .................................................. 4-28
CHECKING THE REAR WHEEL ............................................................ 4-28
CHECKING THE REAR BRAKE CALIPER BRACKET........................... 4-28
CHECKING THE REAR WHEEL DRIVE HUB........................................ 4-29
CHECKING AND REPLACING THE REAR WHEEL PULLEY ............... 4-29
ASSEMBLING THE REAR WHEEL ........................................................ 4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-29
INSTALLING THE REAR WHEEL (DISC) .............................................. 4-29
FRONT BRAKE............................................................................................. 4-31
INTRODUCTION..................................................................................... 4-36
CHECKING THE FRONT BRAKE DISCS............................................... 4-36
REPLACING THE FRONT BRAKE PADS .............................................. 4-37
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-38
DISASSEMBLING THE FRONT BRAKE CALIPERS ............................. 4-38
CHECKING THE FRONT BRAKE CALIPERS........................................ 4-39
ASSEMBLING THE FRONT BRAKE CALIPERS ................................... 4-39
INSTALLING THE FRONT BRAKE CALIPERS...................................... 4-39
REMOVING THE FRONT BRAKE MASTER CYLINDER....................... 4-40
CHECKING THE FRONT BRAKE MASTER CYLINDER ....................... 4-40
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-41
INSTALLING THE FRONT BRAKE MASTER CYLINDER ..................... 4-41
4
REAR BRAKE............................................................................................... 4-43
INTRODUCTION..................................................................................... 4-49
CHECKING THE REAR BRAKE DISC ................................................... 4-49
REPLACING THE REAR BRAKE PADS ................................................ 4-49
REMOVING THE REAR BRAKE CALIPER ............................................ 4-50
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-50
CHECKING THE REAR BRAKE CALIPER............................................. 4-51
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-51
INSTALLING THE REAR BRAKE CALIPER........................................... 4-51
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-52
CHECKING THE REAR BRAKE MASTER CYLINDER.......................... 4-52
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ..................... 4-53
INSTALLING THE REAR BRAKE MASTER CYLINDER........................ 4-53
HANDLEBAR ................................................................................................ 4-55
REMOVING THE HANDLEBAR.............................................................. 4-57
CHECKING THE HANDLEBAR .............................................................. 4-57
INSTALLING THE HANDLEBAR ............................................................ 4-57
FRONT FORK ............................................................................................... 4-60
REMOVING THE FRONT FORK LEGS.................................................. 4-64
DISASSEMBLING THE FRONT FORK LEGS........................................ 4-64
CHECKING THE FRONT FORK LEGS .................................................. 4-65
ASSEMBLING THE FRONT FORK LEGS.............................................. 4-65
INSTALLING THE FRONT FORK LEGS ................................................ 4-68
STEERING HEAD ......................................................................................... 4-69
REMOVING THE LOWER BRACKET .................................................... 4-71
CHECKING THE STEERING HEAD....................................................... 4-71
INSTALLING THE STEERING HEAD..................................................... 4-71
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM...................... 4-73
HANDLING THE REAR SHOCK ABSORBER........................................ 4-76
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-76
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND
SWINGARM ........................................................................................... 4-76
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-77
CHECKING THE CONNECTING ARM AND RELAY ARM..................... 4-77
CHECKING THE SWINGARM ................................................................ 4-77
INSTALLING THE RELAY ARM, REAR SHOCK ABSORBER
ASSEMBLY AND CONNECTING ARMS............................................... 4-77
INSTALLING THE SWINGARM .............................................................. 4-79
BELT DRIVE ................................................................................................. 4-80
REMOVING THE DRIVE BELT AND DRIVE PULLEY ........................... 4-82
CHECKING THE DRIVE BELT ............................................................... 4-82
INSTALLING THE DRIVE BELT AND DRIVE PULLEY.......................... 4-82
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the windshield (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))
5
1
T
R
23 Nm (2.3 m • kg, 17 ft • Ib)
LT
6
R
4
23 Nm (2.3 m • kg, 17 ft • Ib)
LT
LT
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
LT
2
3
R
R
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T
8 Nm (0.8 m • kg, 5.8 ft • Ib)
3
R
T
R
Order
Job/Parts to remove
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
1
Windshield
2
Windshield bracket brace
1
3
Windshield bracket (left and right)
2
4
Windshield brace (left and right)
2
5
Windshield screen
1
6
Windshield holder bracket assembly (left and
right)
2
Remarks
1
For installation, reverse the removal procedure.
4-1
GENERAL CHASSIS
ET1D71039
REMOVING THE WINDSHIELD
1. Remove:
• Windshield
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a. Insert the key “1” into the windshield lock, turn
it clockwise and then remove the key.
2
b
2
1
ET1D71040
INSTALLING THE WINDSHIELD
1. Install:
• Right windshield holder bracket assembly “1”
NOTE:
Pass the throttle cables “2” between the front
fork and the right windshield holder bracket assembly.
2. Unlock.
b. Remove the windshield by pushing it forward,
and then pulling it upward as shown.
EW1D71016
WARNING
Be careful not to push the vehicle forward
when removing the windshield. The vehicle
could fall off the sidestand.
2
1
EC1D71025
CAUTION:
Securely hold the windshield to prevent it
from falling when removing.
2. Install:
• Windshield
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the slot “a” in each windshield bracket (left
and right side) into its holder “b”.
NOTE:
Make sure that the throttle cables “1” are not
pinched.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71045
a
ASSEMBLING THE WINDSHIELD
1. Install:
• Windshield lock “1”
b
NOTE:
Align the projection “a” on the lock “1” with the
slot “b” in the windshield bracket “2”.
1
b. Push the windshield backward until it snaps
into place.
4-2
GENERAL CHASSIS
c. Insert the key into the windshield lock, turn it
counterclockwise until it stops to lock the fastener, and then remove the key.
1
2
1. Lock
2. Fastener
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-3
GENERAL CHASSIS
Removing the sidebags and backrest (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T
R
23 Nm (2.3 m • kg, 17 ft • Ib)
4
6
3
5
2
7
1
5
7
1
T
R
Order
Job/Parts to remove
12 Nm (1.2 m • kg, 8.7 ft • Ib)
Q’ty
Remarks
NOTE:
1
Sidebag (left and right)
2
2
Backrest assembly
1
3
Backrest upper bracket stay
1
4
Backrest pad
1
5
Backrest plate
2
6
Backrest upper bracket
1
7
Backrest lower bracket (left and right)
2
Water can be harmful to untreated leather.
Use Yamaha Saddle Soap or another quality
brand according to the manufacturer’s directions to clean the leather on the sidebags.
Polish the dry leather with a soft cloth, and
then treat with Yamaha Mink Oil or another
high-quality leather protectant for increased
water resistance.
For installation, reverse the removal procedure.
4-4
GENERAL CHASSIS
ET1D71041
NOTE:
REMOVING THE BACKREST
1. Remove:
• Backrest
Align the projection “a” on the lock “1” with the
slot “b” in the left backrest lower bracket “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Open the sidebag lids.
b. Insert the key “1” into the backrest lock, turn
it counterclockwise, and then remove the
key.
a
1
2
2
b
2. Install:
• Backrest lower brackets “1”
• Backrest upper bracket “2”
• Backrest plate
1
NOTE:
2. Unlock.
Before tightening the bolts “3” to specification,
temporarily install the backrest lower brackets
on the backrest holders, making sure not to push
down on the rear of the brackets. The lower bolts
cannot be tightened when the backrest lower
brackets are installed completely.
c. Pull the lever “1” on each side of the backrest
upward.
2
1
1
1
d. While holding the levers in the upward position, lift the backrest upward and remove it by
pulling it to the rear.
3
ET1D71042
INSTALLING THE BACKREST
1. Install:
• Backrest
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the slot “a” on each backrest bracket (left
and right side) into the groove of its holder “b”.
EC1D71026
CAUTION:
Be careful not to scratch the rear fender
when fitting the slot into the groove.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71046
ASSEMBLING THE BACKREST
1. Install:
• Backrest lock “1”
4-5
GENERAL CHASSIS
b
a
b. Push the rear of the backrest down smoothly
but forcefully to lock it in place and make sure
that the lever hook “1” on each side is securely fit over its holder “2”.
EW1D71017
WARNING
Both lever hooks must be securely fitted
over their holder. If the backrest is loose, a
passenger might lose balance and fall.
1
2
c. Insert the key into the backrest lock, turn it
clockwise, and then remove the key.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS
Removing the sidebag brackets (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))
R
48 Nm (4.8 m • kg, 35 ft • Ib)
4
LT
1
3
4
LT
1
3
2
T
R
R
R
48 Nm (4.8 m • kg, 35 ft • Ib)
T
T
Order
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Parts to remove
Q’ty
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Sidebag/Backrest
1
Passenger footrest (left and right)
2
2
Sidebag bracket brace
1
NOTE:
3
Sidebag bracket (left and right)
2
4
O2 sensor lead guide
1
Remove only one sidebag bracket at a time.
If both brackets are removed at the same
time, the rear fender will fall.
NOTE:
Pass the O2 sensor lead through the guide.
For installation, reverse the removal procedure.
4-7
GENERAL CHASSIS
ET1D71047
CHECKING THE SIDEBAG BRACKET
SPRING NUTS
1. Check:
• Sidebag bracket spring nut height “a”
Out of specification → Adjust.
Sidebag bracket spring nut
height
12.0 mm (0.47 in)
a
2. Check:
• Sidebag bracket spring nuts
Damage → Replace.
4-8
GENERAL CHASSIS
Removing the seats and side covers
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
2
3
1
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
LT
6
4
T
23 Nm (2.3 m • kg, 17 ft • Ib)
R
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
7
5
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
8
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T
R
Order
Job/Parts to remove
Q’ty
1
Rider seat
1
2
Passenger seat
1
3
Tool kit
1
4
Tool kit tray
1
5
Rider seat bracket assembly
1
6
Right side cover
1
7
Left side cover
1
8
Seat lock cable assembly
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
4-9
GENERAL CHASSIS
Removing the headlight
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
2
3
1
13
10
10
7
9
5
6
8
12
4
11
T
R
Order
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Parts to remove
Q’ty
Headlight cover
Remarks
1
2
Air temperature sensor coupler
1
3
Air temperature sensor
1
Disconnect.
4
Headlight (low beam) coupler
1
Disconnect.
5
Headlight (high beam) coupler
1
Disconnect.
6
Headlight lens unit
1
7
Front left turn signal/position light coupler
1
Disconnect.
8
Front right turn signal/position light coupler
1
Disconnect.
9
Wire harness stopper bracket
1
10
Left handlebar switch coupler
4
Disconnect.
11
Right handlebar switch coupler
3
Disconnect.
12
Main switch coupler
2
Disconnect.
13
Headlight body
1
For installation, reverse the removal procedure.
4-10
GENERAL CHASSIS
Removing the battery
1
6
4
10
5
2
9
7
8
3
16
17
18
15
13
(3)
11
14
19
12
20
19
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Tool kit tray/Seat bracket
1
ECU band
1
2
ECU (electronic control unit)
1
3
Coupler tray
1
4
Negative terminal cover
1
5
Negative battery lead
1
Disconnect.
6
Positive battery lead
1
Disconnect.
7
Battery
1
8
Battery band
1
9
Sub-wire harness 1
1
10
Main fuse
1
11
Plastic locking tie
1
12
Fuse box
1
13
Starter relay coupler
1
14
Starter relay
1
15
Diode 1
1
16
Relay unit
1
4-11
Disconnect.
Disconnect.
GENERAL CHASSIS
Removing the battery
1
6
4
10
5
2
9
7
8
3
16
17
18
15
13
(3)
11
14
19
12
20
19
Order
17
Job/Parts to remove
Q’ty
Headlight relay
Remarks
1
18
Turn signal relay
1
19
Plastic locking tie
2
20
Battery box
1
For installation, reverse the removal procedure.
4-12
GENERAL CHASSIS
Removing the air filter case
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
(7)
9
1
2
5
15
10
7
6
16
13
8
12
14
17
16
3
11
4
Order
Job/Parts to remove
Q’ty
Remarks
Rider seat
Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Pressure regulator cover
Refer to “THROTTLE BODIES” on page 6-6.
1
Air filter case cover
1
2
Air filter element
1
3
Cylinder-#1 intake air pressure sensor coupler
1
Disconnect.
4
Cylinder-#1 intake air pressure sensor hose
1
Disconnect.
5
Cylinder-#1 intake air pressure sensor
1
6
Cylinder-#1 intake air pressure sensor bracket
1
7
Cylinder-#2 intake air pressure sensor coupler
1
Disconnect.
8
Cylinder-#2 intake air pressure sensor hose
1
Disconnect.
9
Cylinder-#2 intake air pressure sensor
1
10
Cylinder-#2 intake air pressure sensor bracket
1
11
Cylinder head breather hose
1
Disconnect.
12
Air filter case breather hose 1
1
Disconnect.
13
Air filter case breather hose 2
1
Disconnect.
14
ISC (idle speed control) unit inlet hose
1
Disconnect.
4-13
GENERAL CHASSIS
Removing the air filter case
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
(7)
9
1
2
5
15
10
7
6
16
13
8
12
14
17
16
3
11
4
Order
15
Job/Parts to remove
Q’ty
Air filter case bracket
1
16
Air filter case joint clamp screw
2
17
Air filter case
1
Remarks
Loosen.
For installation, reverse the removal procedure.
4-14
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
40 Nm (4.0 m • kg, 29 ft • Ib)
R
40 Nm (4.0 m • kg, 29 ft • Ib)
R
R
8
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
9
5
LT
1
10
7
4
6
(4)
LT
R
LT
9
11
LT
8
10
16 Nm (1.6 m • kg, 11 ft • Ib)
3
12
R
T
T
R
15
R
14
72 Nm (7.2 m • kg, 52 ft • Ib)
16
(6)
23 Nm (2.3 m • kg, 17 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
2
LT
16
LT
T
R
13
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
LT
R
23 Nm (2.3 m • kg, 17 ft • Ib)
R
Job/Parts to remove
T
Order
(6)
23 Nm (2.3 m • kg, 17 ft • Ib)
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
1
Right front fender stay
1
2
Left front fender stay
1
3
Front fender stay rod
1
4
Front brake hose guide
2
5
Right front brake hose guide bracket
1
6
Left front brake hose guide bracket
1
7
Front fender
1
8
Reflector
2
9
Reflector bracket
2
10
Front brake caliper
2
11
Front wheel axle pinch bolt
1
12
Front wheel axle
1
13
Front wheel
1
4-15
Loosen.
FRONT WHEEL
Removing the front wheel and brake discs
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
40 Nm (4.0 m • kg, 29 ft • Ib)
R
40 Nm (4.0 m • kg, 29 ft • Ib)
T
R
8
LT
R
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
9
5
LT
1
10
7
4
6
(4)
LT
R
LT
3
9
11
LT
8
10
16 Nm (1.6 m • kg, 11 ft • Ib)
12
R
T
T
R
15
R
14
72 Nm (7.2 m • kg, 52 ft • Ib)
16
(6)
23 Nm (2.3 m • kg, 17 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
2
LT
16
LT
T
R
13
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
LT
R
23 Nm (2.3 m • kg, 17 ft • Ib)
R
14
Job/Parts to remove
T
Order
(6)
Q’ty
Collar
2
15
Front brake disc cover
1
16
Front brake disc
2
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
For installation, reverse the removal procedure.
4-16
FRONT WHEEL
Disassembling the front wheel
New 1
2
LS
3
2
1 New
LS
Order
Job/Parts to remove
Q’ty
1
Oil seal
2
2
Wheel bearing
2
3
Spacer
1
Remarks
For assembly, reverse the disassembly procedure.
4-17
FRONT WHEEL
EAS21900
EAS21910
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
DISASSEMBLING THE FRONT WHEEL
1. Remove:
• Oil seals
• Wheel bearings
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Right front fender stay “1”
• Left front fender stay “2”
• Front fender stay rod “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
NOTE:
• Remove the right front fender stay bolts and
left front fender stay bolt (rear side), then hold
the rod with a wrench “4” and remove the left
front fender stay bolt (front side) “5”.
• Remove the rod from the right side of the vehicle.
c. Remove the wheel bearings “3” with a general bearing puller.
3
2
5
1
4
3. Loosen:
• Front wheel axle pinch bolt “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21920
CHECKING THE FRONT WHEEL
1. Check:
• Front wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
1
4. Remove:
• Front brake calipers
EWA13460
WARNING
NOTE:
Do not attempt to straighten a bent wheel axle.
Do not apply the brake lever when removing the
brake calipers.
5. Elevate:
• Front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
4-18
FRONT WHEEL
EAS21960
ASSEMBLING THE FRONT WHEEL
1. Install:
• Wheel bearings New
• Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals in
the reverse order of disassembly.
EC1D71011
CAUTION:
2. Check:
• Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-27 and “CHECKING THE WHEELS” on
page 3-29.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
NOTE:
Use a socket “4” that matches the diameter of
the wheel bearing outer race and oil seal.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21970
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose → Replace the wheel bearings.
• Oil seals
Damage/wear → Replace.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
4-19
FRONT WHEEL
c. Turn the front wheel 90° so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
3. Adjust:
• Front wheel static balance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “X”.
EAS22000
INSTALLING THE FRONT WHEEL (FRONT
BRAKE DISCS)
The following procedure applies to both of the
front brake discs.
1. Install:
• Front brake disc
• Front brake disc cover
NOTE:
Start with the lightest weight.
T.
R
Front brake disc bolt
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
NOTE:
Tighten the front brake disc bolts in stages and
in a crisscross pattern.
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
4-20
FRONT WHEEL
T.
R
Front brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
EWA13500
WARNING
Make sure the brake hose is routed properly.
2. Check:
• Front brake discs
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-36.
3. Lubricate:
• Oil seal lips
7. Install:
• Front fender
• Left front brake hose guide bracket
• Right front brake hose guide bracket
NOTE:
• Temporarily tighten the front fender bolts.
• Apply locking agent (LOCTITE®) to the threads
of the front fender bolts.
8. Install:
• Front fender stay rod “1”
• Left front fender stay “2”
• Right front fender stay “3”
Recommended lubricant
Lithium-soap-based grease
4. Install:
• Front wheel axle
NOTE:
• Insert the rod into the front wheel axle from the
right side of the vehicle.
• Tighten the left front fender stay bolt (front
side) “4” to specification while holding the rod
with a wrench “5”, and then tighten the left front
fender stay bolt (rear side) and right front fender stay bolts to specification.
NOTE:
Install the tire and wheel with the mark “1” pointing in the direction of wheel rotation.
1
2
5. Tighten:
• Front wheel axle
• Front wheel axle pinch bolt
4
5
3
9. Tighten:
• Front fender bolts
T.
R
Front wheel axle
72 Nm (7.2 m·kg, 52 ft·lb)
Front wheel axle pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R
EC1D71004
CAUTION:
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
6. Install:
• Front brake calipers
4-21
Front fender bolt
16 Nm (1.6 m·kg, 11 ft·lb)
LOCTITE®
FRONT WHEEL
4-22
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear fender
3
1
LT
2
3
4
LT
3
3
2
R
23 Nm (2.3 m • kg, 17 ft • Ib)
T
R
40 Nm (4.0 m • kg, 29 ft • Ib)
Order
Job/Parts to remove
Q’ty
Refer to “GENERAL CHASSIS” on page
4-1.
Rider seat/Passenger seat/Tool kit tray
1
Remarks
Sub-wire harness 1 coupler
1
2
Rear fender bracket
2
3
Dowel pin
4
4
Rear fender assembly
1
Disconnect.
For installation, reverse the removal procedure.
4-23
REAR WHEEL
Removing the rear wheel
R
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
16 Nm (1.6 m • kg, 11 ft • Ib)
T
R
6
150 Nm (15.0 m • kg, 110 ft • lb)
T
5
R
27 Nm (2.7 m • kg, 19 ft • Ib)
10
8 7
1
LS
6
5
11
9
3
2
4
LS
12
4
13
LS
14
15
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
Muffler
Refer to “ENGINE REMOVAL” on page 5-1.
1
Upper drive belt cover
1
2
Rear brake caliper
1
3
Rear brake pad
2
4
Brake pad spring
2
5
Drive belt adjusting locknut
2
Loosen.
6
Drive belt adjusting bolt
2
Loosen.
7
Rear wheel axle nut
1
8
Washer
1
9
Rear wheel axle
1
10
Right drive belt puller
1
11
Left drive belt puller
1
12
Rear brake caliper bracket
1
13
Collar
1
4-24
Black
REAR WHEEL
Removing the rear wheel
R
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
16 Nm (1.6 m • kg, 11 ft • Ib)
T
R
6
T
5
150 Nm (15.0 m • kg, 110 ft • lb)
R
27 Nm (2.7 m • kg, 19 ft • Ib)
10
8 7
1
LS
6
5
11
9
3
2
4
LS
12
4
13
LS
14
15
Order
Job/Parts to remove
Q’ty
14
Collar
1
15
Rear wheel
1
Remarks
Silver
For installation, reverse the removal procedure.
4-25
REAR WHEEL
Removing the rear brake disc and rear wheel drive hub
Order
Job/Parts to remove
Q’ty
1
Rear brake disc cover
2
Rear brake disc
1
3
Rear wheel pulley
1
4
Oil seal
1
5
Circlip
1
6
Rear wheel drive hub
1
7
Circlip
1
8
Bearing
1
9
Collar
1
Remarks
1
10
Bearing
1
11
Rear wheel drive hub damper
6
12
Rear wheel
1
For installation, reverse the removal procedure.
4-26
REAR WHEEL
Disassembling the rear wheel
New 4
5
6
LS
3
2
1
Order
Job/Parts to remove
Q’ty
1
Collar
2
Bearing
1
3
Spacer
1
4
Oil seal
1
5
Circlip
1
6
Bearing
1
Remarks
1
For assembly, reverse the disassembly procedure.
4-27
REAR WHEEL
EAS28760
REMOVING THE REAR WHEEL (DISC)
1. Stand the vehicle on a level surface.
1
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2
NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Remove:
• Rear brake caliper “1”
EAS22080
DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seals
• Wheel bearings
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-18.
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
EAS22090
CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Wheel bearings
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-18.
2. Check:
• Tire
• Rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-27 and “CHECKING THE WHEELS” on
page 3-29.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-18.
1
3. Loosen:
• Drive belt adjusting locknuts “1”
• Drive belt adjusting bolts “2”
2
1
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Remove:
• Rear wheel axle nut “1”
• Rear wheel axle “2”
• Rear wheel
NOTE:
ET1D71024
Push the rear wheel forward and remove the
drive belt from the rear wheel pulley.
CHECKING THE REAR BRAKE CALIPER
BRACKET
1. Check:
• Rear brake caliper bracket
Cracks/damage → Replace.
4-28
REAR WHEEL
EAS22110
EAS22150
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• Rear wheel drive hub
Cracks/damage → Replace.
• Rear wheel drive hub dampers
Damage/wear → Replace.
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.
EAS22130
CHECKING AND REPLACING THE REAR
WHEEL PULLEY
1. Check:
• Rear wheel pulley
Surface plating has come off → Replace the
rear wheel pulley.
Bent teeth → Replace the rear wheel pulley.
2. Replace:
• Rear wheel pulley
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-19.
EAS28770
INSTALLING THE REAR WHEEL (DISC)
1. Lubricate:
• Rear wheel axle
• Oil seal lips
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear
wheel pulley.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
pulley.
c. Install the new rear wheel pulley.
Recommended lubricant
Lithium-soap-based grease
2. Install:
• Rear brake disc
• Rear brake disc cover
T.
R
Rear brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
T.
Rear wheel pulley self-locking
nut
95 Nm (9.5 m·kg, 68 ft·lb)
R
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
NOTE:
• Apply locking agent (LOCTITE®) to the threads
of the brake disc bolts.
• Tighten the brake disc bolts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
LT
EAS22140
ASSEMBLING THE REAR WHEEL
1. Install:
3. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-49.
4. Install:
• Rear wheel axle
• Washer
• Rear wheel axle nut
• Wheel bearings New
• Oil seals New
Refer to “ASSEMBLING THE FRONT
WHEEL” on page 4-19.
4-29
REAR WHEEL
NOTE:
Temporarily tighten the wheel axle nut.
5. Adjust:
• Drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-24.
6. Tighten:
• Rear wheel axle nut
T.
R
Rear wheel axle nut
150 Nm (15.0 m·kg, 110 ft·lb)
7. Install:
• Rear brake caliper
T.
R
Rear brake caliper
27 Nm (2.7 m·kg, 19 ft·lb)
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-30
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
3
2
LT
4
6
5
9
T
R
40 Nm (4.0 m • kg, 29 ft • Ib)
T
R
6 Nm (0.6 m • kg, 4.3 ft • Ib)
8
9
Order
Job/Parts to remove
Q’ty
7
Remarks
The following procedure applies to both of
the front brake calipers.
1
Brake hose holder
1
2
Reflector
1
3
Reflector bracket
1
4
Front brake caliper
1
5
Brake pad clip
2
6
Brake pad pin
1
7
Brake pad spring
1
8
Brake pad
2
9
Brake pad shim
2
For installation, reverse the removal procedure.
4-31
FRONT BRAKE
Removing the front brake master cylinder
1
2
3
4
LS
R
30 Nm (3.0 m • kg, 22 ft • Ib)
10 9
12
9
8
6
New
5
7
11
T
R
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Remarks
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Brake fluid
1
Right rearview mirror
1
2
Brake master cylinder reservoir cap
1
3
Brake master cylinder reservoir diaphragm holder
1
4
Brake master cylinder reservoir diaphragm
1
5
Brake lever
1
6
Brake light switch connector
2
7
Brake light switch
1
8
Front brake hose union bolt
1
9
Copper washer
2
10
Front brake hose
1
11
Front brake master cylinder holder
1
12
Front brake master cylinder
1
Disconnect.
For installation, reverse the removal procedure.
4-32
FRONT BRAKE
Disassembling the front brake master cylinder
4
3 New
2
New
1
LS
Order
Job/Parts to remove
Q’ty
1
Dust boot
1
2
Circlip
1
3
Brake master cylinder kit
1
4
Brake master cylinder body
1
Remarks
For assembly, reverse the disassembly procedure.
4-33
FRONT BRAKE
Removing the front brake calipers
6
7
5
3 New
R
40 Nm (4.0 m • kg, 29 ft • Ib)
1
T
R
32 Nm (3.2 m • kg, 23 ft • Ib)
4
2
R
Order
Job/Parts to remove
Q’ty
LT
3 New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Brake fluid
1
Brake hose holder
1
2
Front brake hose union bolt
1
3
Copper washer
2
4
Front brake hose
1
5
Reflector
1
6
Reflector bracket
1
7
Front brake caliper
1
For installation, reverse the removal procedure.
4-34
FRONT BRAKE
Disassembling the front brake calipers
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front brake calipers.
1
Brake pad clip
2
2
Brake pad pin
1
3
Brake pad spring
1
4
Brake pad
2
5
Brake pad shim
2
6
Brake caliper piston
4
7
Brake caliper piston seal
8
8
Bleed screw
1
For assembly, reverse the disassembly procedure.
4-35
FRONT BRAKE
e. Measure the deflection 1.5 mm (0.06 in) below the edge of the brake disc.
EAS22220
INTRODUCTION
EWA14100
WARNING
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
• Never disassemble brake components unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
• Never use solvents on internal brake components.
• Use only clean or new brake fluid for cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get immediate medical attention.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
Brake disc thickness limit
4.5 mm (0.18 in)
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-15.
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
T.
R
Brake disc deflection limit
0.10 mm (0.0039 in)
5. Adjust:
• Brake disc deflection
Front brake disc bolt
23 Nm (2.3 m·kg, 17ft·lb)
LOCTITE®
NOTE:
• Apply locking agent (LOCTITE®) to the threads
of the brake disc bolts.
• Tighten the brake disc bolts in stages and in a
crisscross pattern.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-36
FRONT BRAKE
a
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
2. Install:
• Brake 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.
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-15.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
2
1
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (inner)
5.5 mm (0.22 in)
Limit
0.5 mm (0.02 in)
Brake pad lining thickness (outer)
5.5 mm (0.22 in)
Limit
0.5 mm (0.02 in)
c. Tighten the bleed screw.
T.
R
Bleed screw (front brake caliper)
6 Nm (0.6 m·kg, 4.3ft·lb)
d. Install a new brake pad shim onto each new
brake pad.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow mark “a” on the brake pad spring
must point in the direction of disc rotation.
4-37
FRONT BRAKE
• Front brake hose “4”
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
1
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper
2
3
EAS22350
T.
R
Front brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston seals “2”
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
EW1D71001
WARNING
Do not loosen the bolts “3”.
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
EWA13560
WARNING
EAS22300
• Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pistons are expelled from the brake caliper.
• Never try to pry out the brake caliper pistons.
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose holder “1”
• Front brake hose union bolt “2”
• Copper washers “3”
4-38
FRONT BRAKE
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA13620
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
a
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22390
CHECKING THE FRONT BRAKE CALIPERS
Recommended fluid
DOT 4
Recommended brake component replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
EAS22440
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Install:
• Front brake caliper “1”
(temporarily)
• Copper washers New
• Front brake hose “2”
• Front brake hose union bolt “3”
T.
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
R
Front brake hose union bolt
32 Nm (3.2 m·kg, 23 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
EWA13600
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
2
3
a
1
2
b
3
1
1
4-39
FRONT BRAKE
2. Remove:
• Front brake caliper
3. Install:
• Brake pads
• Brake pad spring
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Brake hose guide
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
T.
R
Brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
Brake hose holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
7. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-37.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT 4
EAS22490
REMOVING THE FRONT BRAKE MASTER
CYLINDER
NOTE:
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake system.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
1. Remove:
• Front brake hose union bolt “1”
• Copper washers “2”
• Front brake hose “3”
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
1
ECA13540
CAUTION:
2
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
6. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder “1”
Damage/scratches/wear → Replace.
4-40
FRONT BRAKE
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
• First, tighten the rear bolt, then the front bolt.
1
a
1
2. Install:
• Copper washers New
• Front brake hose “1”
• Front brake hose union bolt “2”
R
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
T.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
EAS22520
2
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
NOTE:
• Install the brake hose at a right angle to the
front brake master cylinder as shown in the illustration.
• While holding the brake hose, tighten the union
bolt.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
EWA13520
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components.
Recommended fluid
DOT 4
EAS22530
2
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
1
10–30˚
T.
R
Front brake master cylinder holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
NOTE:
• Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar.
Recommended fluid
DOT 4
4-41
FRONT BRAKE
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause
vapor lock.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
4-42
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
T
R
4
6 Nm (0.6 m • kg, 4.3 ft • Ib)
3
4
2
LS
1
1
R
Order
1
27 Nm (2.7 m • kg, 19 ft • Ib)
Job/Parts to remove
Q’ty
Rear brake caliper bolt
Remarks
2
2
Rear brake caliper
1
3
Rear brake pad
2
4
Brake pad spring
2
For installation, reverse the removal procedure.
4-43
REAR BRAKE
Removing the rear brake master cylinder
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
4
1
2
5
10
LS
11
New
12
14
13
15
T
R
9
T
R
R
16 Nm (1.6 m • kg, 11 ft • Ib)
30 Nm (3.0 m kg, 22 ft Ib)
•
R
Order
48 Nm (4.8 m • kg, 35 ft • Ib)
6
7 8 New
23 Nm (2.3 m • kg, 17 ft • Ib)
LT
•
Job/Parts to remove
Q’ty
Remarks
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Brake fluid
1
Brake fluid reservoir cap
1
2
Brake fluid reservoir diaphragm holder
1
3
Brake fluid reservoir diaphragm
1
4
Brake fluid reservoir
1
5
Brake fluid reservoir hose
1
6
Rear brake master cylinder cover
1
7
Rear brake hose union bolt
1
8
Copper washer
2
9
Rear brake hose
1
10
Rear brake light switch
1
11
Right rider footrest assembly
1
12
Brake rod
1
13
Locknut
1
14
Brake master cylinder bracket
1
4-44
REAR BRAKE
Removing the rear brake master cylinder
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
4
1
2
5
10
LS
11
New
12
14
13
15
T
R
9
T
R
R
R
15
16 Nm (1.6 m • kg, 11 ft • Ib)
30 Nm (3.0 m kg, 22 ft Ib)
•
Order
48 Nm (4.8 m • kg, 35 ft • Ib)
6
7 8 New
23 Nm (2.3 m • kg, 17 ft • Ib)
LT
•
Job/Parts to remove
Q’ty
Brake master cylinder
Remarks
1
For installation, reverse the removal procedure.
4-45
REAR BRAKE
Disassembling the rear brake master cylinder
1
2 New
4 New
3 New
5
6
7
Order
Job/Parts to remove
Q’ty
1
Dust boot
1
2
Circlip
1
3
Brake master cylinder kit
1
4
Circlip
1
5
Brake hose joint
1
6
O-ring
1
7
Brake master cylinder body
1
Remarks
For assembly, reverse the disassembly procedure.
4-46
REAR BRAKE
Removing the rear brake caliper
5
LS
4
3
4
2 New
T
R
Order
R
1
30 Nm (3.0 m • kg, 22 ft • Ib)
27 Nm (2.7 m • kg, 19 ft • Ib)
Job/Parts to remove
Q’ty
Remarks
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Brake fluid
1
Rear brake hose union bolt
1
2
Copper washer
2
3
Rear brake hose
1
4
Rear brake caliper bolt
2
5
Rear brake caliper
1
For installation, reverse the removal procedure.
4-47
REAR BRAKE
Disassembling the rear brake caliper
1
2 New
T
R
6 Nm (0.6 m • kg, 4.3 ft • Ib)
3
Order
Job/Parts to remove
Q’ty
1
Brake caliper piston
2
Brake caliper piston seal
2
3
Bleed screw
1
Remarks
1
For assembly, reverse the disassembly procedure.
4-48
REAR BRAKE
EAS22560
INTRODUCTION
Brake disc thickness limit
5.5 mm (0.22 in)
EWA14100
WARNING
5. Adjust:
• Brake disc deflection
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-36.
T.
R
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
• Never disassemble brake components unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
• Never use solvents on internal brake components.
• Use only clean or new brake fluid for cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get immediate medical attention.
Brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
6. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-23.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (inner)
5.8 mm (0.23 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness (outer)
5.8 mm (0.23 in)
Limit
0.8 mm (0.03 in)
EAS22570
CHECKING THE REAR BRAKE DISC
1. Remove:
• Rear wheel
Refer to “REAR WHEEL” on page 4-23.
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-36.
a
Brake disc deflection limit
0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-36.
2. Install:
• Brake pads
• Brake pad springs
4-49
REAR BRAKE
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
NOTE:
Always install new brake pads and brake pad
springs as a set.
EAS22590
REMOVING THE REAR BRAKE CALIPER
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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 piston into the brake caliper with your
finger.
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Rear brake hose union bolt “1”
• Copper washers “2”
• Rear brake hose “3”
2
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
1
c. Tighten the bleed screw.
T.
R
Bleed screw (rear brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake caliper
1
3
EAS22600
T.
R
DISASSEMBLING THE REAR BRAKE
CALIPER
1. Remove:
• Brake caliper piston
• Brake caliper piston seals
Rear brake caliper bolt
27 Nm (2.7 m·kg, 19 ft·lb)
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the piston from the
brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
a
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
4-50
REAR BRAKE
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
EWA13620
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
a
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Recommended fluid
DOT 4
EAS22640
CHECKING THE REAR BRAKE CALIPER
Recommended brake component replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Rear brake caliper “1”
(temporarily)
• Copper washers New
• Rear brake hose “2”
• Rear brake hose union bolt “3”
T.
1. Check:
• Brake caliper piston “1”
Rust/scratches/wear → Replace the brake
caliper piston.
• Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
R
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
b
3
1
1
3
2. Remove:
• Rear brake caliper
3. Install:
• Brake pads
2
4-51
a
2
REAR BRAKE
• Brake pad springs
• Rear brake caliper bolts
• Rear brake caliper
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-49.
T.
R
Rear brake caliper bolt
27 Nm (2.7 m·kg, 19 ft·lb)
a
4. Fill:
• Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
7. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
Recommended fluid
DOT 4
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
EAS22700
REMOVING THE REAR BRAKE MASTER
CYLINDER
NOTE:
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake system.
1. Remove:
• Rear brake hose union bolt “1”
• Copper washers “2”
• Rear brake hose “3”
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
ECA13540
CAUTION:
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” on page 3-22.
6. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
3
1
2
EAS22720
CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
4-52
REAR BRAKE
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir
Cracks/damage → Replace.
• Brake fluid reservoir diaphragm
Cracks/damage → Replace.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
a
2
3
1 New
2. Fill:
• Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
EAS22730
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA13520
Recommended fluid
DOT 4
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.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Recommended fluid
DOT 4
EAS22740
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• Copper washers “1” New
• Rear brake hose “2”
• Rear brake hose union bolt “3”
ECA13540
CAUTION:
T.
R
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
EWA13530
WARNING
3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
EC1D71009
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection “a” on the brake
caliper bracket as shown.
4-53
REAR BRAKE
a
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-20.
7. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-22.
4-54
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
1
T
R
28 Nm (2.8 m • kg, 20 ft • Ib)
1
5
LS
13
2
6
2
7
16
17
8
10
4
3
14
LS
9
7
T
23 Nm (2.3 m • kg, 17 ft • Ib)
R
19
11
15
14
9
LT
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12
R
50 Nm (5.0 m • kg, 36 ft • Ib)
18
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
Order
32 Nm (3.2 m • kg, 23 ft • Ib)
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Headlight body
1
Rearview mirror
2
2
Plastic clamp
2
3
Front brake light switch connector
2
4
Front brake master cylinder holder
1
5
Front brake master cylinder assembly
1
6
Throttle cable holder
1
7
Right handlebar switch
1
8
Throttle cable
2
9
Grip end
2
10
Throttle grip
1
11
Clutch switch coupler
1
12
Clutch master cylinder holder
1
13
Clutch master cylinder assembly
1
14
Left handlebar switch
2
4-55
Disconnect.
Disconnect.
HANDLEBAR
Removing the handlebar
1
T
R
28 Nm (2.8 m • kg, 20 ft • Ib)
1
5
LS
13
2
6
2
7
16
17
8
10
4
3
14
LS
9
7
T
23 Nm (2.3 m • kg, 17 ft • Ib)
R
19
11
15
14
9
LT
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12
R
50 Nm (5.0 m • kg, 36 ft • Ib)
18
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
Order
15
32 Nm (3.2 m • kg, 23 ft • Ib)
Job/Parts to remove
Q’ty
Handlebar grip
Remarks
1
16
Upper handlebar holder
1
17
Handlebar
1
18
Hose guide
1
19
Lower handlebar holder
1
For installation, reverse the removal procedure.
4-56
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
1
2
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Handlebar grip “1”
NOTE:
3. Pass the left and right handlebar switch leads
through the handlebar.
4. Install:
• Handlebar “1”
• Upper handlebar holder “2”
Blow compressed air between the handlebar
and the left handlebar grip, and gradually push
the grip off the handlebar.
T.
Upper handlebar holder bolt
28 Nm (2.8 m·kg, 20 ft·lb)
R
ECA14250
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage → Replace.
NOTE:
Align the match marks “a” on the handlebar with
the upper surface of the lower handlebar holders.
EWA13690
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
2
EAS22930
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
a
1
2. Connect:
• Throttle cable (decelerator cable) “1”
(to the right handlebar switch “2”)
5. Install:
• Handlebar grip
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Rotate the right handlebar switch and screw it
onto the end of the throttle cable.
4-57
HANDLEBAR
• There should be 1–3 mm (0.04–0.12 in) of
clearance “c” between the throttle grip and the
grip end.
EWA13700
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b
6. Install:
• Left handlebar switch “1”
NOTE:
Align the projection “a” on the left handlebar
switch with the hole “b” in the handlebar.
a
1
b
c
2
1
a
7. Install:
• Clutch master cylinder “1”
• Clutch master cylinder holder “2”
T.
9. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
R
Clutch master cylinder holder
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R
NOTE:
• Align the end of the clutch master cylinder
holder with the punch mark “a” on the handlebar.
• First tighten the rear bolt, then the front bolt.
Front brake master cylinder holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• Align the end of the front brake master cylinder
holder with the punch mark “a” on the handlebar.
• First tighten the rear bolt, then the front bolt.
1
1
a
2
8. Install:
• Throttle grip
• Throttle cables
• Right handlebar switch “1”
• Grip end “2”
2
a
10.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
NOTE:
• Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
4-58
HANDLEBAR
Throttle cable free play
4.0–6.0 mm (0.16–0.24 in)
4-59
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
6
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
115 Nm (11.5 m • kg, 85 ft • lb)
R
19 Nm (1.9 m • kg, 13 ft • Ib)
R
7
9
16 Nm (1.6 m • kg, 11 ft • Ib)
LT
4
8
1
2
10
11
5
LT
LT
3
R
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
23 Nm (2.3 m • kg, 17 ft • Ib)
12
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front fork legs.
Windshield bracket (left and right)
For XV19CTS(C)/XV19CT(C)/
XV19CTM(C) only
Lower handlebar holder
Refer to “HANDLEBAR” on page 4-55.
Front fender
Refer to “FRONT WHEEL” on page 4-15.
1
Upper bracket cover
1
2
Upper bracket pinch bolt
4
Loosen.
3
Cap bolt
1
Loosen.
4
Steering stem nut
1
5
Upper bracket
1
6
Upper front fork cover
1
7
Upper front fork cover spacer
1
8
Upper front fork cover washer
1
9
Lower front fork cover nut
2
10
Lower bracket pinch bolt
2
11
Lower front fork cover
1
4-60
Loosen.
FRONT FORK
Removing the front fork legs
6
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
115 Nm (11.5 m • kg, 85 ft • lb)
R
19 Nm (1.9 m • kg, 13 ft • Ib)
R
7
9
16 Nm (1.6 m • kg, 11 ft • Ib)
LT
4
8
1
2
10
11
5
LT
LT
3
R
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
23 Nm (2.3 m • kg, 17 ft • Ib)
12
R
Order
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Front fork leg
Remarks
1
For installation, reverse the removal procedure.
4-61
FRONT FORK
Disassembling the front fork legs
T
R
23 Nm (2.3 m • kg, 17 ft • Ib)
1
New 2
3
12
6 New
4
7 New
13 New
5
14
15 New
16 New
10
19
17
18
11
9 New
8
LT
R
Order
Job/Parts to remove
40 Nm (4.0 m • kg, 29 ft • Ib)
Q’ty
Remarks
The following procedure applies to both of
the front fork legs.
1
Cap bolt
1
2
O-ring
1
3
Spacer
1
4
Spring seat
1
5
Fork spring
1
6
Dust seal
1
7
Oil seal clip
1
8
Damper rod bolt
1
9
Copper washer
1
10
Damper rod
1
11
Rebound spring
1
12
Inner tube
1
13
Oil seal
1
14
Washer
1
15
Outer tube bushing
1
16
Inner tube bushing
1
4-62
FRONT FORK
Disassembling the front fork legs
T
R
23 Nm (2.3 m • kg, 17 ft • Ib)
1
New 2
3
12
6 New
4
7 New
13 New
5
14
15 New
16 New
10
19
17
18
11
9 New
8
LT
R
Order
Job/Parts to remove
40 Nm (4.0 m • kg, 29 ft • Ib)
Q’ty
17
Spring
1
18
Oil flow stopper
1
19
Outer tube
1
Remarks
For assembly, reverse the disassembly procedure.
4-63
FRONT FORK
EAS22960
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
3. Remove:
• Damper rod bolt “1”
• Copper washer
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Loosen:
• Lower bracket pinch bolts
NOTE:
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
EW1D71007
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
EAS22980
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Drain:
• Fork oil
NOTE:
Stroke the outer tube several times while draining the fork oil.
4. Remove:
• Inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but carefully.
2. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flathead screwdriver)
ECA14180
CAUTION:
ECA14190
CAUTION:
Do not scratch the inner tube.
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
• Avoid bottoming the inner tube into the outer tube during the above procedure, as the
oil flow stopper will be damaged.
4-64
FRONT FORK
ECA14200
CAUTION:
• The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
4. Check:
• Cap bolt O-ring
Damage/wear → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches → Replace.
EAS23020
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
EWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
EWA13650
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.
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 all of the components are clean.
Fork spring free length
273.9 mm (10.78 in)
Limit
268.4 mm (10.57 in)
1. Install:
• Inner tube bushing “1”
• Damper rod “2”
• Rebound spring
• Spring “3”
• Oil flow stopper “4”
EC1D71012
CAUTION:
Allow the damper rod to slide slowly down
the inner tube “5” until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• Oil flow stopper
Damage → Replace.
4-65
FRONT FORK
• Washer
(with the fork seal driver “2”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46
mm)
YM-01442
3
4
5
1
2
2. Lubricate:
• Inner tube’s outer surface
Recommended oil
Fork oil 10WT
3. Install:
• Inner tube
(in the outer tube)
4. Install:
7. Install:
• Oil seal “1”
(with the fork seal driver “2”)
• Copper washer New
• Damper rod bolt
5. Tighten:
• Damper rod bolt “1”
T.
R
Damper rod bolt
40 Nm (4.0 m·kg, 29 ft·lb)
LOCTITE®
ECA14220
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
NOTE:
While holding the damper rod assembly with the
damper rod holder “2” and T-handle “3”, tighten
the damper rod bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
6. Install:
• Outer tube bushing “1”
4-66
FRONT FORK
Quantity
571.0 cm³ (19.31 US oz) (20.10
Imp.oz)
Recommended oil
Fork oil 10WT
2
11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
1
8. Install:
• Oil seal clip “1”
NOTE:
Level
124.0 mm (4.88 in)
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
9. Install:
• Dust seal “1”
(with the fork seal driver weight “2”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46
mm)
YM-01442
12.Install:
• Spring “1”
• Spring seat “2”
• Spacer
• Cap bolt
(with O-ring)
NOTE:
• Install the spring with the smaller pitch facing
up.
• Before installing the cap bolt, lubricate its Oring with grease.
• Temporarily tighten the cap bolt.
10.Fill:
• Front fork leg
(with the specified amount of the recommended fork oil)
4-67
FRONT FORK
NOTE:
Align the groove “a” in the upper front fork cover
“1” with the lower front fork cover nut “2”.
2
a
1
1
EAS23050
2
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• Lower front fork cover “1”
• Front fork leg “2”
• Upper bracket “3”
Temporarily tighten the lower bracket pinch
bolts and steering stem nut.
6. Tighten:
• Steering stem nut
T.
R
Steering stem nut
115 Nm (11.5 m·kg, 85 ft·lb)
• Cap bolt
NOTE:
T.
Make sure the inner tube end is flush with the top
of the upper bracket.
R
Cap bolt
23 Nm (2.3 m·kg, 17 ft·lb)
• Upper bracket pinch bolts
3
T.
R
Upper bracket pinch bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
2
1
NOTE:
Tighten the upper bracket pinch bolts to specification twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
• Upper bracket cover bolts
2. Tighten:
• Lower bracket pinch bolts
T.
R
T.
R
Lower bracket pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
3. Remove:
• Upper bracket
4. Tighten:
• Lower front fork cover nuts
Upper bracket cover bolt
19 Nm (1.9 m·kg, 13 ft·lb)
LOCTITE®
• Upper bracket cover bolts
T.
R
T.
R
Lower front fork cover nut
7 Nm (0.7 m·kg, 5.1 ft·lb)
Upper bracket cover bolt
16 Nm (1.6 m·kg, 11 ft·lb)
LOCTITE®
EWA13680
WARNING
5. Install:
• Upper front fork cover “1”
• Upper bracket
Make sure the brake hoses are routed properly.
4-68
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
T
T
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
1st 52 Nm (5.2 m • kg, 37 ft • lb)
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
4
5
6
7
LS
LT
9
10
1
13
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
8
13
11
3
2
LT
12
LS
LT
R
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Lower handlebar holder
Remarks
Refer to “HANDLEBAR” on page 4-55.
Upper bracket/Front fork legs
Refer to “FRONT FORK” on page 4-60.
1
Headlight bracket and throttle cable guide
1
2
Front brake hose guide
1
3
Front brake hose joint
1
4
Lock washer
1
5
Upper ring nut
1
6
Rubber washer
1
7
Lower ring nut
1
8
Lower bracket
1
9
Upper bearing cover
1
10
Upper bearing
1
11
Lower bearing
1
12
Dust seal
1
4-69
STEERING HEAD
Removing the lower bracket
T
T
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
1st 52 Nm (5.2 m • kg, 37 ft • lb)
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
4
5
6
7
LS
LT
9
10
1
13
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
8
13
11
3
2
LT
12
LS
LT
R
Order
13
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Bearing outer race
Remarks
2
For installation, reverse the removal procedure.
4-70
STEERING HEAD
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS23110
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
a. Remove the bearing races from the steering
head pipe with a long rod “1” and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel “2” and hammer.
c. Install a new dust seal and new bearing races.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
ECA14270
2. Remove:
• Upper ring nut
• Rubber washer
• Lower ring nut “1”
• Lower bracket
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
EWA13730
• Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
NOTE:
Remove the lower ring nut with the steering nut
wrench “2”.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
2
1
EAS23120
CHECKING THE STEERING HEAD
1. Wash:
• Bearings
• Bearing races
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
Recommended cleaning solvent
Kerosene
2. Check:
• Bearings
• Bearing races
Damage/pitting → Replace.
3. Replace:
• Bearings
• Bearing races
EAS23140
INSTALLING THE STEERING HEAD
1. Lubricate:
• Upper bearing
• Lower bearing
• Bearing races
Recommended lubricant
Lithium-soap-based grease
4-71
STEERING HEAD
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-25.
3. Install:
• Front brake hose joint “1”
• Front brake hose guide “2”
NOTE:
• Make sure that the projection “a” on the lower
bracket contacts the side “b” of the front brake
hose joint “1”.
• Align the projection “c” on the front brake hose
guide with the hole “d” in the lower bracket.
1
d c
b
2
a
4. Install:
• Front fork legs
• Upper bracket
Refer to “FRONT FORK” on page 4-60.
4-72
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
ET1D71001
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
Removing the rear shock absorber assembly and swingarm
T
48 Nm (4.8 m • kg, 35 ft • Ib)
R
5
8
T
R
LT
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LS
9
4
10
6
6
7
T
2
R
3
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
R
125 Nm (12.5 m • kg, 90 ft • lb)
LT
R
48 Nm (4.8 m • kg, 35 ft • Ib)
6
T
R
Order
59 Nm (5.9 m • kg, 43 ft • Ib)
Job/Parts to remove
Q’ty
Rear wheel
Remarks
Refer to “REAR WHEEL” on page 4-23.
Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
Brake master cylinder bracket
Refer to “REAR BRAKE” on page 4-43.
Engine mounting nut (rear lower side)
Loosen.
Refer to “ENGINE REMOVAL” on page 5-1.
1
Horn 1 coupler
1
2
Horn 1
1
3
Passenger footrest (left and right)
2
4
O2 sensor lead guide
1
5
Rear brake hose guide
1
6
Self-locking nut/Bolt/Spacer/Washer
Disconnect.
For XV19S(C)/XV19(C)/XV19M(C) only
NOTE:
1/1/1/1
7
Pivot shaft nut/Washer
8
Pivot shaft
1/1
1
9
Rear shock absorber and swingarm assembly
1
4-73
Pass the O2 sensor lead through the guide.
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
Removing the rear shock absorber assembly and swingarm
T
48 Nm (4.8 m • kg, 35 ft • Ib)
R
5
8
T
R
LT
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LS
9
4
10
6
6
7
T
2
R
3
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
R
125 Nm (12.5 m • kg, 90 ft • lb)
LT
R
48 Nm (4.8 m • kg, 35 ft • Ib)
6
T
R
Order
10
59 Nm (5.9 m • kg, 43 ft • Ib)
Job/Parts to remove
Q’ty
Lower drive belt cover
Remarks
1
For installation, reverse the removal procedure.
4-74
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
Removing the rear shock absorber and swingarm
LS
3
New
2
LS
1
R
40 Nm (4.0 m • kg, 29 ft • Ib)
2
LS
13
9
4
12
1
LS
12
6
14
5
8
9
6
14
LS
13
11
New
14
LS
LS
10
7
14
6
LS
T
8
R
6
5
59 Nm (5.9 m • kg, 43 ft • Ib)
4
T
R
59 Nm (5.9 m • kg, 43 ft • Ib)
LS
Order
Job/Parts to remove
Q’ty
1
Self-locking nut/Washer/Bolt
2
Oil seal/Collar/Bushing/Bearing
3
Swingarm
4
Self-locking nut/Washer/Bolt
5
Connecting arm
2
6
O-ring
4
7
Spacer
1
8
Bushing
4
9
Self-locking nut/Washer/Bolt
Remarks
1/2/1
2/2/1/2
1
1/1/1
1/2/1
10
Rear shock absorber
1
11
Relay arm
1
12
Oil seal/Spacer/Bearing
2/1/1
13
Oil seal/Spacer/Bearing
2/1/2
14
Collar/Oil seal/Spacer/Bearing
2/2/1/2
For installation, reverse the removal procedure.
4-75
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
EAS23180
HANDLING THE REAR SHOCK ABSORBER
NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
EWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsible for property damage or personal injury
that may result from improper handling of
the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping performance.
2. Loosen:
• Engine mounting nut (rear lower side)
Refer to “ENGINE REMOVAL” on page 5-1.
NOTE:
Because there is force being exerted on the engine mounting bracket (left and right rear lower
sides), it is necessary to loosen the engine
mounting nut (rear lower side) in order to create
some space between the connecting arms and
engine bracket before removing the rear shock
absorber and swingarm.
3. Remove:
• Connecting arm bolt (frame side)
NOTE:
When removing the connecting arm bolt (frame
side), hold the swingarm so that it does not drop
down.
4. Measure:
• Swingarm side play
• Swingarm vertical movement
EAS23190
DISPOSING OF A REAR SHOCK ABSORBER
1. Gas pressure must be released before disposing of a rear shock absorber. To release
the gas pressure, drill a 2–3 mm (0.08–0.12
in) hole through the rear shock absorber at a
point 15–20 mm (0.59–0.79 in) from its end
as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
T.
R
EWA13760
WARNING
Pivot shaft nut
125 Nm (12.5 m·kg, 90 ft·lb)
b. Measure the swingarm side play “A” by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and oil seals.
Wear eye protection to prevent eye damage
from released gas or metal chips.
Swingarm side play (at the end of
the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement “B”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, bearings, washers, and oil seals.
ET1D71002
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY AND SWINGARM
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
4-76
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
EAS23360
B
CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage → Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
A
EWA13770
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Do not attempt to straighten a bent pivot
shaft.
EAS23240
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
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.
• Bushing
Damage/wear → Replace the rear shock absorber assembly.
• Spacer
Damage/scratches → Replace.
• Bolts
Bends/damage/wear → Replace.
3. Wash:
• Pivot shaft
• Bushing
• Washer
• Bearings
• Collars
Recommended cleaning solvent
Kerosene
EAS23260
4. Check:
• Washer
• Oil seals
• Bushing
Damage/wear → Replace.
• Bearings
Damage/pitting → Replace.
• Collar
Damage/scratches → Replace.
CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arms
• Relay arm
Damage/wear → Replace.
2. Check:
• Bearings
• Oil seals
Damage/pitting → Replace.
3. Check:
• Bushings
Damage/wear → Replace.
4. Check:
• Spacers
• Collars
Damage/scratches → Replace.
ET1D71003
INSTALLING THE RELAY ARM, REAR
SHOCK ABSORBER ASSEMBLY AND
CONNECTING ARMS
1. Lubricate:
• Oil seals
Recommended lubricant
Lithium-soap-based grease
4-77
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
2. Install:
• Bearings “1”, “2”, “3”
(to the relay arm)
• Oil seals “4”, “5”
(to the relay arm)
• Spacer “2”
EC1D71010
CAUTION:
When inserting the spacer into the connecting arms and the rear shock absorber, be
careful not to damage the bushings and Orings.
Installed depth “a”
4.5 mm (0.18 in)
Installed depth “b”
1.0 mm (0.04 in)
Installed depth “c”
6.0 mm (0.24 in)
Installed depth “d”
2.5 mm (0.10 in)
1
NOTE:
Install the bushings so that the slits “b” in the
bushings are within the areas shown in the illustration.
Installed depth “a”
4.5 mm (0.18 in)
a
1
3
4
5
B
b
b
b
b
3
1
2
B
4
A
5
a
a
a
a
A
4
4
a
2
4
a
C
c
d
c
3
3
3
d
1
b
C
A. Right side
B. Left side
3.
4.
A.
B.
C.
3. Lubricate:
• Bushings
• Oil seals
• O-rings
• Collar
5. Install:
• Connecting arms
• Rear shock absorber assembly
(to relay arm)
• Relay arm
(to the swingarm)
Recommended lubricant
Lithium-soap-based grease
NOTE:
Apply grease only to the collar between the connecting arms and rear shock absorber.
Connecting arm
Rear shock absorber
Right side
Left side
90°
NOTE:
Be sure to face the “FWD” mark “a” on the relay
arm “1” toward the front of the vehicle and to
face the label “b” on the rear shock absorber “2”
downward.
4. Install:
• Bushings “1”
(to connecting arms)
4-78
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
1
1
b
2
1
A
B
2
a
a
a
6. Tighten:
• Connecting-arm-to-relay-arm nut
2. Swingarm
A. Left side
B. Right side
T.
R
Connecting-arm-to-relay-arm nut
59 Nm (5.9 m·kg, 43 ft·lb)
3. Install:
• Pivot shaft
• Washer
• Pivot shaft nut
• Rear-shock-absorber-assembly-to-relay-arm
nut
T.
R
Rear-shock-absorber-assemblyto-relay-arm nut
40 Nm (4.0 m·kg, 29 ft·lb)
• Relay-arm-to-swingarm nut
NOTE:
Temporarily tighten the pivot shaft nut.
4. Install:
• Connecting arm bolt (front side)
NOTE:
T.
R
When installing the connecting arm bolt, hold the
swingarm so that it does not drop down.
Relay-arm-to-swingarm nut
59 Nm (5.9 m·kg, 43 ft·lb)
5. Tighten:
• Pivot shaft nut
• Engine mounting nut (rear lower side)
• Connecting arm nut (front side)
EAS28780
T.
INSTALLING THE SWINGARM
1. Lubricate:
• Bearings
• Collars
• Oil seals
• Pivot shaft
R
Recommended lubricant
Lithium-soap-based grease
2. Install:
• Bearings “1”
(to swingarm)
Pivot shaft nut
125 Nm (12.5 m·kg, 90 ft·lb)
Engine mounting nut (rear lower
side)
98 Nm (9.8 m·kg, 71 ft·lb)
Connecting arm nut (front side)
59 Nm (5.9 m·kg, 43 ft·lb)
6. Adjust:
• Drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-24.
Installed depth “a”
1.0 mm (0.04 in)
4-79
BELT DRIVE
EAS23510
BELT DRIVE
Removing the drive belt and drive pulley
T
R
R
53 Nm (5.3 m • kg, 38 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
9
63 Nm (6.3 m • kg, 45 ft • Ib)
10
T
13
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
(3)
7
8
LT
5
LT
7
12
8
(3)
New 11
3
R
140 Nm (14.0 m • kg, 100 ft • lb)
(4)
T
R
Order
1
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
4
(6)
Q’ty
Remarks
Rear wheel
Refer to “REAR WHEEL” on page 4-23.
Rear shock absorber assembly and swingarm
Refer to “REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM” on page 4-73.
1
Rectifier/regulator cover
1
2
Lead cover
1
3
Stator coil coupler
1
Disconnect.
4
Rectifier/regulator coupler
1
Disconnect.
5
Rectifier/regulator
1
6
Drive pulley cover
1
7
Slider
2
8
Dowel pin
2
9
Transfer gear case bracket
1
10
Drive belt
1
11
Drive pulley nut
1
12
Conical spring washer
1
4-80
BELT DRIVE
Removing the drive belt and drive pulley
T
R
R
53 Nm (5.3 m • kg, 38 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
9
63 Nm (6.3 m • kg, 45 ft • Ib)
10
T
13
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
(3)
7
8
LT
5
LT
7
12
8
(3)
New 11
3
R
140 Nm (14.0 m • kg, 100 ft • lb)
(4)
T
R
Order
13
Q’ty
Drive pulley
1
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
4
(6)
Remarks
1
For installation, reverse the removal procedure.
4-81
BELT DRIVE
• The drive belt can not be bent smaller than
127 mm (5 in) “a”.
• The removed drive belt can not be twisted
inside out.
EAS23520
REMOVING THE DRIVE BELT AND DRIVE
PULLEY
NOTE:
Loosen the drive pulley nut before removing the
rear wheel.
1. Loosen:
• Drive pulley nut “1”
NOTE:
When loosening the drive pulley nut, press down
on the brake pedal so the drive pulley does not
move.
3. Check:
• Drive pulley
• Rear wheel pulley
Bent teeth → Replace the drive belt and pulleys as a set.
EAS23540
1
INSTALLING THE DRIVE BELT AND DRIVE
PULLEY
1. Install:
• Drive pulley “1”
• Conical spring washer “2”
EAS23530
CHECKING THE DRIVE BELT
1. Clean:
• Drive belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Drive pulley nut “3” New
NOTE:
a. Wipe the drive belt with a clean cloth.
b. Put the drive belt in a mixture of mild detergent and water. Then, remove any dirt from
the drive belt.
c. Remove the drive belt from the mixture and
rinse it off with clean water. Then, let the drive
belt thoroughly dry.
Install the conical spring washer “2” with the
“OUT” mark “a” facing out.
2
OUT
a
1
3 New
2. Install:
• Drive belt
ECA14710
CAUTION:
Install the drive belt facing the same way it
was removed.
Do not twist the drive belt when installing it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drive belt
ECA14690
CAUTION:
• To protect the drive belt from damage, handle it with care.
4-82
BELT DRIVE
3. Install:
• Swingarm
• Rear shock absorber
Refer to “REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM” on page 4-73.
• Rear wheel
Refer to “REAR WHEEL” on page 4-23.
4. Tighten:
• Drive pulley nut
T.
R
Drive pulley nut
140 Nm (14.0 m·kg, 100 ft·lb)
NOTE:
• When tightening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.
• Stake the drive pulley nut “1” at a cutout “a” in
the middle driven shaft.
a
1
5. Adjust:
• Drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-24.
4-83
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1
INSTALLING THE SHIFT PEDAL ASSEMBLY......................................... 5-5
CHECKING THE OIL COOLER ................................................................ 5-7
REMOVING THE ENGINE...................................................................... 5-12
INSTALLING THE ENGINE .................................................................... 5-12
CAMSHAFTS ................................................................................................ 5-14
REMOVING THE CYLINDER HEAD COVERS ...................................... 5-21
REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE
LIFTERS................................................................................................. 5-21
REMOVING THE CAMSHAFTS ............................................................. 5-21
CHECKING THE CAMSHAFTS .............................................................. 5-23
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-24
CHECKING THE ROCKER ARM BASES............................................... 5-25
CHECKING THE PUSH RODS............................................................... 5-25
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES ......... 5-25
CHECKING THE PUSH ROD COVER ................................................... 5-26
CHECKING THE DECOMPRESSION SYSTEM .................................... 5-26
CHECKING THE DECOMPRESSION CAM SPRING ............................ 5-26
CHECKING THE OIL DELIVERY PIPE .................................................. 5-27
INSTALLING THE CAMSHAFTS ............................................................ 5-27
BLEEDING A VALVE LIFTER................................................................. 5-29
INSTALLING THE VALVE LIFTERS....................................................... 5-30
INSTALLING THE ROCKER ARMS AND PUSH RODS ........................ 5-31
INSTALLING THE CYLINDER HEAD COVERS..................................... 5-32
INSTALLING THE SHIFT PEDAL ASSEMBLY....................................... 5-32
CYLINDER HEADS....................................................................................... 5-33
REMOVING THE CYLINDER HEADS .................................................... 5-35
CHECKING THE CYLINDER HEADS..................................................... 5-35
CHECKING THE OIL PIPE ..................................................................... 5-35
INSTALLING THE CYLINDER HEADS................................................... 5-36
VALVES AND VALVE SPRINGS ................................................................. 5-38
REMOVING THE VALVES ..................................................................... 5-39
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-39
CHECKING THE VALVE SEATS............................................................ 5-41
CHECKING THE VALVE SPRINGS ....................................................... 5-42
INSTALLING THE VALVES .................................................................... 5-43
CYLINDERS AND PISTONS ........................................................................ 5-45
REMOVING THE PISTON ...................................................................... 5-46
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-46
CHECKING THE PISTON RINGS .......................................................... 5-47
CHECKING THE PISTON PINS ............................................................. 5-48
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-48
5
CLUTCH ........................................................................................................ 5-50
REMOVING THE CLUTCH ..................................................................... 5-60
REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-60
REMOVING THE LEFT BALANCER DRIVE GEAR ............................... 5-60
CHECKING THE FRICTION PLATES .................................................... 5-61
CHECKING THE CLUTCH PLATES....................................................... 5-61
CHECKING THE CLUTCH SPRING PLATE .......................................... 5-61
CHECKING THE CLUTCH HOUSING.................................................... 5-62
CHECKING THE CLUTCH BOSS........................................................... 5-62
CHECKING THE PRESSURE PLATE .................................................... 5-62
CHECKING THE CLUTCH PUSH RODS ............................................... 5-62
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-62
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-62
CHECKING THE LEFT BALANCER GEARS ......................................... 5-62
INSTALLING THE LEFT BALANCER DRIVE GEAR.............................. 5-63
INSTALLING THE PRIMARY DRIVE GEAR........................................... 5-64
INSTALLING THE CLUTCH.................................................................... 5-65
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-66
CHECKING THE CLUTCH MASTER CYLINDER .................................. 5-66
ASSEMBLING THE CLUTCH MASTER CYLINDER .............................. 5-67
INSTALLING THE CLUTCH MASTER CYLINDER ................................ 5-67
REMOVING THE CLUTCH RELEASE CYLINDER ................................ 5-68
CHECKING THE CLUTCH RELEASE CYLINDER................................. 5-68
ASSEMBLING THE CLUTCH RELEASE CYLINDER ............................ 5-68
INSTALLING THE CLUTCH RELEASE CYLINDER............................... 5-69
SHIFT SHAFT ............................................................................................... 5-70
CHECKING THE SHIFT SHAFT ............................................................. 5-71
CHECKING THE STOPPER LEVER ...................................................... 5-71
INSTALLING THE SHIFT SHAFT ........................................................... 5-71
GENERATOR AND STARTER CLUTCH ..................................................... 5-72
REMOVING THE GENERATOR............................................................. 5-74
REMOVING THE STARTER CLUTCH ................................................... 5-74
CHECKING THE STARTER CLUTCH.................................................... 5-74
CHECKING THE TORQUE LIMITER...................................................... 5-75
INSTALLING THE STARTER CLUTCH.................................................. 5-75
INSTALLING THE GENERATOR ........................................................... 5-75
ELECTRIC STARTER................................................................................... 5-77
CHECKING THE STARTER MOTOR ..................................................... 5-79
ASSEMBLING THE STARTER MOTOR................................................. 5-80
TRANSFER GEAR CASE............................................................................. 5-81
REMOVING THE MIDDLE DRIVEN SHAFT........................................... 5-86
CHECKING THE MIDDLE DRIVE........................................................... 5-86
CHECKING THE OIL STRAINER ........................................................... 5-86
CHECKING THE TRANSFER GEAR OIL PUMP ................................... 5-86
CHECKING THE OIL PIPES................................................................... 5-87
ASSEMBLING THE TRANSFER GEAR OIL PUMP ............................... 5-87
INSTALLING THE TRANSFER GEAR CASE......................................... 5-87
CRANKCASE................................................................................................ 5-89
DISASSEMBLING THE CRANKCASE ................................................... 5-92
CHECKING THE CRANKCASE.............................................................. 5-92
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-92
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE.......................... 5-92
CHECKING THE OIL STRAINERS......................................................... 5-92
CHECKING THE ENGINE OIL PUMP DRIVEN GEAR .......................... 5-93
INSTALLING THE BEARING RETAINERS ............................................ 5-93
ASSEMBLING THE CRANKCASE ......................................................... 5-93
OIL PUMP ..................................................................................................... 5-95
CHECKING THE OIL PUMP ................................................................... 5-98
CHECKING THE RELIEF VALVE ........................................................... 5-98
CHECKING THE BALL SPRING AND RELIEF VALVE SPRING ........... 5-98
CHECKING THE OIL STRAINER ........................................................... 5-99
ASSEMBLING THE OIL PUMP .............................................................. 5-99
INSTALLING THE OIL PUMP ............................................................... 5-100
CRANKSHAFT............................................................................................ 5-101
REMOVING THE CONNECTING RODS .............................................. 5-102
CHECKING THE CRANKSHAFT AND CONNECTING RODS............. 5-102
INSTALLING THE CONNECTING RODS............................................. 5-105
INSTALLING THE CRANKSHAFT ASSEMBLY ................................... 5-106
TRANSMISSION ......................................................................................... 5-107
CHECKING THE SHIFT FORKS .......................................................... 5-111
CHECKING THE SHIFT DRUM ASSEMBLY........................................ 5-111
CHECKING THE TRANSMISSION....................................................... 5-111
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE............................ 5-112
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY .... 5-112
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler and exhaust pipes
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
29 Nm (2.9 m • kg, 21 ft • Ib)
T
53 Nm (5.3 m • kg, 38 ft • Ib)
R
5
6
7
T
24 Nm (2.4 m • kg, 17 ft • Ib)
R
T
R
44 Nm (4.4 m • kg, 32 ft • Ib)
8
LT
9 New
4
12 New
LS
10
1
2
New
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
3
13
R
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
T
R
T
R
20 Nm (2.0 m • kg, 14 ft • Ib)
LT
48 Nm (4.8 m • kg, 35 ft • Ib)
1
R
New 12
Order
14
Job/Parts to remove
20 Nm (2.0 m • kg, 14 ft • Ib)
Q’ty
Rear brake light switch
Remarks
1
2
Right rider footrest assembly
1
3
EXUP valve pulley cover
1
4
EXUP cable
2
5
O2 sensor coupler holder
1
6
O2 sensor coupler
1
7
Muffler bracket
1
8
Muffler
1
9
Gasket
1
10
Rear exhaust pipe cover
1
11
Rear exhaust pipe
1
12
Gasket
2
13
O2 sensor
1
14
Front exhaust pipe
1
5-1
Disconnect.
Disconnect.
ENGINE REMOVAL
Removing the muffler and exhaust pipes
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
29 Nm (2.9 m • kg, 21 ft • Ib)
T
53 Nm (5.3 m • kg, 38 ft • Ib)
R
5
6
7
T
24 Nm (2.4 m • kg, 17 ft • Ib)
R
T
R
44 Nm (4.4 m • kg, 32 ft • Ib)
8
LT
9 New
4
12 New
LS
10
1
2
New
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
3
13
R
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
T
R
T
R
20 Nm (2.0 m • kg, 14 ft • Ib)
LT
48 Nm (4.8 m • kg, 35 ft • Ib)
15
R
New 12
Order
14
Job/Parts to remove
20 Nm (2.0 m • kg, 14 ft • Ib)
Q’ty
Gasket
Remarks
1
For installation, reverse the removal procedure.
5-2
ENGINE REMOVAL
Removing the cylinder-#1 ignition coils and sidestand
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
LT
1
5
T
R
4
12 Nm (1.2 m • kg, 8.7 ft • Ib)
9
2
3
10
3
LT
6
11
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
16 Nm (1.6 m • kg, 11 ft • Ib)
T
R
13 Nm (1.3 m • kg, 9.4 ft • Ib)
16
17
18
New
14
12
7
LT
19
LT
8
LT
T
R
63 Nm (6.3 m • kg, 45 ft • Ib)
48 Nm (4.8 m • kg, 35 ft • Ib)
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
T
Order
15
Job/Parts to remove
13
18 Nm (1.8 m • kg, 13 ft • Ib)
Q’ty
Remarks
Rider seat/Left side cover/Battery box/Air filter
case
Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank/Sub-fuel tank
Refer to “FUEL TANK” on page 6-1.
Throttle body/Intake manifold/Pressure regulator bracket/Rollover valve/Canister
Refer to “THROTTLE BODIES” on page 6-6.
Rear brake master cylinder bracket
Refer to “REAR BRAKE” on page 4-43.
Drive pulley
Refer to “BELT DRIVE” on page 4-80.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Transfer gear oil
Drain.
Refer to “CHANGING THE TRANSFER
GEAR OIL” on page 3-14.
Starter motor
Refer to “ELECTRIC STARTER” on page
5-77.
1
Cylinder-#1 ignition coil cover
1
2
Spark plug cap
2
3
Ignition coil connector
4
4
Cylinder-#1 left ignition coil
1
5
Cylinder-#1 right ignition coil
1
5-3
Disconnect.
ENGINE REMOVAL
Removing the cylinder-#1 ignition coils and sidestand
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
LT
1
5
T
R
4
12 Nm (1.2 m • kg, 8.7 ft • Ib)
9
2
3
10
3
LT
6
11
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
16 Nm (1.6 m • kg, 11 ft • Ib)
T
R
13 Nm (1.3 m • kg, 9.4 ft • Ib)
16
17
18
New
14
12
7
LT
19
LT
8
LT
T
R
63 Nm (6.3 m • kg, 45 ft • Ib)
48 Nm (4.8 m • kg, 35 ft • Ib)
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
T
Order
15
Job/Parts to remove
Q’ty
13
18 Nm (1.8 m • kg, 13 ft • Ib)
Remarks
6
Cylinder-#1 ignition coil bracket
1
7
Horn 1 connector
2
Except for California
Disconnect.
8
Horn 1
1
Except for California
9
Horn 2 coupler
1
10
Horn 2
1
11
Shift rod
1
12
Rear brake light switch coupler
1
13
Left rider footrest assembly
1
14
Shift pedal shaft bracket
1
15
Shift pedal (toe side)
1
16
Shift pedal (heel side)
1
17
Shift pedal shaft
1
18
Sidestand switch
1
19
Sidestand
1
For installation, reverse the removal procedure.
5-4
ENGINE REMOVAL
ET1D71029
INSTALLING THE SHIFT PEDAL ASSEMBLY
1. Assemble:
• Shift pedal (heel side) “1”
• Shift pedal (toe side) “2”
T.
R
Shift pedal (heel side) bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
NOTE:
Align the mark “a” on the pin on the toe side with
the mark “b” on the heel side.
2
1
b
a
2. Install:
• Shift pedal assembly “1”
T.
R
Shift pedal bolt
18 Nm (1.8 m·kg, 13 ft·lb)
NOTE:
Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.
1
a
3. Adjust:
• Shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
on page 3-23.
5-5
ENGINE REMOVAL
Removing the oil cooler and oil filter bracket
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
LS
New
5
New
LS
3
New
LS
2
New
New
New
LS
T
R
LS
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
1
7
LS
R
New
New
E
(4)
T
Order
LT
R
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
17 Nm (1.7 m • kg, 12 ft • Ib)
70 Nm (7.0 m • kg, 50 ft • lb)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
1
Oil filter cartridge
1
2
Oil cooler outlet hose
1
3
Oil cooler inlet hose
1
4
Oil cooler
1
5
Oil cooler bracket
1
6
Oil filter bolt
1
7
Oil filter bracket
1
Remarks
For installation, reverse the removal procedure.
5-6
ENGINE REMOVAL
ET1D71028
CHECKING THE OIL COOLER
1. Check:
• Oil cooler fins
Obstruction → Clean.
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead
screwdriver.
2. Check:
• Oil cooler inlet hose
• Oil cooler outlet hose
Cracks/damage → Replace.
5-7
ENGINE REMOVAL
Disconnecting the leads
1
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12 3
4
13
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
6
15
LT
2
14
10
11
7
8
LT
9
Job/Parts to remove
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Refer to “TRANSFER GEAR CASE” on
page 5-81.
Drive pulley case
1
R
R
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Spark plug cap
2
2
Stator coil lead
1
3
Neutral switch coupler
1
4
Neutral switch lead
1
5
Lead holder bracket
1
6
Wire harness guide
1
7
Throttle cable guide
1
8
Starter motor lead
1
9
Horn 2 lead
1
10
Rear brake light switch lead
1
11
Sidestand switch lead
1
12
Crankshaft position sensor coupler
1
13
Crankshaft position sensor lead
1
14
Rectifier/regulator lead
1
5-8
Disconnect.
Disconnect.
ENGINE REMOVAL
Disconnecting the leads
1
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12 3
4
13
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
6
15
LT
2
14
10
11
7
8
LT
9
15
Job/Parts to remove
Q’ty
Speed sensor lead
R
R
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
1
For installation, reverse the removal procedure.
5-9
ENGINE REMOVAL
Removing the engine
59 Nm (5.9 m • kg, 43 ft • Ib)
R
R
R
105 Nm (10.5 m • kg, 75 ft • lb)
T
T
R
R
18 Nm (1.8 m • kg, 13 ft • Ib)
T
T
R
R
98 Nm (9.8 m • kg, 71 ft • lb)
53 Nm (5.3 m • kg, 38 ft • Ib)
66 Nm (6.6 m • kg, 48 ft • Ib)
53 Nm (5.3 m • kg, 38 ft • Ib)
E
LT
19
22
12
8
2
17
1
13
2
6
3
5
15 18
20
24
23 4
E
21
11
16
25
10
18
14
LT
9
7
LT
R
30 Nm (3.0 m • kg, 22 ft • Ib)
T
R
53 Nm (5.3 m • kg, 38 ft • Ib)
13
12
R
98 Nm (9.8 m • kg, 71 ft • lb)
53 Nm (5.3 m • kg, 38 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
Place a suitable stand under the frame and
engine.
Refer to “TRANSFER GEAR CASE” on
page 5-81.
Transfer gear case
1
Engine mounting bolt (right upper side)
2
2
Engine mounting bolt (left upper side)
2
3
Engine bracket bolt (right upper side)
2
4
Engine bracket (right upper side)
1
5
Engine bracket bolt (left upper side)
2
6
Engine bracket (left upper side)
1
7
Engine mounting nut (front upper side)
1
8
Engine mounting bolt (front upper side)
1
9
Engine cross-member bracket bolt
2
10
Engine cross-member bracket
1
11
Engine bracket nut (front upper side)
4
12
Engine bracket bolt (front upper side)
4
13
Engine bracket (front upper side)
2
5-10
ENGINE REMOVAL
Removing the engine
59 Nm (5.9 m • kg, 43 ft • Ib)
R
R
R
105 Nm (10.5 m • kg, 75 ft • lb)
T
T
R
R
18 Nm (1.8 m • kg, 13 ft • Ib)
T
T
R
R
98 Nm (9.8 m • kg, 71 ft • lb)
53 Nm (5.3 m • kg, 38 ft • Ib)
66 Nm (6.6 m • kg, 48 ft • Ib)
53 Nm (5.3 m • kg, 38 ft • Ib)
E
LT
19
22
12
8
2
17
1
13
2
6
3
5
15 18
20
24
23 4
E
21
11
16
25
10
18
14
LT
9
7
LT
R
30 Nm (3.0 m • kg, 22 ft • Ib)
T
R
53 Nm (5.3 m • kg, 38 ft • Ib)
13
12
R
98 Nm (9.8 m • kg, 71 ft • lb)
53 Nm (5.3 m • kg, 38 ft • Ib)
Order
Job/Parts to remove
Q’ty
14
Engine mounting nut (rear upper side)
1
15
Engine mounting bolt (rear upper side)
1
16
Engine bracket nut (rear upper side)
2
17
Engine bracket bolt (rear upper side)
2
18
Engine bracket (rear upper side)
2
19
Engine mounting nut (front lower side)
1
20
Spacer bolt
1
21
Engine mounting bolt (front lower side)
1
22
Engine mounting nut (rear lower side)
1
23
Engine mounting bolt (rear lower side)
1
24
Washer
1
25
Engine
1
Remarks
Loosen.
For installation, reverse the removal procedure.
5-11
ENGINE REMOVAL
3. Tighten:
• Spacer bolt “1”
ET1D71019
REMOVING THE ENGINE
1. Loosen:
• Spacer bolt
Spacer bolt
18 Nm (1.8 m·kg, 13 ft·lb)
T.
NOTE:
R
Loosen the spacer bolt with the pivot shaft
wrench “1”.
NOTE:
• Tighten the spacer bolt “1” to specification with
a pivot shaft wrench.
• When tightened, the spacer bolt should be flat
against the engine surface.
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
E
3
5
1
4
1
EAS23720
INSTALLING THE ENGINE
1. Install:
• Spacer bolt “1”
• Engine “2”
• Washer “3”
• Engine mounting bolt (rear lower side) “4”
• Engine mounting nut (rear lower side) “5”
• Engine mounting bolt (front lower side) “6”
• Engine mounting nut (front lower side) “7”
• Engine brackets (rear upper side) “8”
• Engine bracket bolts (rear upper side) “9”
• Engine bracket nuts (rear upper side) “10”
• Engine mounting bolt (rear upper side) “11”
• Engine mounting nut (rear upper side) “12”
• Engine bracket (left upper side) “13”
• Engine mounting bolts (left upper side) “14”
• Engine bracket bolts (left upper side) “15”
• Engine bracket (right upper side) “16”
• Engine mounting bolts (right upper side) “17”
• Engine bracket bolts (right upper side) “18”
7
14 13 14
6
17
11
18 9
9 8
LT
15
E
16
2
8
12 10
4. Tighten:
• Engine mounting nut (rear lower side) “5”
• Engine mounting nut (front lower side) “7”
• Engine bracket nuts (rear upper side) “10”
• Engine mounting nut (rear upper side) “12”
• Engine mounting bolts (left upper side) “14”
• Engine bracket bolts (left upper side) “15”
• Engine mounting bolts (right upper side) “17”
• Engine bracket bolts (right upper side) “18”
NOTE:
• Lubricate the engine mounting bolt (front lower
side) threads and nut with engine oil.
• Apply locking agent (LOCTITE®) to the threads
of the engine mounting bolts (left upper side).
• Do not fully tighten the bolts and nuts.
2. Remove:
• Engine mounting nut (front lower side) “7”
5-12
ENGINE REMOVAL
T.
R
9. Tighten:
• Engine bracket nut (front upper side) “3”
• Engine cross-member bracket bolts “5”
• Engine mounting nut (front upper side) “7”
Engine bracket nut (front upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
Engine cross-member bracket
bolt
30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®
Engine mounting nut (front upper
side)
98 Nm (9.8 m·kg, 71 ft·lb)
T.
Engine mounting nut (rear lower
side)
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting nut (front lower
side)
105 Nm (10.5 m·kg, 75 ft·lb)
Engine bracket nut (rear upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
Engine mounting nut (rear upper
side)
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting bolt (left upper
side)
66 Nm (6.6 m·kg, 48 ft·lb)
LOCTITE®
Engine mounting bolt (right upper side)
59 Nm (5.9 m·kg, 43 ft·lb)
Engine bracket bolt (left upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
Engine bracket bolt (right upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
R
3
7
6
2
1
2
5
4
5
1
5. Install:
• Engine brackets (front upper side) “1”
• Engine bracket bolts (front upper side) “2”
• Engine bracket nuts (front upper side) “3”
• Engine cross-member bracket “4”
• Engine cross-member bracket bolts “5”
• Engine mounting bolt (front upper side) “6”
• Engine mounting nut (front upper side) “7”
NOTE:
Do not fully tighten the bolts and nuts.
6. Install:
• Lead holder bracket
• Lead
(removed during engine removal)
NOTE:
To install and route the leads, refer to “CABLE
ROUTING” on page 2-45.
Refer to “ENGINE REMOVAL” on page 5-1.
7. Install:
• Transfer gear case
• Drive pulley case
Refer to “TRANSFER GEAR CASE” on page
5-81.
8. Install:
• Drive pulley
• Transfer gear case bracket
Refer to “BELT DRIVE” on page 4-80.
5-13
CAMSHAFTS
EAS23750
CAMSHAFTS
Removing the camshaft sprocket cover
1
1
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
T
R
1
2
1
(5)
18 Nm (1.8 m • kg, 13 ft • Ib)
2
2
(3)
9
8
New 10
5
(3)
New
7
LS
6
T
R
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
Order
Job/Parts to remove
4
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
18 Nm (1.8 m • kg, 13 ft • Ib)
Remarks
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page
4-1.
Muffler/Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
1
Spark plug cap
4
2
Spark plug
4
3
Shift pedal assembly
1
4
Damper cover
1
5
Damper
1
6
Timing mark accessing screw
1
7
Crankshaft end screw
1
8
Camshaft sprocket cover
1
9
Dowel pin
2
10
Camshaft sprocket cover gasket
1
Disconnect.
For installation, reverse the removal procedure.
5-14
CAMSHAFTS
Removing the cylinder head covers
T
R
7
1
7
6
7
7 6
6
7
6
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
6
6
8
9
10 New
10 New
2
11
11
4
3
5
LT
T
R
Order
Job/Parts to remove
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
1
Cylinder head breather hose
1
2
Oil tank breather hose
1
3
Wire harness guide
1
4
Fuel tank damper
1
5
Fuel outlet hose
1
Disconnect.
6
Cylinder head cover bolt
8
l = 40 mm (1.57 in)
7
Cylinder head cover bolt
20
l = 60 mm (2.36 in)
8
Rear cylinder head cover
1
9
Front cylinder head cover
1
10
Cylinder head cover gasket
2
11
Dowel pin
4
Disconnect.
For installation, reverse the removal procedure.
5-15
CAMSHAFTS
Removing the push rods and rocker arms
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
24 Nm (2.4 m • kg, 17 ft • Ib)
T
R
24 Nm (2.4 m • kg, 17 ft • Ib)
T
R
8
10
11
1
9
10
11
20 Nm (2.0 m • kg, 14 ft • Ib)
10
11
8
E
2
10
11
9
E
7
7
E
13
12
7
E
4
New 3
E
4
E
4
5
3 New
E
5
6
E
E
Order
E
Job/Parts to remove
Q’ty
Remarks
1
Rear rocker arm base assembly
1
2
Front rocker arm base assembly
1
3
Rocker arm base gasket
2
4
Dowel pin
4
5
Pull rod 1
3
l = 286.5 mm (11.280 in) pink painting
6
Pull rod 2
1
l = 288.5 mm (11.358 in) sky blue painting
7
Rocker arm shaft
4
8
Rocker arm 1
2
9
Rocker arm 2
2
10
Locknut
4
11
Adjusting screw
4
12
Rear rocker arm base
1
13
Front rocker arm base
1
For installation, reverse the removal procedure.
5-16
CAMSHAFTS
Removing the valve lifters
LS
T
LT
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
2 New
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
LS
LS
New
New
LT
6
New
LS
1
2
LS
E
7
E
1
New 4
New 3
7
4 New
LS
LS
3 New
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “CYLINDERS AND PISTONS” on
page 5-45.
Front cylinder
1
Push rod cover
2
2
O-ring
2
3
O-ring
2
4
Seal
2
5
Rear valve lifter case
1
6
Front valve lifter case
1
7
Valve lifter
4
For installation, reverse the removal procedure.
5-17
CAMSHAFTS
Removing the camshafts and right balancer
18
M
20
R
R
19
40 Nm (4.0 m • kg, 29 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
17 New
LS
New
16
15
M
21
7
6
5
18
4
8
9
2
E
New 3
14
11
(7)
E
1
13
E
12
10
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
T
1
Job/Parts to remove
Q’ty
Camshaft driven gear
1
2
Straight key
1
3
Circlip
1
4
Washer
1
5
Conical spring washer
1
6
Washer
1
7
Rear cylinder camshaft gear
1
8
Front cylinder camshaft gear
1
9
Straight key
1
10
Right balancer driven gear
1
11
Straight key
1
12
Camshaft drive gear
1
13
Right balancer drive gear
1
14
Straight key
1
15
Oil delivery pipe 1
1
16
Camshaft cover
1
17
Camshaft cover gasket
1
5-18
R
R
Order
40 Nm (4.0 m • kg, 29 ft • Ib)
60 Nm (6.0 m • kg, 43 ft • Ib)
Remarks
CAMSHAFTS
Removing the camshafts and right balancer
18
M
20
R
R
19
40 Nm (4.0 m • kg, 29 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
17 New
LS
New
16
15
M
21
7
6
5
18
4
8
9
2
E
New 3
14
11
(7)
E
1
13
E
12
10
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
T
18
Job/Parts to remove
Q’ty
Dowel pin
2
19
Rear cylinder camshaft
1
20
Front cylinder camshaft
1
21
Right balancer
1
R
R
Order
40 Nm (4.0 m • kg, 29 ft • Ib)
60 Nm (6.0 m • kg, 43 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5-19
CAMSHAFTS
Disassembling the camshafts
5
4
6
New 1
2
E
3
2
E
1 New
3
5
7
4
E
E
Order
Job/Parts to remove
Q’ty
1
Circlip
2
2
Washer
2
3
Decompression cam spring
2
4
Decompression cam
2
5
Decompression pin
2
6
Front cylinder camshaft
1
7
Rear cylinder camshaft
1
Remarks
For assembly, reverse the disassembly procedure.
5-20
CAMSHAFTS
ET1D71030
REMOVING THE CYLINDER HEAD COVERS
1. Remove:
• Front cylinder
• Rear cylinder “1”
d
NOTE:
c
Due to the small clearance between the frame
and the rear cylinder head cover, the three bolts
“2” cannot be removed when the cover is in
place. Loosen the bolts, and then remove the
cover from the right side of the vehicle, making
sure that the bolts do not scratch the rocker arms
or other engine parts.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• Rocker arm bases
(with the rocker arms)
3. Remove:
• Valve lifters
2
NOTE:
Make a note of the position of each valve lifter so
that they can be installed in the correct place.
1
2
EAS23790
REMOVING THE ROCKER ARMS, PUSH
RODS AND VALVE LIFTERS
1. Align:
• TDC mark “a” on the crankshaft position sensor rotor
(with the pointer “b” on the clutch cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the
crankshaft position sensor rotor with the
pointer “b” on the clutch cover.
b
a
EAS23830
REMOVING THE CAMSHAFTS
1. Loosen:
• Camshaft driven gear bolt “1”
NOTE:
• Place a folded copper washer “2” between the
teeth of the camshaft drive gear and camshaft
driven gear in order to lock them.
• Do not damage the teeth of the camshaft drive
and camshaft driven gears.
c. Check the camshaft drive gear mark “c” position and camshaft driven gear mark “d” position as shown.
If the marks are not aligned, turn the crankshaft counterclockwise 360 degrees and recheck step (b).
5-21
CAMSHAFTS
NOTE:
• Place a folded copper washer “3” between the
teeth of the right balancer drive gear and right
balancer driven gear in order to lock them.
• Place a folded copper washer “4” between the
teeth of the right balancer drive gear and right
balancer driven gear in order to lock them.
• Do not damage the teeth of the right balancer
drive and right balancer driven gears.
1
2
2. Remove:
• Camshaft driven gear
• Straight key
NOTE:
3
Cover the crankcase hole with a clean rag to
prevent the straight key from falling into the
crankcase.
1
3. Loosen:
• Front cylinder camshaft gear bolt “1”
NOTE:
• Place a folded copper washer “2” between the
teeth of the front cylinder camshaft gear and
rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
camshaft and rear cylinder camshaft gears.
2
2
1
4
6. Remove:
• Right balancer driven gear
• Camshaft drive gear
• Right balancer drive gear
• Straight keys
NOTE:
Cover the crankcase hole with a clean rag to
prevent the straight keys from falling into the
crankcase.
4. Remove:
• Rear cylinder camshaft gear
• Front cylinder camshaft gear
• Straight key
7. Remove:
• Oil delivery pipe 1 “1”
• Camshaft cover “2”
NOTE:
Cover the crankcase hole with a clean rag to
prevent the straight key from falling into the
crankcase.
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
5. Loosen:
• Camshaft drive gear bolt “1”
• Right balancer driven gear bolt “2”
5-22
CAMSHAFTS
1
2
EAS23860
CHECKING THE CAMSHAFTS
1. Check:
• Cam
Blue discoloration/pitting/scratches → Replace the camshaft.
2. Measure:
• Cam dimensions A “a” and B “b”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions
Intake A
42.532–42.632 mm (1.6745–
1.6784 in)
Limit
42.432 mm (1.6705 in)
Intake B
35.950–36.050 mm (1.4154–
1.4193 in)
Limit
35.850 mm (1.4114 in)
Exhaust A
42.530–42.630 mm (1.6744–
1.6783 in) (cylinder #1)
42.531–42.631 mm (1.6744–
1.6784 in) (cylinder #2)
Limit
42.430 mm (1.6705 in) (cylinder
#1)
42.431 mm (1.6705 in) (cylinder
#2)
Exhaust B
35.950–36.050 mm (1.4154–
1.4193 in)
Limit
35.850 mm (1.4114 in)
3. Measure:
• Camshaft journal diameter (crankcase side)
“a”
Out of specification → Replace the camshaft.
Camshaft journal diameter
(crankcase side)
24.957–24.980 mm (0.9826–
0.9835 in)
a
a
4. Measure:
• Camshaft journal diameter (camshaft cover
side) “a”
Out of specification → Replace the camshaft.
Camshaft journal diameter (camshaft cover side)
27.957–27.980 mm (1.1007–
1.1016 in)
5-23
CAMSHAFTS
NOTE:
Calculate the clearance by subtracting the camshaft journal diameter (crankcase side) from the
crankcase hole inside diameter.
Camshaft to crankcase clearance
0.020–0.064 mm (0.0008–0.0025
in)
a
a
5. Measure:
• Crankcase hole inside diameter “a”
Out of specification → Replace the crankcase.
8. Calculate:
• Camshaft to camshaft cover clearance
Out of specification → Replace the defective
part(s).
NOTE:
Calculate the clearance by subtracting the camshaft journal diameter (camshaft cover side)
from the camshaft cover hole inside diameter.
Crankcase hole inside diameter
25.000–25.021 mm (0.9843–
0.9851 in)
Camshaft to camshaft cover
clearance
0.020–0.064 mm (0.0008–0.0025
in)
a
9. Check:
• Camshaft drive gears
• Camshaft driven gears
• Front cylinder camshaft gears
• Rear cylinder camshaft gears
Chips/pitting/roughness/wear → Replace the
defective part(s).
a
6. Measure:
• Camshaft cover hole inside diameter “a”
Out of specification → Replace the camshaft
cover.
EAS23890
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
Damage/wear → Replace.
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication
system.
3. Measure:
• Rocker arm inside diameter “a”
Out of specification → Replace.
Camshaft cover hole inside diameter
28.000–28.021 mm (1.1024–
1.1032 in)
a
a
Rocker arm inside diameter
18.000–18.018 mm (0.7087–
0.7094 in)
7. Calculate:
• Camshaft-to-crankcase clearance
Out of specification → Replace the defective
part(s).
5-24
CAMSHAFTS
• Push rod end
Bends/damage → Replace.
2. Measure:
• Push rod runout
Out of specification → Replace.
Valve push rod runout
0.3 mm (0.012 in)
4. Measure:
• Rocker arm shaft outside diameter “a”
Out of specification → Replace.
Rocker arm shaft outside diameter
17.976–17.991 mm (0.7077–
0.7083 in)
EAS23920
CHECKING THE VALVE LIFTERS AND
VALVE LIFTER CASES
1. Check:
• Valve lifter
Blue discoloration/excessive wear/pitting/
scratches → Replace and check the lubrication system.
2. Check:
• Valve lifter case “1”
Damage/wear → Replace the valve lifter
case.
• O-rings “2”
Damage/wear → Replace the O-ring.
5. Calculate:
• Rocker arm to rocker arm shaft clearance
NOTE:
Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker
arm inside diameter.
Above 0.08 mm (0.003 in) → Replace the defective part(s).
1
Rocker-arm-to-rocker-arm-shaft
clearance
0.009–0.042 mm (0.0004–0.0017
in)
2
3. Measure:
• Valve lifter outside diameter “a”
Out of specification → Replace.
EAS23900
CHECKING THE ROCKER ARM BASES
1. Check:
• Rocker arm base
Cracks/damage → Replace.
EAS23910
CHECKING THE PUSH RODS
1. Check:
• Push rod
5-25
CAMSHAFTS
Valve lifter outside diameter (intake)
22.962–22.974 mm (0.9040–
0.9045 in)
Valve lifter outside diameter (exhaust)
22.962–22.974 mm (0.9040–
0.9045 in)
Valve-lifter-to-valve-lifter-hole
clearance
0.026–0.059 mm (0.0010–0.0023
in)
EAS23930
CHECKING THE PUSH ROD COVER
1. Check:
• Push rod cover
Cranks/damage → Replace.
• Seal
• O-ring
Damage/wear → Replace the seal and Oring as a set.
EAS23980
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• Decompression system
4. Measure:
• Valve lifter case inside diameter “a”
Out of specification → Replace.
NOTE:
• Check that the decompression pin “1” projects
from the camshaft.
• Check that the decompression cam “2” and decompression pin “1” moves smoothly.
Valve lifter hole inside diameter
(intake)
23.000–23.021 mm (0.9055–
0.9063 in)
Valve lifter hole inside diameter
(exhaust)
23.000–23.021 mm (0.9055–
0.9063 in)
1
2
a
2. Check:
• Decompression cam
• Decompression pin
Damage/wear → Replace.
ET1D71031
CHECKING THE DECOMPRESSION CAM
SPRING
The following procedure applies to all of the decompression cam springs.
1. Measure:
• Decompression cam spring free length “a”
Out of specification → Replace the decompression cam spring.
5. Calculate:
• Valve lifter-to-valve lifter case clearance
NOTE:
Calculate the clearance by subtracting the valve
lifter outside diameter from the valve lifter case
inside diameter.
Above 0.072 mm (0.0028 in) → Replace the
defective part(s).
5-26
CAMSHAFTS
EAS24030
Decompression cam spring
Free length
20.0 mm (0.79 in)
Limit
19.0 mm (0.75 in)
INSTALLING THE CAMSHAFTS
1. Install:
• Camshafts
NOTE:
Lubricate molybdenum disulfide oil onto the
camshaft journals and lobes.
2. Install:
• Camshaft cover 1 “1”
• Oil delivery pipe 1 “2”
NOTE:
Tighten the camshaft cover bolts in stages and
in a crisscross pattern.
2
2. Measure:
• Compressed decompression cam spring
force “a”
Out of specification → Replace the decompression cam spring.
1
Decompression cam spring
Installed compression spring
force
0.1335–0.1631 N (0.0300–0.0367
lb) (0.0136–0.0166 kgf)
Installed length
8.0 mm (0.31 in)
3. Install:
• Straight keys
• Right balancer drive gear “1”
• Right balancer driven gear “2”
• Camshaft driven gear
NOTE:
• Cover the crankcase hole with a clean rag to
prevent the straight keys from falling into the
crankcase.
• Align the punch mark “a” on the right balancer
drive gear “1” with the punch mark “b” on the
right balancer driven gear “2”.
b. Installed length
b
EAS23990
CHECKING THE OIL DELIVERY PIPE
1. Check:
• Oil delivery pipe 1
Damage → Replace.
Obstruction → Wash and blow out with compressed air.
• O-rings
Damage/wear → Replace.
a
2
1
4. Tighten:
• Camshaft drive gear bolt “1”
• Right balancer driven gear bolt “2”
5-27
CAMSHAFTS
T.
R
Camshaft drive gear bolt
60 Nm (6.0 m·kg, 43 ft·lb)
Right balancer driven gear bolt
40 Nm (4.0 m·kg, 29 ft·lb)
NOTE:
• Align the projection “a” on the washer “3” with
the punch mark “b” on the front cylinder camshaft gear.
• Install the conical spring washer “4” as shown
in the illustration.
• Lubricate the front cylinder camshaft gear bolt
threads with engine oil.
NOTE:
• Lubricate the camshaft drive gear bolt and right
balancer driven gear bolt threads with engine
oil.
• Place a folded copper washer “3” between the
teeth of the right balancer drive gear and right
balancer driven gear in order to lock them.
• Place a folded copper washer “4” between the
teeth of the right balancer drive gear and right
balancer driven gear in order to lock them.
• Do not damage the teeth of the right balancer
drive and right balancer driven gears.
• After tightening the camshaft driven gear bolt,
remove the copper washer to clean the teeth of
the right balancer drive gear and right balancer
driven gear.
2
3
b
1
a
3
4
5
6 New
1
6. Tighten:
• Front cylinder camshaft gear bolt “1”
3
T.
R
Front cylinder camshaft gear bolt
40 Nm (4.0 m·kg, 29 ft·lb)
NOTE:
• Place a folded copper washer “2” between the
teeth of the front cylinder camshaft gear and
rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
camshaft and rear cylinder camshaft gears.
• After tightening the front cylinder camshaft
gear bolt, remove the copper washer to clean
the teeth of the front cylinder camshaft and rear
cylinder camshaft gears.
4
2
5. Install:
• Rear cylinder camshaft gear “1”
• Front cylinder camshaft gear “2”
• Washer “3”
• Conical spring washer “4”
• Washer “5”
• Circlip “6” New
5-28
CAMSHAFTS
NOTE:
• Place a folded copper washer “2” between the
teeth of the camshaft drive gear and camshaft
driven gear in order to lock them.
• Do not damage the teeth of the camshaft drive
and camshaft driven gears.
• After tightening the camshaft driven gear bolt,
remove the copper washer to clean the teeth of
the camshaft drive and camshaft driven gears.
1
2
7. Install:
• Straight key
• Camshaft driven gear “1”
1
NOTE:
• Cover the crankcase hole with a clean rag to
prevent the straight key from falling into the
crankcase.
• Align the punch mark “a” on the camshaft driven gear “1” with the punch mark “b” on the
camshaft drive gear “2”.
• Insert a cross-headed screwdriver into one of
the holes in the outer camshaft driven gear and
rotate the gear until the teeth of both driven
gears are aligned. The teeth of both camshaft
driven gears must be aligned for installation.
1
2
EAS24050
BLEEDING A VALVE LIFTER
A valve lifter must be bled in the following cases.
• When installing a new valve lifter
• When the valve lifter leaks oil
1. Bleed:
• Valve lifter
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill a container with kerosene and place the
valve lifter into the container as shown.
Pump the plunger side of the valve lifter with
a press a number of times to let in kerosene.
b
ECA14630
2
CAUTION:
• Do not pump the valve lifter excessively.
• Kerosene is highly flammable.
8. Tighten:
• Camshaft driven gear bolt “1”
1. Kerosene
2. Valve lifter
T.
R
Camshaft driven gear bolt
60 Nm (6.0 m·kg, 43 ft·lb)
b. Install the valve lifter into the engine.
5-29
CAMSHAFTS
h. Rotate the crankshaft until the mark (on the
camshaft driven gear) for the valve lifter to be
bled aligns with the camshaft drive gear as
shown.
Example:
For bleeding the cylinder #2 intake valve lifter, align mark “2” as shown.
ECA14650
CAUTION:
Be sure to install the valve lifter in its appropriate position.
Start the engine and warm it up.
Stop the engine.
Remove the camshaft sprocket cover.
Rotate the camshaft until the punch mark “1”
on the camshaft driven gear aligns with the
punch mark on the camshaft drive gear as
shown. This is the condition in which piston
#1 is at top dead center (TDC).
NOTE:
1918 1
716
The crankshaft can be rotated smoothly when
the spark plugs are removed.
EWA12880
1 19
17 8
16
15
14
13
12
11
10
9
8
7
6
5
4 3
WARNING
1
2
2 1 1
15
14
13
12
11
10
9
8
7
6
5
4
3
c.
d.
e.
f.
2
Be careful since the engine is hot.
g. With piston #1 at TDC, count the indicated
number of gear teeth and place marks “2”
through “5” on the camshaft driven gear as
shown. When these marks align between the
centers of the camshaft drive and driven
gears, the corresponding valve lifter is at its
highest point.
1. Piston #1 TDC punch mark
2. Cylinder #2 intake valve at its highest point
i. Leave the camshaft drive and driven gears
aligned for five minutes to allow the valve lifter to bleed.
j. If necessary, repeat steps (h) and (i) to bleed
other valve lifters.
1918 17 16 15
19
14
18
13
12
17
4
11
16
15
10
14
9
13
8
3
12
7
11
5 6
5
10
2
4
9
1
8
3
2
7
1
6 5
4 3 2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24060
INSTALLING THE VALVE LIFTERS
1. Install:
• Front valve lifter case
• Rear valve lifter case
• Valve lifters
T.
R
1.
2.
3.
4.
5.
Piston #1 TDC punch mark
Cylinder #2 intake valve at its highest point
Cylinder #1 exhaust valve at its highest point
Cylinder #1 intake valve at its highest point
Cylinder #2 exhaust valve at its highest point
Valve lifter case bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
NOTE:
• Install the valve lifter in the correct place.
• After installing the valve lifters, fill the tops of
them with engine oil.
5-30
CAMSHAFTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Put the rocker arm base on the cylinder head.
b. Install the push rods.
NOTE:
• Be sure to correctly install the push rods between the rocker arms and valve lifters as
shown. The illustration is viewed from the right
side of the vehicle.
• The lengths of push rod 1 and push rod 2 are
different. Therefore, be sure to install them in
the proper position.
• Lubricate the push rod end balls with engine
oil.
E
2. Install:
• Push rod covers “1”
NOTE:
Install the push rod covers so that their paint
marks “a” are facing towards the cylinder heads.
a
a
1
1
EAS24070
INSTALLING THE ROCKER ARMS AND
PUSH RODS
The following procedure applies to both cylinders.
1. Install:
• Rocker arms “1”
• Rocker arm shafts “2”
(onto rocker arm base)
A.
B.
1.
2.
3.
4.
5.
6.
NOTE:
The thread hole “a” of the rocker arm shaft must
face to the outside.
1
a
Rear cylinder
Front cylinder
Exhaust side rocker arm
Intake side rocker arm
Exhaust valve lifter
Intake valve lifter
Push rod 1 l = 286.5 mm (11.280 in)
Push rod 2 l = 288.5 mm (11.358 in)
c. Install the rocker arm base bolts (M6) “1” and
rocker arm base bolts (M8) “2” and “3”.
NOTE:
Tighten the rocker arm base bolts in stages and
in a crisscross pattern.
a
2
T.
2. Install:
• Rocker arm base
(with rocker arms)
• Push rods
R
5-31
Rocker arm base bolt (M6)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Rocker arm base bolt (M8)
24 Nm (2.4 m·kg, 17ft·lb)
CAMSHAFTS
Bolts “2”: l = 45 mm (1.77 in)
Bolts “3”: l = 70 mm (2.76 in)
5
1
5
2
4
3
2
5
5
5
5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24080
1
3
INSTALLING THE CYLINDER HEAD
COVERS
1. Install:
• Rear cylinder head cover “1”
• Front cylinder head cover “2”
4
5
NOTE:
3
Due to the small clearance between the frame
and the rear cylinder head cover, the three bolts
“3” cannot be installed when the cover is in
place. Set the bolts in the cylinder head cover,
and then install the cover from the right side of
the vehicle.
5
3
ET1D71032
INSTALLING THE SHIFT PEDAL ASSEMBLY
1. Install:
• Shift pedal assembly “1”
NOTE:
Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.
T.
R
Cylinder head cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Bolts “4”: l = 40 mm (1.57 in)
Bolts “5”: l = 60 mm (2.36 in)
1
a
5-32
CYLINDER HEADS
EAS24110
CYLINDER HEADS
Removing the cylinder heads
T
R
59 Nm (5.9 m • kg, 43 ft • Ib)
T
R
T
R
53 Nm (5.3 m • kg, 38 ft • Ib)
66 Nm (6.6 m • kg, 48 ft • Ib)
2
LT
R
LT
T
1
20 Nm (2.0 m • kg, 14 ft • Ib)
R
53 Nm (5.3 m • kg, 38 ft • Ib)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
60 Nm (6.0 m • kg, 43 ft • Ib)
(3)
11
12
E
New 7
13 New
5 New
New 9
10
3
4
New 5
T
R
20 Nm (2.0 m • kg, 14 ft • Ib)
New
6 New
8
Q’ty
Cylinder-#1 ignition coil bracket
R
Job/Parts to remove
10
18 Nm (1.8 m • kg, 13 ft • Ib)
T
Order
R
New 9
21 Nm (2.1 m • kg, 15 ft • Ib)
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
Throttle bodies/Intake manifolds
Refer to “THROTTLE BODIES” on page 6-6.
Cylinder head covers/Rocker arms
Refer to “CAMSHAFTS” on page 5-14.
1
Engine bracket (right upper side)
1
2
Engine bracket (left upper side)
1
3
Engine temperature sensor
1
4
Oil pipe 1
1
5
Copper washer
4
6
Copper washer
2
7
Rear cylinder head
1
8
Front cylinder head
1
9
Cylinder head gasket
2
10
Dowel pin
4
11
Rear exhaust pipe joint cover
1
12
Rear exhaust pipe joint
1
5-33
CYLINDER HEADS
Removing the cylinder heads
T
R
59 Nm (5.9 m • kg, 43 ft • Ib)
T
R
T
R
53 Nm (5.3 m • kg, 38 ft • Ib)
66 Nm (6.6 m • kg, 48 ft • Ib)
2
LT
R
LT
T
1
20 Nm (2.0 m • kg, 14 ft • Ib)
R
53 Nm (5.3 m • kg, 38 ft • Ib)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
60 Nm (6.0 m • kg, 43 ft • Ib)
(3)
11
12
E
New 7
13 New
5 New
New 9
10
3
4
New 5
T
R
20 Nm (2.0 m • kg, 14 ft • Ib)
New
6 New
8
Q’ty
Rear exhaust pipe gasket
R
13
Job/Parts to remove
10
18 Nm (1.8 m • kg, 13 ft • Ib)
T
Order
R
New 9
21 Nm (2.1 m • kg, 15 ft • Ib)
Remarks
1
For installation, reverse the removal procedure.
5-34
CYLINDER HEADS
EAS24140
REMOVING THE CYLINDER HEADS
1. Remove:
• Cylinder head nuts
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
A
2
3
4
1
2. Check:
• Cylinder head
Damage/scratches → Replace.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in)
B
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4
2
a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
1
3
A. Front cylinder
B. Rear cylinder
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS24170
CHECKING THE CYLINDER HEADS
The following procedure applies to all of the cylinder heads.
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• Spark plug bore threads
• Valve seats
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24220
CHECKING THE OIL PIPE
1. Check:
• Oil pipe 1
Damage → Replace.
Obstruction → Wash and blow out with compressed air.
5-35
CYLINDER HEADS
EAS24250
INSTALLING THE CYLINDER HEADS
1. Install:
B
• Cylinder head gasket “1” New
• Dowel pins “2”
1
4
NOTE:
The “1D7” mark on the cylinder head gasket
must face up and towards the left side of the cylinder.
3
2
A. Front cylinder
B. Rear cylinder
1 New
2
4. Install:
• Copper washers New
• Oil pipe 1
• Oil pipe union bolt (M8)
2
T.
R
2. Install:
• Cylinder heads
• Washers
• Cylinder head nuts
Oil pipe union bolt (M8)
18 Nm (1.8 m·kg, 13ft·lb)
• Oil pipe union bolts (M10)
T.
R
NOTE:
Lubricate the cylinder head nuts and washers
with engine oil.
NOTE:
Tighten the three union bolts evenly, and then
torque them to specification.
3. Tighten:
• Cylinder head nuts
T.
R
5. Install:
• Engine bracket (right upper side)
• Engine bracket bolts (right upper side)
• Engine mounting bolts (right upper side)
• Engine bracket (left upper side)
• Engine bracket bolts (left upper side)
• Engine mounting bolts (left upper side)
Cylinder head nut
60 Nm (6.0 m·kg, 43 ft·lb)
NOTE:
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque them
in two stages.
Oil pipe union bolt (M10)
21 Nm (2.1 m·kg, 15 ft·lb)
NOTE:
• Apply locking agent (LOCTITE®) to the threads
of the engine mounting bolts (left upper side).
• Do not fully tighten the bolts.
A
3
2
1
4
6. Tighten:
• Engine mounting bolts (right upper side)
• Engine mounting bolts (left upper side)
• Engine bracket bolts (right upper side)
• Engine bracket bolts (left upper side)
5-36
CYLINDER HEADS
T.
R
Engine mounting bolt (right upper side)
59 Nm (5.9 m·kg, 43 ft·lb)
Engine mounting bolt (left upper
side)
66 Nm (6.6 m·kg, 48 ft·lb)
LOCTITE®
Engine bracket bolt (right upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
Engine bracket bolt (left upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
5-37
VALVES AND VALVE SPRINGS
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
1
2
1
New 6
2
1
3
6 New
7
M
2
7
3
M
6 New
8
8
3
1
7
8
2
New 6
3
7
8
E
4 5
E
M
M
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both cylinders.
Cylinder heads
Refer to “CYLINDER HEADS” on page 5-33.
1
Valve cotter
8
2
Upper spring seat
4
3
Valve spring
4
4
Intake valve
2
5
Exhaust valve
2
6
Valve stem seal
4
7
Lower spring seat
4
8
Valve guide
4
For installation, reverse the removal procedure.
5-38
VALVES AND VALVE SPRINGS
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-41.
3. Remove:
• Upper spring seat “1”
• Valve spring “2”
• Valve “3”
• Valve stem seal “4”
• Lower spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
NOTE:
There should be no leakage at the valve seat “1”.
EAS24290
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” Valve stem diameter “b”
2. Remove:
• Valve cotters
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
set “1”.
Valve spring compressor
90890-04019
YM-04019
5-39
VALVES AND VALVE SPRINGS
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
2. Replace:
• Valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
5-40
VALVES AND VALVE SPRINGS
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• Valve seat width C “a”
Out of specification → Replace the cylinder
head.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve margin thickness D “a”
Out of specification → Replace the valve.
Valve margin thickness D (intake)
1.15–1.45 mm (0.0453–0.0571 in)
Limit
0.4 mm (0.02 in)
Valve margin thickness D (exhaust)
1.15–1.45 mm (0.0453–0.0571 in)
Limit
0.4 mm (0.02 in)
Valve seat width C (intake)
1.10–1.30 mm (0.0433–0.0512 in)
Limit
2.0 mm (0.08 in)
Valve seat width C (exhaust)
1.10–1.30 mm (0.0433–0.0512 in)
Limit
2.0 mm (0.08 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
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NOTE:
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always replace the valve stem seal.
Valve stem runout
0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
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5-41
VALVES AND VALVE SPRINGS
4. Lap:
• Valve face
• Valve seat
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
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a. Apply a coarse lapping compound “a” to the
valve face.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
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EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
5-42
VALVES AND VALVE SPRINGS
Free length (intake)
46.71 mm (1.84 in)
Limit
44.71 mm (1.76 in)
Free length (exhaust)
46.71 mm (1.84 in)
Limit
44.71 mm (1.76 in)
Spring tilt (intake)
2.5 °/2.0 mm
Spring tilt (exhaust)
2.5 °/2.0 mm
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
2. Measure:
• Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
Installed compression spring
force (intake)
217.00–249.00 N (48.78–55.98 lb)
(22.13–25.39 kgf)
Installed compression spring
force (exhaust)
217.00–249.00 N (48.78–55.98 lb)
(22.13–25.39 kgf)
Installed length (intake)
32.66 mm (1.29 in)
Installed length (exhaust)
32.66 mm (1.29 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
3. Install:
• Valve guide “1”
5-43
VALVES AND VALVE SPRINGS
• Lower spring seat “2”
• Valve stem seal “3”
• Valve “4”
• Valve spring “5”
• Upper spring seat “6”
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
set “1”.
Valve spring compressor
90890-04019
YM-04019
5-44
CYLINDERS AND PISTONS
EAS24360
CYLINDERS AND PISTONS
Removing the cylinders and pistons
2
8
New 3
9
8
9
10
10
E
4
5 New
E
1
E
5
7
7
6
6
New 5
5 New
New
New 3
4
Order
Job/Parts to remove
Q’ty
Cylinder heads
Remarks
Refer to “CYLINDER HEADS” on page 5-33.
1
Front cylinder
1
2
Rear cylinder
1
3
Cylinder gasket
2
4
Dowel pin
4
5
Circlip
4
6
Piston pin
2
7
Piston
2
8
Top ring
2
9
2nd ring
2
10
Oil ring
2
For installation, reverse the removal procedure.
5-45
CYLINDERS AND PISTONS
EAS24380
NOTE:
REMOVING THE PISTON
1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
ECA13810
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
• For reference during installation, put an identification mark on each piston crown.
• Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
EAS24410
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of the cylinders and pistons.
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• Piston-to-cylinder clearance
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
3
NOTE:
1
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
2
Bore
100.000–100.010 mm (3.9370–
3.9374 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D1–D6
“T” = maximum of D1 or D2 - maximum of D5
or D6
“R” = maximum of D1, D3 or D5 - minimum of
D2, D4 or D6
2. Remove:
• Top ring
• 2nd ring
• Oil ring
5-46
CYLINDERS AND PISTONS
EAS24430
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter D “a” with the
micrometer.
Piston ring
Top ring
Ring side clearance
0.030–0.080 mm (0.0012–
0.0032 in)
Limit
0.120 mm (0.0047 in)
2nd ring
Ring side clearance
0.030–0.070 mm (0.0012–
0.0028 in)
Limit
0.120 mm (0.0047 in)
Piston
Diameter D
99.960–99.975 mm (3.9354–
3.9360 in)
b. 10 mm (0.39 in) from the bottom edge of the
piston
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
• Piston-to-cylinder clearance =
Cylinder bore “C” Piston skirt diameter “D”
2. Install:
• Piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
Piston-to-cylinder clearance
0.025–0.050 mm (0.0010–0.0020
in)
Limit
0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
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a. 10 mm (0.39 in)
5-47
CYLINDERS AND PISTONS
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring
Top ring
End gap (installed)
0.20–0.35 mm (0.0079–0.0138
in)
Limit
0.55 mm (0.0217 in)
2nd ring
End gap (installed)
0.45–0.60 mm (0.0177–0.0236
in)
Limit
0.95 mm (0.0374 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.0079–0.0276
in)
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter
23.004–23.015 mm (0.9057–
0.9061 in)
Limit
23.045 mm (0.9073 in)
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication system.
2. Measure:
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
and piston as a set.
• Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” Piston pin outside diameter “a”
Piston-pin-to-piston-pin-bore
clearance
0.004–0.024 mm (0.00016–
0.00094 in)
Piston pin outside diameter
22.991–23.000 mm (0.9052–
0.9055 in)
Limit
22.971 mm (0.9044 in)
EAS24460
INSTALLING THE PISTONS AND
CYLINDERS
The following procedure applies to all of the pistons and cylinders.
1. Install:
• Top ring “1”
• 2nd ring “2”
• Lower oil ring rail “3”
• Upper oil ring rail “4”
5-48
CYLINDERS AND PISTONS
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
• Oil ring expander “5”
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
Recommended lubricant
Engine oil
4. Offset:
• Piston ring end gaps
A
90 ˚
d.e
b
2. Install:
• Piston “1”
• Piston pin “2”
90 ˚
• Piston pin clips “3” New
NOTE:
45 ˚
• Apply engine oil onto the piston pin.
• Make sure the arrow mark “a” on the piston faces towards the front of the vehicle.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
• Install the piston pin clips, so that the clip ends
are 3 mm (0.12 in) “b” or more from the cutout
in the piston.
• Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#2).
a.
b.
c.
d.
e.
A.
a.c
Top ring
Upper oil ring rail
Oil ring expander
Lower oil ring rail
2nd ring
forward
5. Install:
• Cylinder “1”
NOTE:
While compressing the piston rings with one
hand, install the cylinder with the other hand.
1
b
3 New
5-49
CLUTCH
EAS25060
CLUTCH
Removing the clutch cover
1
T
R
12 Nm (1.2 m • kg, 8.7 ft • Ib)
2
5
5
R
New 4
(5)
(11)
R
3
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Left side cover
Refer to “GENERAL CHASSIS” on page
4-1.
Horn 1/Canister
Refer to “THROTTLE BODIES” on page 6-6.
For California only
Fuel tank/Sub-fuel tank
Refer to “FUEL TANK” on page 6-1.
Left rider footrest assembly/Shift rod/Sidestand
Refer to “ENGINE REMOVAL” on page 5-1.
Generator cover
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-72.
Drive pulley case
Refer to “TRANSFER GEAR CASE” on
page 5-81.
1
Crankshaft position sensor coupler
1
2
Shift arm
1
3
Clutch cover
1
4
Clutch cover gasket
1
5-50
Disconnect.
CLUTCH
Removing the clutch cover
1
T
R
12 Nm (1.2 m • kg, 8.7 ft • Ib)
2
5
5
R
New 4
(5)
(11)
5
R
3
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Dowel pin
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
2
For installation, reverse the removal procedure.
5-51
CLUTCH
Removing the crankshaft position sensor
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
5
LT
LT
3
5
LT
LT
4
6
5
LT
2
New 1
LS
Order
Job/Parts to remove
Q’ty
1
Oil seal
1
2
Bearing
1
3
Clutch cover damper plate
1
4
Clutch cover damper
1
5
Crankshaft position sensor lead holder
3
6
Crankshaft position sensor
1
Remarks
For installation, reverse the removal procedure.
5-52
CLUTCH
Removing the clutch
LS
28
27
26 25
24
New
23
19
E
E
20
22
17
R
18
T
21
105 Nm (10.5 m • kg, 75 ft • lb)
16
23
32
15 14
13 12 New
New
33
9
31
30 29
11
65
E
10
E
8
R
100 Nm (10.0 m • kg, 72 ft • lb)
7
(6)
New
LS
4
E
T
R
Order
Job/Parts to remove
Q’ty
1
Clutch spring plate retainer
1
2
Clutch spring plate
1
3
Clutch spring plate seat
1
4
Pressure plate
1
5
Short clutch push rod
1
6
Friction plate 1
1
7
Clutch plate
9
8
Friction plate 2
9
9
Clutch boss nut
1
10
Conical spring washer
1
11
Washer
1
12
Wire circlip
1
13
Clutch plate
1
14
Friction plate 3
1
15
Clutch damper spring
1
16
Clutch damper spring seat
1
17
Clutch boss
1
5-53
3
2
1
8 Nm (0.8 m kg, 5.8 ft • Ib)
•
Remarks
Inside diameter: 124 mm (4.88 in)
Inside diameter: 135 mm (5.31 in)
CLUTCH
Removing the clutch
LS
28
27
26 25
24
New
23
19
E
E
20
22
17
R
18
T
21
105 Nm (10.5 m • kg, 75 ft • lb)
16
23
32
15 14
13 12 New
New
33
9
31
30 29
11
65
E
10
E
8
R
100 Nm (10.0 m • kg, 72 ft • lb)
7
(6)
New
LS
4
E
T
R
Order
Job/Parts to remove
Q’ty
18
Thrust washer 1
1
19
Clutch housing
1
20
Circlip
1
21
Washer
1
22
Oil pump drive gear
1
23
Dowel pin
2
24
Bearing
1
25
Collar
1
26
Thrust washer 2
1
27
Ball
1
28
Long push rod
1
29
Spacer
1
30
Crankshaft position sensor rotor
1
31
Primary drive gear
1
32
Straight key
1
33
Washer
1
3
2
1
8 Nm (0.8 m kg, 5.8 ft • Ib)
•
Remarks
For installation, reverse the removal procedure.
5-54
CLUTCH
Removing the left balancer
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
12 New
(6)
9
8
10
LS
2
1 11
2
LS
(3)
New 3
5
4
R
7
LS
3 New
T
6
E
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
T
R
Order
40 Nm (4.0 m • kg, 29 ft • Ib)
Job/Parts to remove
Q’ty
1
Left balancer idle gear shaft holder
2
Dowel pin
2
3
O-ring
2
4
Left balancer idle gear
1
5
Left balancer idle gear shaft
1
6
Left balancer drive gear
1
7
Straight key
1
8
Left balancer driven gear
1
9
Left balancer weight 1
1
Remarks
1
10
Left balancer weight 2
1
11
Left balancer driven gear housing
1
12
Gasket
1
For installation, reverse the removal procedure.
5-55
CLUTCH
Removing the clutch master cylinder
2
3
4
1
T
R
30 Nm (3.0 m • kg, 22 ft • Ib)
13
New 10
LS
6
7
5
9
8
12
11
LT
T
R
Order
Job/Parts to remove
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
Remarks
Drain.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
Clutch fluid
1
Left rearview mirror
1
2
Clutch master cylinder reservoir cap
1
3
Clutch master cylinder reservoir diaphragm
holder
1
4
Clutch master cylinder reservoir diaphragm
1
5
Clutch lever
1
6
Clutch master cylinder push rod pin
1
7
Clutch switch coupler
1
8
Clutch switch
1
9
Clutch hose union bolt
1
10
Copper washer
2
11
Clutch hose
1
12
Clutch master cylinder holder
1
13
Clutch master cylinder
1
Disconnect.
For installation, reverse the removal procedure.
5-56
CLUTCH
Disassembling the clutch master cylinder
LS
5 New
6
4
3 New
2
1
Order
Job/Parts to remove
Q’ty
1
Clutch master cylinder push rod
2
Dust boot
1
3
Circlip
1
4
Washer
1
5
Clutch master cylinder kit
1
6
Clutch master cylinder body
1
Remarks
1
For assembly, reverse the disassembly procedure.
5-57
CLUTCH
Removing the clutch release cylinder
R
19 Nm (1.9 m • kg, 13 ft • Ib)
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New 3
4
2
1
6
T
R
26 Nm (2.6 m • kg, 19 ft • Ib)
5
T
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
Remarks
Clutch fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
Muffler/Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
1
Clutch pipe union bolt cap
1
2
Clutch pipe union bolt
1
3
Copper washer
2
4
Clutch pipe
1
5
Clutch release cylinder
1
6
Dowel pin
2
For installation, reverse the removal procedure.
5-58
CLUTCH
Disassembling the clutch release cylinder
5
6 Nm (0.6 m • kg, 4.3 ft • Ib)
LS
6
3
New 4
2
LS
1
Order
Job/Parts to remove
Q’ty
1
Boots
1
2
Clutch release cylinder piston
1
3
Clutch release cylinder spring
1
4
Clutch release cylinder piston seal
1
5
Bleed screw
1
6
Clutch release cylinder body
1
Remarks
For assembly, reverse the disassembly procedure.
5-59
CLUTCH
EAS25080
REMOVING THE CLUTCH
1. Loosen:
• Clutch boss nut “1”
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
NOTE:
While holding the clutch boss “2” with the universal clutch holder “3”, loosen the clutch boss nut.
Universal clutch holder
90890-04086
YM-91042
2
3
1
1
2. Remove:
• Clutch boss nut “1”
• Conical spring washer “2”
• Washer “3”
• Clutch boss assembly “4”
3
2
ET1D71021
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip “5” and disassemble the
built-in damper unless there is serious clutch
chattering.
REMOVING THE LEFT BALANCER DRIVE
GEAR
1. Loosen:
• Left balancer drive gear bolt “1”
NOTE:
While the holding the generator rotor “2” with the
primary sheave holder “3”, loosen the left balancer drive gear bolt.
4
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5
3
2
1
EAS25090
REMOVING THE PRIMARY DRIVE GEAR
1. Loosen:
• Primary drive gear bolt “1”
1
NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, loosen the primary drive gear
bolt.
5-60
CLUTCH
A
B
3
2
A. Friction plate 1, 3
B. Friction plate 2
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
• Friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• Clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
NOTE:
Measure the friction plate at four places.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
Friction plate 1, 3 thickness
2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.80 mm (0.110 in)
Friction plate 2 thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
Clutch plate thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.20 mm (0.0079 in)
EAS25130
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• Clutch spring plate
Damage → Replace.
5-61
CLUTCH
• Bearing
Damage/wear → Replace.
2. Check:
• Clutch spring plate seat
Damage → Replace.
EAS25190
CHECKING THE CLUTCH PUSH RODS
1. Check:
• O-ring
• Short clutch push rod
• Long clutch push rod
• Ball
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• Long clutch push rod bending limit
Out of specification → Replace the defective
part(s).
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic clutch operation.
Long clutch push rod bending
limit
0.30 mm (0.0118 in)
EAS25200
CHECKING THE PRIMARY DRIVE GEAR
1. Check:
• Primary drive gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
2. Check:
• Bearing
Damage/wear → Replace the bearing and
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• Primary driven gear “1”
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
• Pressure plate
Cracks/damage → Replace.
ET1D71033
CHECKING THE LEFT BALANCER GEARS
1. Check:
• Left balancer drive gear
5-62
CLUTCH
• Left balancer driven gear
• Left balancer idle gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
2. Measure:
• Left balancer driven gear inside diameter “a”
Out of specification → Replace.
NOTE:
Calculate the clearance by subtracting the left
balancer driven gear housing outside diameter
from the left balancer driven gear inside diameter.
Left-balancer-driven-gear-to-leftbalancer-driven-gear-housing
clearance
0.050–0.103 mm (0.0020–0.0041
in)
Left balancer driven gear inside
diameter “a”
59.010–59.028 mm (2.323–2.324
in)
Limit
59.100 mm (2.327 in)
ET1D71022
INSTALLING THE LEFT BALANCER DRIVE
GEAR
1. Install:
• Left balancer weight 1 “1”
• Left balancer weight 2 “2”
• Left balancer driven gear “3”
a
NOTE:
Make sure that the punch marks “a” on the left
balancer driven gear are facing toward left balancer weight 2.
Left balancer weight bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
T.
3. Measure:
• Left balancer driven gear housing outside diameter “a”
Out of specification → Replace.
R
Left balancer driven gear housing outside diameter “a”
58.925–58.960 mm (2.320–2.321
in)
Limit
58.900 mm (2.318 in)
3
2
a
a
1
2. Remove:
• Generator rotor
Refer to “REMOVING THE GENERATOR”
on page 5-74.
3. Align:
• Mark “a” on the generator drive gear of the
crankshaft
(with the mark “b” on the generator shaft driven gear)
4. Calculate:
• Left-balancer-driven-gear-to-left-balancerdriven-gear-housing clearance
Out of specification → Replace the defective
part(s).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft.
b. When the front and rear pistons are near
TDC, align the mark “a” on the generator
drive gear of the crankshaft with the mark “b”
on the generator shaft driven gear.
5-63
CLUTCH
1
a
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Generator rotor
Refer to “INSTALLING THE GENERATOR”
on page 5-75.
5. Install:
• Left balancer drive gear “1”
• Left balancer idle gear “2”
• Left balancer driven gear “3”
3
2
NOTE:
• Align the punch mark “a” on the left balancer
drive gear with the punch mark “b” on the left
balancer idle gear.
• Align the punch marks “c” on the left balancer
idle gear with the punch marks “d” on the left
balancer driven gear.
c
d
EAS25230
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
• Washer
• Straight key
• Primary drive gear
• Crankshaft position sensor rotor “1”
• Spacer
• Primary drive gear bolt “2”
3
T.
R
1
a
Primary drive gear bolt
100 Nm (10.0 m·kg, 72 ft·lb)
EC1D71007
CAUTION:
The timing marks on the crankshaft position
sensor rotor must face outside.
b 2
6. Tighten:
• Left balancer drive gear bolt “1”
NOTE:
T.
R
• Lubricate the primary drive gear bolt threads
with engine oil.
• While holding the generator rotor “3” with the
sheave holder “4”, tighten the primary drive
gear bolt.
Left balancer drive gear bolt
40 Nm (4.0 m·kg, 29 ft·lb)
NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, tighten the left balancer drive
gear bolt.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-64
CLUTCH
• Washer
• Conical spring washer “2”
• Clutch boss nut “3”
T.
Clutch boss nut
105 Nm (10.5 m·kg, 75 ft·lb)
R
1
NOTE:
2
• Lubricate the clutch boss nut threads and conical spring washer mating surfaces with engine
oil.
• Install the conical spring washer “2” with the
“OUT” mark “a” facing out.
• While holding the clutch boss with the universal clutch holder “4”, tighten the clutch boss
nut.
• Stake the clutch boss nut “3” at a cutout “b” in
the main axle.
4
3
Universal clutch holder
90890-04086
YM-91042
EAS25260
INSTALLING THE CLUTCH
1. Install:
• Clutch housing
• Thrust washer
1
4
NOTE:
2
a
• Lubricate the clutch housing bearings with engine oil.
• Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
• Make sure that the primary driven gear teeth
and oil pump driven gear teeth mesh correctly.
b
3
4. Lubricate:
• Friction plates
• Clutch plates
(with the recommended lubricant)
2. Install:
• Clutch boss assembly “1”
NOTE:
• Install the clutch damper spring “2” with the
“OUTSIDE” mark facing out.
• If the wire circlip “3” has been removed, carefully install a new one.
Recommended lubricant
Engine oil
5. Install:
• Friction plates 2 “1”
• Clutch plates
• Friction plate 1 “2”
1
NOTE:
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Align a projection on each friction plate 2 “1”
with the “ ” mark “a” on the clutch housing
and align a projection on friction plate 1 “2” with
the punch mark “b” on the housing.
2
New 3
3. Install:
• Clutch boss “1”
5-65
CLUTCH
a
b
a
1
b
2
1
6. Install:
• Clutch spring plate
• Clutch spring plate retainer
T.
R
Clutch spring plate retainer bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
a
EAS25280
DISASSEMBLING THE CLUTCH MASTER
CYLINDER
NOTE:
Before disassembling the clutch master cylinder,
drain the clutch fluid from the entire clutch system.
NOTE:
Tighten the clutch spring plate retainer bolts in
stages and in a crisscross pattern.
7. Apply:
• Sealant
(onto the crankshaft position sensor lead
grommet)
b
1. Remove:
• Clutch hose union bolt “1”
• Copper washers “2”
• Clutch hose “3”
NOTE:
To collect any remaining clutch fluid, place a
container under the master cylinder and the end
of the clutch hose.
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
2
1
3
ET1D71037
CHECKING THE CLUTCH MASTER
CYLINDER
1. Check:
• Clutch master cylinder
Damage/scratches/wear → Replace.
• Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Clutch master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Clutch master cylinder reservoir
Cracks/damage → Replace.
8. Install:
• Shift arm “1”
T.
R
Shift arm bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
NOTE:
Install the shift arm “1” with its slot “a” aligned
with the mark “b” in end of the shift shaft.
5-66
CLUTCH
• Clutch master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Clutch hose
Cracks/damage/wear → Replace.
EW1D71002
WARNING
Proper clutch hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
NOTE:
EAS25300
ASSEMBLING THE CLUTCH MASTER
CYLINDER
• Install the clutch hose at 5–25° “a” angle to the
clutch master cylinder as shown in the illustration.
• While holding the clutch hose, tighten the
union bolt.
• Turn the handlebar to the left and right to make
sure the clutch hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
EW1D71010
WARNING
• Before installation, all internal clutch components must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch components.
Recommended clutch fluid
Brake fluid DOT 4
EAS25310
INSTALLING THE CLUTCH MASTER
CYLINDER
1. Install:
• Clutch master cylinder “1”
• Clutch master cylinder holder “2”
1
2
a
T.
R
Clutch master cylinder holder
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
3. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
NOTE:
Recommended clutch fluid
Brake fluid DOT 4
• Align the end of the clutch lever holder with the
punch mark “a” on the handlebar.
• First, tighten the rear bolt, then the front bolt.
EWA13370
WARNING
1
2
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch fluids may result in a harmful chemical reaction, leading to poor clutch performance.
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
a
2. Install:
• Copper washers New
• Clutch hose “1”
• Clutch hose union bolt “2”
ECA13420
CAUTION:
T.
R
Clutch hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
5-67
CLUTCH
EAS25330
NOTE:
CHECKING THE CLUTCH RELEASE
CYLINDER
In order to ensure a correct reading of the clutch
fluid level, make sure the top of the reservoir is
horizontal.
Recommended clutch component replacement schedule
4. Bleed:
• Clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
5. Check:
• Clutch fluid level
Below the minimum level mark “a” → Add the
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” on page 3-14.
Piston seal
Every two years
Clutch hose
Every four years
Clutch fluid
Every two years and
whenever the clutch
is disassembled
1. Install:
• Clutch release cylinder body
Cracks/damage → Replace the clutch release cylinder.
2. Check:
• Clutch release cylinder “1”
• Clutch release cylinder piston “2”
Rust/scratches/wear → Replace the clutch
release cylinder and clutch release cylinder
piston as a set.
1
6. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
2
ET1D71004
REMOVING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• Clutch pipe union bolt “1”
• Copper washers “2”
• Clutch pipe “3”
EAS25340
ASSEMBLING THE CLUTCH RELEASE
CYLINDER
EW1D71006
WARNING
• Before installation, all internal clutch components must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch components as they will cause the piston seal
to swell and distort.
• Whenever a clutch release cylinder is disassembled, replace the piston seal.
NOTE:
Put the end of the clutch pipe into a container
and pump out the clutch fluid carefully.
Recommended clutch fluid
Brake fluid DOT 4
1
2
3
5-68
CLUTCH
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
EAS25350
INSTALLING THE CLUTCH RELEASE
CYLINDER
1. Install:
• Copper washers New
• Clutch pipe “1”
• Clutch pipe union bolt “2”
ECA13420
CAUTION:
T.
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
R
Clutch pipe union bolt
26 Nm (2.6 m·kg, 19 ft·lb)
NOTE:
EW1D71003
In order to ensure a correct reading of the clutch
fluid level, make sure that the top of the reservoir
is horizontal.
WARNING
Proper clutch pipe routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.
3. Bleed:
• Clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
4. Check:
• Clutch fluid level
Below the minimum level mark “a” → Add the
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” on page 3-14.
EC1D71005
CAUTION:
When installing the clutch pipe onto the
clutch release cylinder, make sure the pipe
“a” touches the projection “b” on the clutch
release cylinder.
2
a
b
1
2. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
5. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
Recommended clutch fluid
Brake fluid DOT 4
EWA13370
WARNING
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch fluids may result in a harmful chemical reaction, leading to poor clutch performance.
5-69
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
T
R
22 Nm (2.2 m • kg, 16 ft • Ib)
LT
8
New
LS
1
2
1
4
7
3
E
New 2
1
6
5
LT
T
R
Order
Job/Parts to remove
Q’ty
Clutch housing
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Refer to “CLUTCH” on page 5-50.
1
Washer
3
2
Circlip
2
3
Shift shaft
1
4
Shift shaft spring
1
5
Stopper lever
1
6
Collar
1
7
Stopper lever spring
1
8
Shift shaft spring stopper
1
For installation, reverse the removal procedure.
5-70
SHIFT SHAFT
EAS25420
CHECKING THE SHIFT SHAFT
1. Check:
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
Damage/wear → Replace.
1
2
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• Stopper lever spring
Damage/wear → Replace.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
• Stopper lever “1”
• Collar
• Stopper lever bolt “2”
• Stopper lever spring “3”
T.
R
Stopper lever bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
NOTE:
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “4”.
• Mesh the stopper lever with the shift drum segment assembly.
4
3
1
2
2. Install:
• Washers
• Circlips
• Shift shaft spring “1”
• Shift shaft “2”
NOTE:
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “3”.
5-71
3
GENERATOR AND STARTER CLUTCH
EAS24480
GENERATOR AND STARTER CLUTCH
Removing the stator coil
1
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
New
LT
6
2
5
New
LS
LT
7
New
5
4 New
E
LT
3
(5)
Order
R
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
Remarks
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Muffler/Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
Lead cover
Refer to “BELT DRIVE” on page 4-80.
Clutch pipe
Refer to “CLUTCH” on page 5-50.
1
Stator coil coupler
1
2
Oil delivery pipe 2
1
3
Generator cover
1
4
Generator cover gasket
1
5
Dowel pin
2
6
Stator coil lead holder
1
7
Stator coil
1
Disconnect.
For installation, reverse the removal procedure.
5-72
GENERATOR AND STARTER CLUTCH
Removing the generator rotor
7
9
5
T
R
24 Nm (2.4 m • kg, 17 ft • Ib)
8
6
4
LT
3
1
LT
E
2
E
E
(6)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
T
R
Order
80 Nm (8.0 m • kg, 58 ft • Ib)
Job/Parts to remove
Q’ty
1
Torque limiter
1
2
Starter clutch idle gear shaft
1
3
Starter clutch idle gear
1
4
Generator rotor
1
5
Starter clutch
1
6
Woodruff key
1
7
Starter clutch gear
1
8
Bearing
1
9
Bearing housing
1
Remarks
For installation, reverse the removal procedure.
5-73
GENERATOR AND STARTER CLUTCH
EAS24490
NOTE:
REMOVING THE GENERATOR
1. Remove:
• Generator rotor bolt “1”
• Washer
While holding the generator rotor “1” with the
sheave holder “2”, loosen the starter clutch
bolts.
NOTE:
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
While holding the generator rotor “2” with the
sheave holder “3”, loosen the generator rotor
bolt.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
2
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers
Damage/wear → Replace.
2. Check:
• Starter clutch idle gear
• Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
3
1
2
2. Remove:
• Generator rotor “1”
(with the rotor puller “2”)
• Woodruff key
Rotor puller
90890-01080
Stator rotor puller
YM-01080-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Install the starter clutch gear “1” onto the
starter clutch and hold the generator rotor “2”.
b. When turning the starter clutch gear clockwise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counterclockwise “B”, it should turn freely, otherwise
the starter clutch is faulty and must be replaced.
1
EAS24560
REMOVING THE STARTER CLUTCH
1. Remove:
• Starter clutch bolts
• Starter clutch
5-74
GENERATOR AND STARTER CLUTCH
• Generator rotor “1”
• Washer
• Generator rotor bolt “2”
NOTE:
• Clean the tapered portion of the generator
shaft and the generator rotor hub.
• When installing the rotor, make sure the woodruff key is properly seated in the key way of
the generator shaft.
• Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71020
CHECKING THE TORQUE LIMITER
1. Check:
• Torque limiter
Damage/wear → Replace.
NOTE:
Do not disassemble the torque limiter.
2
EAS24600
INSTALLING THE STARTER CLUTCH
1. Install:
• Starter clutch
1
2. Tighten:
• Generator rotor bolt “1”
T.
T.
R
Starter clutch bolt
24 Nm (2.4 m·kg, 17 ft·lb)
LOCTITE®
R
Generator rotor bolt
80 Nm (8.0 m·kg, 58 ft·lb)
NOTE:
NOTE:
While holding the generator rotor “2” with a
sheave holder “3”, tighten the generator rotor
bolt.
While holding the generator rotor “1” with the
sheave holder “2”, tighten the starter clutch
bolts.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
3
2
1
2
3. Apply:
• Sealant
(onto the stator coil lead grommet)
EAS24510
INSTALLING THE GENERATOR
1. Install:
• Woodruff key
5-75
GENERATOR AND STARTER CLUTCH
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
5-76
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
1
2
T
R
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
1
Starter motor lead
1
2
Starter motor
1
Remarks
Disconnect.
For installation, reverse the removal procedure.
5-77
ELECTRIC STARTER
Disassembling the starter motor
LS
LS
New
New 3 2
1
New 4
10 New
New
11
12
7
6
8
New 10
9
5
Order
Job/Parts to remove
Q’ty
1
Starter motor front cover
2
Bearing
1
3
Oil seal
1
4
Circlip
1
5
Starter motor rear cover
1
6
Brush
2
7
Brush holder (along with the brushes)
1
8
Brush seat (along with the brushes)
1
9
Bearing
1
10
Gasket
2
11
Armature assembly
1
12
Starter motor yoke
1
Remarks
1
For assembly, reverse the disassembly procedure.
5-78
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR
1. Check:
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter
motor.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance “1”
0.0081–0.0099 Ω at 20 °C (68 °F)
Insulation resistance “2”
Above 1 MΩ at 20 °C (68 °F)
Limit
27.5 mm (1.08 in)
3. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)
1.50 mm (0.06 in)
b. If any resistance is out of specification, replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Brush length “a”
Out of specification → Replace the brushes
as a set.
Limit
5.00 mm (0.20 in)
NOTE:
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
4. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification → Replace the starter
motor.
Brush spring force
7.36–11.04 N (26.49–39.74 oz)
(750–1126 gf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
with the pocket tester.
5-79
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearings
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
• Starter motor yoke “1”
NOTE:
Align the projection “a” on the brush holder with
the slot “b” in the starter motor yoke.
1
b
a
2. Install:
• Starter motor front cover “1”
NOTE:
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter motor front cover.
a
b
1
5-80
TRANSFER GEAR CASE
EAS25460
TRANSFER GEAR CASE
Removing the middle driven shaft
R
3
18 Nm (1.8 m • kg, 13 ft • Ib)
(5)
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
5 Nm (0.5 m • kg, 3.6 ft • Ib)
(7)
LT
New
LS
13
New
5
5
7
New
LS
4 New
7
12
6
New 1
11
9
2
R
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
New
8
R
New
140 Nm (14.0 m • kg, 100 ft • lb)
New
T
R
40 Nm (4.0 m • kg, 29 ft • Ib)
R
R
Order
T
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Rider seat/Right side cover
Refer to “GENERAL CHASSIS” on page
4-1.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Transfer gear oil
Drain.
Refer to “CHANGING THE TRANSFER
GEAR OIL” on page 3-14.
Muffler/Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1.
Clutch release cylinder
Refer to “CLUTCH” on page 5-50.
Drive pulley
Refer to “BELT DRIVE” on page 4-80.
1
Oil pipe 2
1
2
Oil pipe 4
1
3
Transfer gear case cover
1
4
Transfer gear case gasket
1
5
Dowel pin
2
6
Transfer gear oil pump assembly
1
7
Dowel pin
2
5-81
TRANSFER GEAR CASE
Removing the middle driven shaft
R
3
18 Nm (1.8 m • kg, 13 ft • Ib)
(5)
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
5 Nm (0.5 m • kg, 3.6 ft • Ib)
(7)
LT
New
LS
13
New
5
5
7
New
LS
4 New
7
12
6
New 1
11
9
2
R
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
New
8
R
New
140 Nm (14.0 m • kg, 100 ft • lb)
New
T
R
40 Nm (4.0 m • kg, 29 ft • Ib)
R
R
Order
T
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Parts to remove
8
Oil strainer
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
1
9
Gasket
1
10
Conical spring washer
1
11
Primary chain
1
12
Middle drive gear
1
13
Middle driven shaft
1
For installation, reverse the removal procedure.
5-82
TRANSFER GEAR CASE
Disassembling the transfer gear oil pump
6
4
5
7
3
E
2
1
(6)
T
R
Order
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Job/Parts to remove
Q’ty
1
Transfer gear oil pump cover
1
2
Transfer gear oil pump outer rotor
1
3
Transfer gear oil pump inner rotor
1
4
Pin
1
5
Washer
1
6
Transfer gear oil pump shaft
1
7
Transfer gear oil pump housing
1
Remarks
For assembly, reverse the disassembly procedure.
5-83
TRANSFER GEAR CASE
Removing the transfer gear case
6
(8)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
8
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
3
LS
7
LT
LS
1
4
2
New
New
5
LT
LS
T
New
R
70 Nm (7.0 m • kg, 50 ft • lb)
10
LS
9
E
E
New
LS
(4)
T
R
Order
50 Nm (5.0 m • kg, 36 ft • Ib)
Job/Parts to remove
Q’ty
Remarks
Horn 2 connector
Disconnect.
Refer to “ENGINE REMOVAL” on page 5-1.
Battery box
Refer to “GENERAL CHASSIS” on page
4-1.
Sub-fuel tank
Refer to “FUEL TANK” on page 6-1.
1
Oil tank breather hose
1
2
Speed sensor
1
3
Oil tank damper
1
4
Dipstick
1
5
Dipstick joint
1
6
Drive pulley case
1
7
Dowel pin
2
8
Spacer
1
9
Transfer gear case
1
10
Dowel pin
2
Disconnect.
For installation, reverse the removal procedure.
5-84
TRANSFER GEAR CASE
Disassembling the oil tank
28 Nm (2.8 m • kg, 20 ft • Ib)
T
7
R
4
6
1
New
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
LT
New
New
5
(15)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
43 Nm (4.3 m • kg, 31 ft • Ib)
3 New
2
Order
1
Job/Parts to remove
Q’ty
Sub-fuel tank bracket
1
2
Oil tank cover
1
3
Oil tank cover gasket
1
4
Dowel pin
2
5
Oil strainer
1
6
Oil pipe 5
1
7
Oil tank
1
Remarks
For assembly, reverse the disassembly procedure.
5-85
TRANSFER GEAR CASE
2. Check:
• Primary chain
Damage/stiffness → Replace the primary
chain, middle drive gear and middle driven
shaft as a set.
EAS25470
REMOVING THE MIDDLE DRIVEN SHAFT
NOTE:
Loosen the middle drive gear nut before remove
the drive pulley.
1. Install:
• Right rider footrest assembly
Refer to “ENGINE REMOVAL” on page 5-1.
2. Loosen:
• Middle drive gear nut “1”
EAS25490
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with engine oil.
NOTE:
When loosening the middle drive gear nut, press
down on the brake pedal so the middle drive
gear does not move.
EAS25500
CHECKING THE TRANSFER GEAR OIL
PUMP
1. Check:
• Transfer gear oil pump housing
• Transfer gear oil pump cover
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outerrotor clearance “c”
Out of specification → Replace the transfer
gear oil pump.
1
3. Remove:
• Primary chain “1”
• Middle drive gear “2”
• Middle driven shaft “3”
NOTE:
Remove the primary chain, middle drive gear
and middle driven shaft at the same time.
1
3
2
EAS25480
CHECKING THE MIDDLE DRIVE
1. Check:
• Middle drive gear
• Middle driven gear
Damage/wear → Replace the middle drive
gear, middle driven shaft and primary chain
as a set.
1. Transfer gear oil pump inner rotor
2. Transfer gear oil pump outer rotor
3. Transfer gear oil pump housing
5-86
TRANSFER GEAR CASE
• Transfer gear oil pump outer rotor “6”
• Transfer gear oil pump cover “7”
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove in the inner rotor.
T.
R
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.12 mm (0.0047 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.10–0.15 mm (0.0039–0.0059 in)
Limit
0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-andouter-rotor clearance
0.04–0.09 mm (0.0016–0.0035 in)
Limit
0.160 mm (0.0063 in)
Oil pump housing screw
4 Nm (0.4 m·kg, 2.9 ft·lb)
1
4
E
7
3. Check:
• Transfer gear oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
6
5
3
2
(6)
3. Check:
• Transfer gear oil pump operation
Refer to “CHECKING THE TRANSFER
GEAR OIL PUMP” on page 5-86.
EAS25530
INSTALLING THE TRANSFER GEAR CASE
1. Install:
• Spacer “1”
NOTE:
Install the spacer with its groove “a” towards the
drive pulley.
EAS25510
CHECKING THE OIL PIPES
1. Check:
• Oil pipes
Damage → Replace.
1
EAS25520
ASSEMBLING THE TRANSFER GEAR OIL
PUMP
1. Lubricate:
• Transfer gear oil pump inner rotor
• Transfer gear oil pump outer rotor
• Transfer gear oil pump shaft
(with the recommended lubricant)
a
2. Install:
• Middle driven shaft “1”
• Middle drive gear “2”
• Primary chain “3”
(into the transfer gear case)
• Drive pulley nut
Recommended lubricant
Engine oil
2. Install:
• Transfer gear oil pump shaft “1”
(to the transfer gear oil pump housing “2”)
• Washer “3”
• Pin “4”
• Transfer gear oil pump inner rotor “5”
NOTE:
• Install the primary chain with its blue link “a”
facing outward.
5-87
TRANSFER GEAR CASE
• Install the middle drive gear “2” with its chamfered side facing “b” the transfer gear case.
• Install the middle driven shaft, middle drive
gear and primary chain at the same time.
• Align the splines on the middle drive gear with
the splines on the drive axle.
• Temporarily install the drive pulley nut onto the
middle driven shaft.
3
1
a
2 New
b
a
4. Remove:
• Drive pulley nut
1
2
2
b
3. Install:
• Conical spring washer “1”
• Middle drive gear nut “2” New
T.
R
Middle drive gear nut
140 Nm (14.0 m·kg, 100 ft·lb)
NOTE:
• Lubricate the middle drive gear nut threads
and conical spring washer mating surfaces
with engine oil.
• Install the conical spring washer “1” with the
“OUT” mark “a” facing out.
• Stake the middle drive gear nut “2” at a cutout
“b” in the drive axle.
5-88
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
LS
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
New
2
(5)
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
New
LS
R
(4)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
New
9
3
3
(4)
(4)
11
(8)
LS
LS
12
13
4
LT
24 Nm (2.4 m • kg, 17 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9
New
5
10
New
7
8
LS
T
R
New
(6)
LT
New
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
43 Nm (4.3 m • kg, 31 ft • Ib)
R
Order
6
Job/Parts to remove
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Engine
Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts
Refer to “CAMSHAFTS” on page 5-14.
Pistons
Refer to “CYLINDERS AND PISTONS” on
page 5-45.
Left balancer driven gear housing
Refer to “CLUTCH” on page 5-50.
Shift shaft
Refer to “SHIFT SHAFT” on page 5-70.
Generator rotor
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-72.
1
Neutral switch
1
2
Oil pipe 3
1
3
Oil strainer
2
4
Oil delivery pipe 3
1
5
Engine oil pump driven gear stopper
1
6
Engine oil pump driven gear
1
7
Oil baffle plate (left crankcase)
1
8
Left crankcase
1
9
Dowel pin
2
5-89
CRANKCASE
Separating the crankcase
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
LS
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
New
2
(5)
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
New
LS
R
(4)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
New
9
3
3
(4)
(4)
11
(8)
LS
LS
12
13
4
LT
24 Nm (2.4 m • kg, 17 ft • Ib)
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9
New
5
10
New
7
8
LS
T
R
New
(6)
LT
New
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R
43 Nm (4.3 m • kg, 31 ft • Ib)
R
Order
10
6
Job/Parts to remove
Q’ty
Joint pipe
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
1
11
Oil pipe
1
“R” mark
12
Oil pipe
1
“F” mark
13
Right crankcase
1
For installation, reverse the removal procedure.
5-90
CRANKCASE
Removing the oil seals and bearings
LS
New 4
LS
5
E
LT
New
2
T
R
5
20 Nm (2.0 m • kg, 14 ft • Ib)
New
1
LT
5
LT
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
LT
5
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
E
LT
Order
Job/Parts to remove
Q’ty
Oil pump
Remarks
Refer to “OIL PUMP” on page 5-95.
Crankshaft
Refer to “CRANKSHAFT” on page 5-101.
Transmission
Refer to “TRANSMISSION” on page 5-107.
1
Oil baffle plate (right crankcase)
1
2
Bearing retainer
2
3
Bearing retainer
2
4
Oil seal
2
5
Bearing
4
For installation, reverse the removal procedure.
5-91
CRANKCASE
EAS25570
DISASSEMBLING THE CRANKCASE
1. Remove:
• Crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical order
(refer to the numbers in the illustration).
• M8 × 90 mm bolts: “1”, “2”
• M8 × 65 mm bolt: “3”
• M6 × 100 mm bolts: “4”, “9”–“11”
• M6 × 80 mm bolt: “12”
• M6 × 70 mm bolts: “13”–“16”
• M6 × 60 mm bolts: “5”–“8”
• M6 × 35 mm bolts: “17”–“24”
A
8
7
6
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed air.
1
3
2
5
ET1D71005
CHECKING THE BEARINGS AND OIL SEAL
1. Check:
• Bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement → Replace.
• Oil seals
Damage/wear → Replace.
4
B
13
11
24
EAS25590
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• Oil delivery pipe
• Oil pipes
Damage → Replace.
Obstruction → Wash and blow out with compressed air.
12
23
17
22
21
20 16 15 10 14 19
9
18
A. Right crankcase
B. Left crankcase
2. Remove:
• Left crankcase
ET1D71038
CHECKING THE OIL STRAINERS
1. Check:
• Oil strainers
Damage → Replace.
Contaminants → Clean with solvent.
ECA13900
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves separate evenly.
5-92
CRANKCASE
• Joint pipe “4”
EAS25610
CHECKING THE ENGINE OIL PUMP DRIVEN
GEAR
1. Check:
• Engine oil pump driven gear
Chips/pitting/roughness/wear → Replace.
1
2
3
ET1D71034
INSTALLING THE BEARING RETAINERS
1. Install:
• Bearing retainers “1”
4
3
NOTE:
3. Install:
• Left crankcase
(onto the right crankcase)
• Apply locking agent (LOCTITE®) to the threads
of the bearing retainer bolts.
• Stake the bearing retainer bolts “2”.
NOTE:
Tap lightly on the left crankcase with a soft-face
hammer.
2 1
4. Install:
• Crankcase bolts (M6)
• Crankcase bolts (M8)
T.
1
2
R
Crankcase bolt (M6)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt (M8)
24 Nm (2.4 m·kg, 17 ft·lb)
EAS25690
ASSEMBLING THE CRANKCASE
1. Apply:
• Sealant
(onto the crankcase mating surfaces)
NOTE:
• Lubricate the bolt threads with engine oil.
• Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
• Tighten the bolts in numerical order (refer to
the numbers in the illustration).
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
• M8 × 90 mm bolts: “1”, “2”
• M8 × 65 mm bolt: “3”
• M6 × 100 mm bolts: “4”, “9”–“11”
• M6 × 80 mm bolt: “12”
• M6 × 70 mm bolts: “13”–“16”
• M6 × 60 mm bolts: “5”–“8”
• M6 × 35 mm bolts: “17”–“24”
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
2. Install:
• Oil pipe (“F” mark) “1”
• Oil pipe (“R” mark) “2”
• Dowel pins “3”
5-93
CRANKCASE
A
8
7
6
1
3
2
5
4
B
13
11
24
12
23
22
21
20 16 15 10 14 19
9
17
18
A. Right crankcase
B. Left crankcase
5. Apply:
• Engine oil
(onto the crankshaft pin bearings and oil delivery holes)
6. Check:
• Crankshaft and transmission operation
Rough movement → Repair.
5-94
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
T
R
24 Nm (2.4 m • kg, 17 ft • Ib)
1
Order
Job/Parts to remove
Q’ty
Separate.
Refer to “CRANKCASE” on page 5-89.
Crankcase
1
Remarks
Oil pump assembly
1
For installation, reverse the removal procedure.
5-95
OIL PUMP
Disassembling the oil pump
5
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
2
1
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
E
12
15
16
18 17
11
4
19 New
24
E
7
10
New 20
22
New 21
E
9
23
13
7
14
8
Order
Job/Parts to remove
Q’ty
1
Oil pump housing cover 1
1
2
Oil scavenging pump outer rotor 1
1
3
Oil scavenging pump inner rotor 1
1
4
Pin
1
5
Oil pump housing 1
1
6
Oil strainer
1
7
Pin
2
8
Ball spring
1
9
Oil scavenging pump outer rotor 2
1
10
Oil scavenging pump inner rotor 2
1
11
Pin
1
12
Oil pump housing cover 2
1
13
Relief valve spring
1
14
Relief valve
1
15
Oil feed pump outer rotor
1
16
Oil feed pump inner rotor
1
17
Pin
1
5-96
Remarks
OIL PUMP
Disassembling the oil pump
5
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
2
1
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
E
12
15
16
18 17
11
4
19 New
24
E
7
10
New 20
22
New 21
E
9
23
13
7
14
8
Order
18
Job/Parts to remove
Q’ty
Oil pump shaft
1
19
Oil seal
1
20
Circlip
1
21
Oil seal
1
22
Ball
1
23
Ball guide
1
24
Oil pump housing 2
1
Remarks
For assembly, reverse the disassembly procedure.
5-97
OIL PUMP
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
EAS24960
CHECKING THE OIL PUMP
1. Check:
• Oil pump housing
• Oil pump housing cover
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outerrotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.12 mm (0.0047 in)
Limit
0.20 mm (0.0079 in)
Oil-pump-housing-to-inner-andouter-rotor clearance
0.06–0.13 mm (0.0024–0.0051 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09–0.19 mm (0.0035–0.0075 in)
Limit
0.26 mm (0.0102 in)
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
• Relief valve body
• Relief valve
• Relief valve spring
Damage/wear → Replace the defective
part(s).
ET1D71035
CHECKING THE BALL SPRING AND RELIEF
VALVE SPRING
1. Measure:
• Ball spring free length
• Relief valve spring free length
Out of specification → Replace the defective
part(s).
Ball spring
Free length
34.70 mm (1.37 in)
Limit
32.97 mm (1.30 in)
Relief valve spring
Free length
28.95 mm (1.14 in)
Limit
27.50 mm (1.08 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
a. Free length
5-98
OIL PUMP
2. Measure:
• Ball spring force
• Relief valve spring force
Out of specification → Replace the defective
part(s).
• Oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
• Oil pump housing 2 “1”
• Ball guide “2”
• Ball “3”
Ball spring
Installed compression spring
force
2.23 N (0.60 lb) (0.27 kgf) or less
Installed length
29.4 mm (1.12 in)
Relief valve spring
Installed compression spring
force
52.4 N (11.78 lb) (5.34 kgf) or
less
Installed length
16.8 mm (0.66 in)
• Oil seal “4” New
• Circlip “5” New
• Oil seal “6” New
• Oil pump shaft “7”
• Pin “8”
• Oil feed pump inner rotor “9”
• Oil feed pump outer rotor “10”
• Relief valve “11”
• Relief valve spring “12”
• Oil pump housing cover 2 “13”
T.
R
Oil pump housing cover 2 screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
• Pin “14”
• Oil scavenging pump inner rotor 2 “15”
• Oil scavenging pump outer rotor 2 “16”
• Ball spring “17”
• Pins “18”
• Oil strainer “19”
• Oil pump housing 1 “20”
• Pin “21”
• Oil scavenging pump inner rotor 1 “22”
• Oil scavenging pump outer rotor 1 “23”
• Oil pump housing cover 1 “24”
a. Spring force
b. Installed length
EAS24990
T.
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer “1”
Damage → Replace.
Contaminants → Clean with solvent.
R
Oil pump housing cover 1 screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove in the inner rotor.
1
EAS25000
ASSEMBLING THE OIL PUMP
1. Lubricate:
• Inner rotor
• Outer rotor
5-99
OIL PUMP
20
22
23
24
19
13
E
10
9
78
14 21
E
New 5
New 4
6 New
1
18 E
15
16
3 2
12
11
18
17
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-98.
EAS25020
INSTALLING THE OIL PUMP
1. Install:
• Oil pump assembly “1”
T.
R
Oil pump assembly bolt
24 Nm (2.4 m·kg, 17 ft·lb)
ECA13890
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
1
5-100
CRANKSHAFT
EAS25960
CRANKSHAFT
Removing the crankshaft
Order
Job/Parts to remove
Q’ty
Separate.
Refer to “CRANKCASE” on page 5-89.
Crankcase
1
Remarks
Crankshaft
1
2
Generator shaft
1
3
Connecting rod cap
2
4
Big end lower bearing
2
5
Connecting rod
2
6
Big end upper bearing
2
For installation, reverse the removal procedure.
5-101
CRANKSHAFT
EAS26010
REMOVING THE CONNECTING RODS
1. Remove:
• Connecting rod caps “1”
• Connecting rods
• Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
3. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Journal oil clearance (using plastigauge®)
0.030–0.060 mm (0.0012–0.0024
in)
The following procedure applies to all of the
connecting rods.
EAS26090
CHECKING THE CRANKSHAFT AND
CONNECTING RODS
1. Measure:
• Crankshaft runout
Out of specification → Replace the crankshaft.
Runout limit C
0.040 mm (0.0016 in)
ECA13930
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big
end bearings must be installed in their original positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the connecting rod and the big end lower bearing into
the connecting rod cap.
NOTE:
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
• Generator shaft drive gear “1”
Damage/wear → Replace the crankshaft.
c. Put a piece of Plastigauge® “1” on the crankshaft pin.
5-102
CRANKSHAFT
d. Assemble the connecting rod halves.
h. Tighten the connecting rod bolts further to
reach the specified angle 125–135°.
NOTE:
T.
• Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
• Lubricate the bolts threads with molybdenum
disulfide grease.
• Make sure the projection “c” on the connecting
rod faces towards the left side of the crankshaft.
• Make sure the characters “d” on both the connecting rod and connecting rod cap are
aligned.
R
Connecting rod bolt (final)
Specified angle 125–135°
EW1D71011
WARNING
When a bolt is tightened more than the specified angle, do not loosen and then retighten
it.
Replace the bolt with a new one and perform
the procedure again.
EC1D71001
CAUTION:
e. Tighten the connecting rod bolts.
EWA12890
WARNING
• Replace the connecting rod bolts with new
ones.
• Clean the connecting rod bolts.
NOTE:
The tightening procedure of the connecting rod
bolts is angle controlled, therefore tighten the
bolts using the following procedure.
f. Tighten the connecting rod bolts to the specified torque.
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is at the specified
angle.
i. Remove the connecting rod and big end
bearings.
j. Measure the compressed Plastigauge® width
“e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select replacement big end bearings.
T.
R
Connecting rod bolt (1st)
15 Nm (1.5 m·kg, 11 ft·lb)
g. Put a mark “1” on the connecting rod bolts “2”
and the connecting rod cap “3”.
5-103
CRANKSHAFT
For example, if the connecting rod “P1” and
the crankshaft web “P” numbers are “5” and
“2” respectively, then the bearing size for “P1”
is:
“P1” (connecting rod) - “P” (crankshaft)
=
5 - 2 = 3 (brown)
Bearing color code
1.Blue 2.Black 3.Brown 4.Green
5.Yellow
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Select:
• Big end bearings (“P1”–“P2”)
NOTE:
• The numbers “a” stamped into the crankshaft
web and the numbers “b” on the connecting
rods are used to determine the replacement
big end bearing sizes.
• “P1”–“P2” refer to the bearings shown in the
crankshaft illustration.
P1
5. Measure:
• Crankshaft journal diameter “a”
Out of specification → Replace the crankshaft.
NOTE:
Measure the diameter of each crankshaft journal
at two places.
Crankshaft journal diameter
49.968–49.980 mm (1.9672–
1.9677 in)
P2
a
6. Measure:
• Crankshaft journal bearing inside diameter
“a”
Out of specification → Replace the crankcase assembly.
NOTE:
Measure the inside diameter of each crankshaft
journal bearing at two places.
Crankshaft journal bearing inside
diameter
50.010–50.030 mm (1.9689–
1.9697 in)
5-104
CRANKSHAFT
• Be sure to reinstall each big end bearing in its
original place.
• Make sure the projection “c” on the connecting
rods face towards the left side of the crankshaft.
• Make sure the characters “d” on both the connecting rod and connecting rod cap are
aligned.
7. Calculate:
• Crankshaft journal-to-crankshaft journal
bearing clearance
Out of specification → Replace the crankshaft and crankshaft journal bearings as a
set.
NOTE:
Calculate the clearance by subtracting the
crankshaft journal diameter from the crankshaft
journal bearing inside diameter.
Crankshaft journal-to-crankshaft
journal bearing clearance
0.030–0.060 mm (0.0012–0.0024
in)
EAS26150
INSTALLING THE CONNECTING RODS
1. Lubricate:
• Bolt threads
(with the recommended lubricant)
4. Tighten:
• Connecting rod bolts “1”
Recommended lubricant
Molybdenum disulfide grease
2. Lubricate:
• Crankshaft pins
• Big end bearings
• Connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA12890
WARNING
3. Install:
• Big end bearings
• Connecting rods
• Connecting rod caps
(onto the crankshaft pins)
• Replace the connecting rod bolts with new
ones.
• Clean the connecting rod bolts.
NOTE:
NOTE:
• Align the projections “a” on the big end bearings with the notches “b” in the connecting rods
and connecting rod caps.
The tightening procedure of the connecting rod
bolts is angle controlled, therefore tighten the
bolts using the following procedure.
5-105
CRANKSHAFT
a. Tighten the connecting rod bolts with a torque
wrench.
T.
R
Connecting rod bolt (1st)
15 Nm (1.5 m·kg, 11 ft·lb)
b. Put a mark “1” on the corner of the connecting
rod bolts “2” and the connecting rod “3”.
• Crankshaft assembly “2”
ECA13970
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
NOTE:
• Make sure that the generator shaft drive gear
teeth and generator shaft driven gear teeth
mesh correctly.
• Align the punch mark “a” on the generator shaft
driven gear with the punch mark “b” on the generator shaft drive gear.
• Align the right connecting rod with the front cylinder sleeve hole.
c. Tighten the connecting rod bolts further to
reach the specified angle 125–135°.
T.
R
Connecting rod bolt (final)
Specified angle 125–135°
1
2
EW1D71011
WARNING
When a bolt is tightened more than the specified angle, do not loosen and then retighten
it.
Replace the bolt with a new one and perform
the procedure again.
EC1D71001
CAUTION:
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is at the specified
angle.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26210
INSTALLING THE CRANKSHAFT
ASSEMBLY
1. Install:
• Generator shaft “1”
5-106
b
a
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
New
LS
E
2
7
3
1
3
M
E
5
4
E
1
M
6
Order
Job/Parts to remove
Q’ty
Remarks
Separate.
Refer to “CRANKCASE” on page 5-89.
Crankcase
1
Shift fork guide bar
2
2
Shift drum assembly
1
3
Shift fork 1
2
4
Shift fork 2
1
5
Drive axle assembly
1
6
Main axle assembly
1
7
Spacer
1
For installation, reverse the removal procedure.
5-107
TRANSMISSION
Disassembling the main axle assembly
Order
Job/Parts to remove
Q’ty
1
2nd pinion gear
2
Toothed lock washer
1
3
Toothed lock washer retainer
1
4
5th pinion gear
1
5
Collar
1
6
Toothed washer
1
7
Circlip
1
8
3rd pinion gear
1
9
Circlip
1
10
Toothed washer
1
11
4th pinion gear
1
12
Collar
1
13
Main axle/1st pinion gear
1
Remarks
1
For assembly, reverse the disassembly procedure.
5-108
TRANSMISSION
Disassembling the drive axle assembly
Order
1
Job/Parts to remove
Q’ty
Circlip
1
2
Washer
1
3
1st wheel gear
1
4
Collar
1
5
4th wheel gear
1
6
Circlip
1
7
Toothed washer
1
8
3rd wheel gear
1
9
Collar
1
10
Toothed lock washer
1
11
Toothed lock washer retainer
1
12
5th wheel gear
1
13
Circlip
1
14
Toothed washer
1
15
2nd wheel gear
1
16
Collar
1
5-109
Remarks
TRANSMISSION
Disassembling the drive axle assembly
Order
17
Job/Parts to remove
Q’ty
Drive axle
Remarks
1
For assembly, reverse the disassembly procedure.
5-110
TRANSMISSION
EAS26260
EAS26270
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• Shift drum groove
Damage/scratches/wear → Replace the shift
drum assembly.
• Shift drum segment “1”
Damage/wear → Replace the shift drum assembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum assembly.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EAS26300
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
CHECKING THE TRANSMISSION
1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
Main axle runout limit
0.08 mm (0.0032 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit
0.08 mm (0.0032 in)
5-111
TRANSMISSION
• Install the circlip so that both ends “b” rest on
the sides of a spline “c” with both axles aligned.
1
2 New
3. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2
a
b
c
2. Install:
• Toothed lock washer retainer “1”
• Toothed lock washer “2”
NOTE:
4. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• Circlips
Bends/damage/looseness → Replace.
• With the toothed lock washer retainer “1” in the
groove “a” in the axle, align the projection “c”
on the retainer with an axle spline “b”, and then
install the toothed lock washer “2”.
• Be sure to align the projection on the toothed
lock washer that is between the alignment
marks “e” with the alignment mark “d” on the
retainer.
b
d
1
c
2
b e
a
ET1D71006
c
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
• Toothed washer “1”
2
1
• Circlip “2” New
e
EAS26320
NOTE:
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the toothed washer
and gear. (For main axle)
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY
1. Install:
• Shift forks 1 “1”
• Shift fork 2 “2”
• Shift drum assembly “3”
5-112
TRANSMISSION
• Shift fork guide bars “4”
NOTE:
The embossed marks “1D7” on the shift forks
should face towards the left side of the engine.
4
2
4
3
1
2. Check:
• Transmission
Rough movement → Repair.
NOTE:
• Apply engine oil to each gear and bearing thoroughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-113
FUEL SYSTEM
FUEL TANK .................................................................................................... 6-1
REMOVING THE FUEL TANK.................................................................. 6-3
REMOVING THE FUEL PUMP ................................................................. 6-3
CHECKING THE FUEL PUMP BODY ...................................................... 6-4
CHECKING THE FUEL PUMP OPERATION ........................................... 6-4
INSTALLING THE FUEL PUMP................................................................ 6-4
INSTALLING THE FUEL TANK ................................................................ 6-4
THROTTLE BODIES....................................................................................... 6-6
REMOVING THE FUEL HOSE ............................................................... 6-11
CHECKING THE INJECTORS................................................................ 6-11
CHECKING THE THROTTLE BODIES................................................... 6-11
CHECKING THE ROLLOVER VALVES.................................................. 6-11
CHECKING THE PRESSURE REGULATOR ......................................... 6-11
CHECKING THE PRESSURE REGULATOR OPERATION................... 6-11
ADJUSTING THE THROTTLE POSITION SENSOR ............................. 6-12
INSTALLING THE FUEL PIPE................................................................ 6-12
INSTALLING THE FUEL HOSE.............................................................. 6-13
ISC (IDLE SPEED CONTROL) UNIT............................................................ 6-14
CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM ................... 6-15
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
6
1
4
R
T
R
16 Nm (1.6 m • kg, 11 ft • Ib)
9
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
(4)
T
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
R
4 Nm (0.4 m • kg, 2.9 ft • Ib)
3
5
Order
Job/Parts to remove
Q’ty
Refer to “GENERAL CHASSIS” on page
4-1.
Rider seat/Rider seat bracket
1
Remarks
Meter assembly coupler
3
Disconnect.
2
Meter cover
1
3
Fuel sender coupler
1
Disconnect.
4
Fuel tank breather hose
1
Disconnect.
5
Air vent hose (fuel pump to fuel hose joint)
1
Disconnect.
6
Fuel tank
1
7
Fuel tank bracket (rear side)
1
8
Fuel tank bracket (front side)
1
9
Fuel sender
1
For installation, reverse the removal procedure.
6-1
FUEL TANK
Removing the fuel pump and sub-fuel tank
4
T
R
5 Nm (0.5 m • kg, 3.6 ft • Ib)
5
3
1
New
(6)
6
2
7
New
8
(3)
(3)
9
(3)
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
Rider seat/Rider seat bracket
Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
1
Fuel pump coupler
1
2
Fuel hose connector cover
1
3
Fuel outlet hose
1
4
Air vent hose (fuel pump to fuel hose joint)
1
5
Fuel return hose (fuel return pipe to sub-fuel
tank)
1
6
Fuel pump bracket
1
7
Fuel pump gasket
1
8
Fuel pump
1
9
Sub-fuel tank
1
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-2
FUEL TANK
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel tank
EC1D71021
CAUTION:
1
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remaining in them.
1
d. Disconnect the fuel hose (fuel hose joint to
fuel pump) “1” and air vent hose (fuel pump to
fuel hose joint) “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel hose joint caps “1”.
NOTE:
NOTE:
Before removing the hoses, place a few rags in
the area under where they will be removed.
After removing the fuel hose joint caps, clean the
projection on each cap so that no foreign material will enter the fuel lines.
2
1
1
e. Install the fuel hose joint cap “1” and rubber
plug “2”.
b. Lubricate the O-ring “1” with the recommended silicone lubricant “2”.
NOTE:
Insert the projection on the fuel hose joint cap
completely into the pipe of the fuel hose joint and
insert the rubber plug into the end of the fuel
hose (fuel hose joint to fuel pump).
Recommended lubricant
Silicone protectant and lubricant
ACC-SLCNS-PR-AY
NOTE:
Spray the silicone lubricant in the areas shown in
the illustration.
1
2
2
1
f. Remove the fuel tank.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
• Fuel hose connector cover
2. Disconnect:
• Fuel outlet hose
c. Turn the screws “1” clockwise.
NOTE:
Turn the screws until they stop.
6-3
FUEL TANK
• Install the fuel pump as shown in the illustration.
• Align the projection “a” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tightening sequence as shown.
EC1D71022
CAUTION:
• Be sure to disconnect the fuel outlet hose
by hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hoses, since there may be fuel remaining in them.
NOTE:
• Remove the fuel hose manually without using
any tools.
• Before removing the hoses, place a few rags in
the area under where they will be removed.
3. Remove:
• Fuel pump
2. Connect:
• Fuel outlet hose
3. Install:
• Fuel hose connector cover “1”
ECA14720
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EC1D71023
CAUTION:
When installing the fuel outlet hose, make
sure that it is securely connected, and that
the fuel hose connector cover is installed
correctly, otherwise the fuel outlet hose will
not be properly installed.
EAS26670
CHECKING THE FUEL PUMP BODY
1. Check:
• Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump assembly.
2. Check:
• Diaphragms and gaskets
Tears/fatigue/cracks → Replace fuel pump
assembly.
NOTE:
• Install the fuel outlet hose connector securely
onto the sub fuel tank until a distinct “click” is
heard, and then make sure that it does not
come loose.
• Install the holder “a” of the fuel hose connector
cover, and then install the holder “b”. After installing the fuel hose connector cover, make
sure that it is installed securely.
EAS26690
CHECKING THE FUEL PUMP OPERATION
1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PUMP” on
page 7-89.
1
a
EAS26710
INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump
b
T.
R
Fuel pump bolt
5 Nm (0.5 m·kg, 3.6 ft·lb)
ET1D71025
INSTALLING THE FUEL TANK
1. Install:
• Fuel tank
NOTE:
• Do not damage the installation surfaces of the
sub-fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
6-4
FUEL TANK
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the fuel tank.
b. Remove the fuel hose joint caps.
c. Connect the fuel hose (fuel hose joint to fuel
pump) and air vent hose (fuel pump to fuel
hose joint).
d. Turn the screws “1” counterclockwise.
NOTE:
Turn the screws until they contact the clips “a”.
1
1
a
a
e. Install the fuel hose joint caps.
NOTE:
Install the fuel hose joint caps completely onto
the fuel hose joints.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Meter assembly couplers
• Fuel sender coupler
NOTE:
Make sure that the couplers are positioned as
shown in the illustration in the following order
from left to right: fuel sender coupler “1”, 6-pin
black meter assembly coupler “2”, 6-pin white
meter assembly coupler “3”, and 3-pin black
meter assembly coupler “4”.
4
3
2
1
6-5
THROTTLE BODIES
EAS26970
THROTTLE BODIES
Removing the rollover valves
3
4
7
7
1
6
5
7
7
8
9
2
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
R
Order
Job/Parts to remove
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
1
Horn 1 connector
2
For California only
Disconnect.
2
Horn 1
1
For California only
3
Fuel tank breather hose
1
4
Canister purge hose
1
5
Rollover valve 1
1
6
Rollover valve 2
1
7
Rollover valve hose
4
8
Fuel tank breather/overflow hose
1
9
Canister
1
For California only
10
Canister breather hose
1
For California only
For California only
For installation, reverse the removal procedure.
6-6
THROTTLE BODIES
Removing the pressure regulator
8
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
13 Nm (1.3 m • kg, 9.4 ft • Ib)
7
2
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
1
3
9
4
5
Order
Job/Parts to remove
Q’ty
1
Pressure regulator cover
1
2
Fuel hose (intake manifold assembly to pressure regulator)
1
3
Air filter case breather hose 1
1
4
Air filter case breather hose 2
1
5
Hose clamp
1
6
Pressure regulator
1
7
Fuel return hose
1
8
Fuel return pipe
1
9
Pressure regulator bracket
1
Remarks
For installation, reverse the removal procedure.
6-7
THROTTLE BODIES
Removing the throttle bodies
5
T
R
3 Nm (0.3 m • kg, 2.2 ft • Ib)
7
3
2
6
6
T
R
3 Nm (0.3 m • kg, 2.2 ft • Ib)
8
4
1
Order
Job/Parts to remove
Q’ty
Remarks
Rider seat/Rider seat bracket
Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page
4-1.
Cylinder-#1 ignition coil cover
Refer to “ENGINE REMOVAL” on page 5-1.
1
Throttle position sensor coupler
1
Disconnect.
2
Cylinder-#1 intake air pressure sensor hose
1
3
Cylinder-#2 intake air pressure sensor hose
1
4
Canister purge hose
1
For California only
5
Throttle cable
2
Disconnect.
6
Throttle body joint clamp screw
2
Loosen.
EC1D71013
CAUTION:
7
Throttle body
1
8
Throttle position sensor
1
The throttle bodies should not be disassembled.
For installation, reverse the removal procedure.
6-8
THROTTLE BODIES
Removing the intake manifolds
3
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
(2)
6
New 8
2
(2)
1
4
7
New 8
T
R
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
1
Job/Parts to remove
Q’ty
Remarks
Engine temperature sensor coupler
1
Disconnect.
2
Sub-wire harness 2 coupler
2
Disconnect.
3
Fuel outlet hose
1
Disconnect.
4
Fuel hose (intake manifold assembly to pressure regulator)
1
5
Cylinder-#2 ISC (idle speed control) unit outlet
hose
1
Disconnect.
6
Cylinder-#1 ISC (idle speed control) unit outlet
hose
1
Disconnect.
7
Intake manifold assembly
1
8
Gasket
2
For installation, reverse the removal procedure.
6-9
THROTTLE BODIES
Disassembling the intake manifolds
R
30 Nm (3.0 m • kg, 22 ft • Ib)
New
New
T
R
5 Nm (0.5 m • kg, 3.6 ft • Ib)
4
5
New
New
7
New
New
2
1
New
New
7
3
6
T
R
Order
5 Nm (0.5 m • kg, 3.6 ft • Ib)
Job/Parts to remove
1
Cylinder-#1 injector coupler
2
3
Q’ty
Remarks
1
Disconnect.
Cylinder-#2 injector coupler
1
Disconnect.
Sub-wire harness 2
1
4
Fuel pipe
1
5
Injector joint 1
1
6
Injector joint 2
1
7
Injector
2
For assembly, reverse the disassembly procedure.
6-10
THROTTLE BODIES
b. Blow out all of the passages with compressed
air.
ET1D71026
REMOVING THE FUEL HOSE
1. Disconnect:
• Fuel hose (intake manifold assembly to pressure regulator)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71007
CHECKING THE ROLLOVER VALVES
1. Check:
• Rollover valve 1 “1”
• Rollover valve 2 “2”
Damage/faulty → Replace.
EC1D71014
CAUTION:
Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hose, since there may be fuel remaining
in it.
NOTE:
• Check that air flows smoothly only in the direction of the arrow shown in the illustration.
• The rollover valves must be in an upright position when checking the airflow.
NOTE:
• To remove the fuel hose from the fuel pipe or
pressure regulator, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown, press the two buttons
“2” on the sides of the connector, and then remove the hose.
• Remove the fuel hose manually without using
any tools.
• Before removing the hoses, place a few rags in
the area under where they will be removed.
1
2
EAS27000
1
CHECKING THE PRESSURE REGULATOR
1. Check:
• Pressure regulator
Damage → Replace.
2
EAS27010
CHECKING THE PRESSURE REGULATOR
OPERATION
1. Check:
• Pressure regulator operation
EAS26980
CHECKING THE INJECTORS
1. Check:
• Injectors
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the pressure regulator cover.
Refer to “THROTTLE BODIES” on page 6-6.
b. Disconnect the fuel hose “1” from the pressure regulator “2”.
c. Connect the fuel pressure adapter “3” between the fuel hose “1” and pressure regulator “2”.
d. Connect the pressure gauge “4” to the fuel
pressure adapter “3”.
e. Connect the vacuum/pressure pump gauge
set “5” to the pressure regulator.
EAS26990
CHECKING THE THROTTLE BODIES
1. Check:
• Throttle bodies
Cracks/damage → Replace the throttle bodies as a set.
2. Check:
• Fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle bodies in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
6-11
THROTTLE BODIES
EAS27030
ADJUSTING THE THROTTLE POSITION
SENSOR
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 7-89.
2. Adjust:
• Throttle position sensor angle
Vacuum/pressure pump gauge
set
90890-06756
Pressure gauge
90890-03153
Fuel pressure adapter
90890-03176
YM-03176
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the throttle position sensor coupler
to the throttle position sensor.
b. Connect the digital circuit tester to the throttle
position sensor.
• Positive tester probe
yellow terminal “1”
• Negative tester probe
black terminal “2”
1
2
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
1
4
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
5
2
3
Output voltage (at idle)
0.63–0.73 V
f. Start the engine.
g. Measure the fuel pressure.
e. After adjusting the throttle position sensor angle, tighten the throttle position sensor
screws “3”.
Fuel pressure
392 kPa (3.92 kg/cm², 55.7 psi)
h. Use the vacuum/pressure pump gauge set to
adjust the fuel pressure in relation to the vacuum pressure as described below.
3
NOTE:
3
The vacuum pressure should not exceed 100
kPa (760 mmHg).
2
• Increase the vacuum pressure →
Fuel pressure is decreased
• Decrease the vacuum pressure →
Fuel pressure is increased
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71008
INSTALLING THE FUEL PIPE
1. Install:
• Fuel pipe “1”
Faulty → Replace the pressure regulator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
R
6-12
Fuel pipe bolt
30 Nm (3.0 m·kg, 22 ft·lb)
THROTTLE BODIES
NOTE:
Install the fuel pipe “1” so that it contacts the projections “a” on the injector joints.
1
a
1
a
ET1D71027
INSTALLING THE FUEL HOSE
1. Connect:
• Fuel hose (intake manifold assembly to pressure regulator)
EC1D71015
CAUTION:
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
NOTE:
• Install the fuel hose securely onto the fuel pipe
or pressure regulator until a distinct “click” is
heard.
• To install the fuel hose onto the fuel pipe or
pressure regulator, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.
1
6-13
ISC (IDLE SPEED CONTROL) UNIT
ET1D71009
ISC (IDLE SPEED CONTROL) UNIT
Removing the ISC (idle speed control) unit
T
T
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
1
8
6
7
9
3
(4)
4
3
R
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
T
R
Order
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Parts to remove
Q’ty
Front cylinder head
Remarks
Refer to “CYLINDER HEADS” on page 5-33.
1
Sub-wire harness 4
1
2
Sub-wire harness 3
1
3
Cylinder-#2 ISC (idle speed control) unit outlet
hose
2
4
Cylinder-#1 ISC (idle speed control) unit outlet
hose
2
5
ISC (idle speed control) unit inlet hose
1
6
Cylinder-#2 left ignition coil
1
7
Cylinder-#2 right ignition coil
1
8
ISC (idle speed control) unit
1
9
ISC (idle speed control) unit bracket
1
For installation, reverse the removal procedure.
6-14
ISC (IDLE SPEED CONTROL) UNIT
ET1D71010
CHECKING THE ISC (IDLE SPEED
CONTROL) SYSTEM
1. Check:
• Hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
6-15
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1
CIRCUIT DIAGRAM .................................................................................. 7-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION....................... 7-3
TROUBLESHOOTING .............................................................................. 7-4
ELECTRIC STARTING SYSTEM.................................................................... 7-7
CIRCUIT DIAGRAM .................................................................................. 7-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.......................... 7-9
TROUBLESHOOTING ............................................................................ 7-11
CHARGING SYSTEM ................................................................................... 7-13
CIRCUIT DIAGRAM ................................................................................ 7-13
TROUBLESHOOTING ............................................................................ 7-15
LIGHTING SYSTEM...................................................................................... 7-17
CIRCUIT DIAGRAM ................................................................................ 7-17
TROUBLESHOOTING ............................................................................ 7-19
SIGNALING SYSTEM ................................................................................... 7-21
CIRCUIT DIAGRAM ................................................................................ 7-21
TROUBLESHOOTING ............................................................................ 7-23
FUEL INJECTION SYSTEM ......................................................................... 7-27
CIRCUIT DIAGRAM ................................................................................ 7-27
ECU SELF-DIAGNOSTIC FUNCTION.................................................... 7-29
SELF-DIAGNOSTIC FUNCTION TABLE................................................ 7-30
TROUBLESHOOTING METHOD............................................................ 7-32
DIAGNOSTIC MODE .............................................................................. 7-33
TROUBLESHOOTING DETAILS ............................................................ 7-40
FUEL PUMP SYSTEM .................................................................................. 7-63
CIRCUIT DIAGRAM ................................................................................ 7-63
TROUBLESHOOTING ............................................................................ 7-65
7
ELECTRICAL COMPONENTS ..................................................................... 7-67
CHECKING THE SWITCHES ................................................................. 7-71
CHECKING THE BULBS AND BULB SOCKETS ................................... 7-74
CHECKING THE FUSES ........................................................................ 7-75
CHECKING AND CHARGING THE BATTERY....................................... 7-76
CHECKING THE RELAYS ...................................................................... 7-79
CHECKING THE TURN SIGNAL RELAY ............................................... 7-80
CHECKING THE DIODES ...................................................................... 7-81
CHECKING THE IGNITION SPARK GAP .............................................. 7-82
CHECKING THE SPARK PLUG CAPS .................................................. 7-83
CHECKING THE IGNITION COILS ........................................................ 7-83
CHECKING THE CRANKSHAFT POSITION SENSOR ......................... 7-84
CHECKING THE LEAN ANGLE SENSOR ............................................. 7-84
CHECKING THE STARTER MOTOR OPERATION............................... 7-85
CHECKING THE STATOR COIL ............................................................ 7-85
CHECKING THE RECTIFIER/REGULATOR.......................................... 7-85
CHECKING THE HORNS ....................................................................... 7-86
CHECKING THE ENGINE TEMPERATURE SENSOR .......................... 7-87
CHECKING THE FUEL SENDER (FUEL TANK).................................... 7-87
CHECKING THE FUEL SENDER (FUEL PUMP) ................................... 7-88
CHECKING THE FUEL LEVEL WARNING LIGHT................................. 7-88
CHECKING THE SPEED SENSOR........................................................ 7-88
CHECKING THE THROTTLE POSITION SENSOR............................... 7-89
CHECKING THE FUEL PUMP................................................................ 7-89
CHECKING THE EXUP SERVO MOTOR .............................................. 7-90
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 7-90
CHECKING THE AIR TEMPERATURE SENSOR.................................. 7-90
(GRAY)
WW W
7-1
B
Br
W
W
W
Br B
B R/
Br
(GRAY)
/Y /B
R
B /L
B
B
(BLACK)
Y B
(BLACK)
B
L/B L/Y
(GRAY)
Br
R
B
R
B
Y
Br
A B
Br L
ON
OFF
(BLACK)
R
R
B
L
Br L L/B
L/Y
B
R
L
A
L
B
Br/L
Y
A
Y
R/W
R
Br
R
B
L WW B
(BLACK)
B
W B /W
R/W B/R
G L L/B
B
R
L
R/Y
L
R/Y
Br
R/Y
Y
R/W
R W R/W R/W R/W
R RY
(BLACK)
B/R R W
L B G/L
Y
Br
R/Y
Br/L
L
B
Br/L
B
R
R/G
R
RB
B
R
R
L Y
R
R
B/R
RY
L
R/W
W/B
L/W
LW
B/Y
L
B
LB
LB
G/L
B
B B
L Y/G B/L
(BLACK)
BL PY L
(BLACK)
B/L P W L
(BLACK)
L Y B
B
B
Sb
Sb
Sb W
B L/B
R/L
LY LR
R
Sb
R/W
L/G
L
Y
L
B
B/L
YG
L
L
P/Y
B/L
L
PW
B/L
B
Y
L
Gy B/L
R
BR
E B
E Y
E L
L
Y
B G
B
G
GL
(GRAY)
B /W
(GRAY)
Ch Dg
P B
YR
(GRAY)
B
Y
Br
(BLACK)
B B
B
B B
GYGB
Y B
B/L
B
Y/B
B
Br
B
B
(BLACK)
L/Y B Y
G
B
GW
W L
B
Br
RY
R/Y
G/L
L WY
B/L
(BLACK)
(BLUE)
Y
(BLACK)
(GRAY)
rW
Dg h
B P
R
(GRAY)
(GRAY)
B/Y L/Y
G/B G/Y
(BLACK)
B
Y
(BLUE)
G
G/L
B
B/L
Gy
(BLUE)
R/L
R/W L W R/L
Sb B/Y Sb/W
Br W B/L
L G L/Y
B L/G
B
(BLUE)
B Gy
B
B
L R R/Y
LG
B/R
R/W
B
Ch
YB
G/L
Br
Br/W
Y
Br
G
(L)
N
(R)
B
Dg
Br/W
Ch
Br
Y/G
B/Y
RL
L/R
R/B
R/B
B /W
Br
P/W
P/Y
L/W
BL
Y
L
WY
R/W
L/B
Gy
Y/R
Br/W Y/R
B
Ch A Ch
Dg A Dg
Dg
GL
BL
L
W/Y
G/W B
R/L B
B
B
Gy R
G
Gy Y/B Gy R
O
O
B
B
W Y Y/R
P
Br
Br W
W/Y
PUSH
B
Ch L
G/B
GY
P
Br
(BLACK)
B/Br B
B/Br B
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
Y/B
Gy/G
Gy W
YL
WR
B/G
B/R
R/G
P/L
W/G
B /L
O
O
Gy/R
Gy/R
B
Dg L
R/B
R/B
D D
R/B
R/B
R/B
R/B
B
BW
WGRB RG
/ RB PL
R/G
P/L
WG
Br/L
L Dg
Dg L
B
B
(BLACK) (BLACK)
RG
R/G
PL
P/L
W/G
WG
B /L D Br L
Gy R C Gy R
Gy R C Gy R
Gy G L B
Br W P/Y W R L
R/L R/W R/B B/Br P L B/L R/G B Y
LW WY
Y G Br
Gy R/B B/Br Y L Y Br L W/G
P/W L R
Gy W B/R
B/G
G
B
B G
G
Gy
B
G
G
Gy
B/G
B/R
Gy/R
BR
Gy/R
BR
O
BR
W
BL
Gy/W
(BLACK)
Gy W R L
Gy/G B L
RL
B B
W L
W Gy
(GRAY)
B
(DARK GRAY)
W B
W
W
W G
(BLACK)
L WR BL
BG R
Gy/G
Gy
G
L
W/R
B/L
B/R
B/R
O
BR
W
W
Y
Dg
Ch
L
G/B
RG
Y/L
GW
G
RW
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
Br
B
G Gy
W W
B
L
(BLACK)
R G R/B W G
P L R/B B /L
L Y
B
(BLACK)
G/Y
G/B
(BLACK)
G/B
G/Y
(BLACK)
R/G G/W Y/L
B G
Y L G/W R G
G B
(BLACK)
Dg L Y
Ch Sb W R W
Sb/W
SUB W RE HARNESS2
E
SUB W RE HARNESS4
D
Y L Dg
R/W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W G R/B R/G
Br L R/B P/L
SUB W RE HARNESS3
(BLACK)
W RE HARNESS
y R B/R Gy R
(BLACK)
C
SUB W RE HARNESS2
B
SUB W RE HARNESS1
A
Gy R B R y R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27110
CIRCUIT DIAGRAM
IGNITION SYSTEM
3. Main switch
4. Main fuse
6. Battery
11.Relay unit
14.Neutral switch
16.Sidestand switch
19.Crankshaft position sensor
23.Lean angle sensor
27.ECU (electronic control unit)
28.Cylinder-#1 left ignition coil
29.Cylinder-#1 right ignition coil
30.Cylinder-#2 left ignition coil
31.Cylinder-#2 right ignition coil
32.Spark plug
68.Engine stop switch
77.Ignition fuse
81.ECU fuse
7-2
IGNITION SYSTEM
ET1D71043
ENGINE STOPPING DUE TO SIDESTAND OPERATION
When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ignition coils does not flow to the ECU when
both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from
producing a spark. However, the engine continues to run under the following conditions:
• The transmission is in gear (the neutral switch circuit is open) and the sidestand is up (the sidestand
switch circuit is closed).
• The transmission is in neutral (the neutral switch circuit is closed) and the sidestand is down (the sidestand switch circuit is open).
2
1
3
4
5
10
8
6
11
9
7
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Ignition coil
7. Spark plug
8. ECU (electronic control unit)
9. Sidestand switch
10. Relay unit (diode)
11. Neutral switch
7-3
IGNITION SYSTEM
EAS27140
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Rider seat bracket assembly
4. Fuel tank
5. Air filter case
6. Headlight assembly
7. Exhaust pipes
8. Front cylinder
1. Check the fuses.
(Main, ignition and ECU)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the spark plugs.
Refer to “CHECKING THE SPARK
PLUGS” on page 3-9.
NG →
Re-gap or replace the spark plug(s).
OK ↓
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNITION SPARK GAP” on page 7-82.
OK →
Ignition system is OK.
NG ↓
5. Check the spark plug caps.
Refer to “CHECKING THE SPARK
PLUG CAPS” on page 7-83.
NG →
Replace the spark plug cap(s).
OK ↓
6. Check the ignition coils.
Refer to “CHECKING THE IGNITION COILS” on page 7-83.
NG →
Replace the ignition coil(s).
OK ↓
7. Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on
page 7-84.
NG →
Replace the crankshaft position sensor.
OK ↓
7-4
IGNITION SYSTEM
8. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the main switch.
OK ↓
9. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The engine stop switch is faulty. Replace
the right handlebar switch.
OK ↓
10.Check the neutral switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the neutral switch.
OK ↓
11.Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the sidestand switch.
OK ↓
12.Check the relay unit (diode).
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the relay unit.
OK ↓
13.Check the lean angle sensor.
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 7-84.
NG →
Replace the lean angle sensor.
OK ↓
14.Check the entire ignition system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-1.
NG →
Properly connect or repair the ignition system wiring.
OK ↓
Replace the ECU.
7-5
IGNITION SYSTEM
7-6
(GRAY)
WW W
7-7
B
Br
W
W
W
Br B
B RL
Br
(GRAY)
L/Y /B
R
B /L
B
B
(BLACK)
Y Br
(BLACK)
B
L/B L/Y
(GRAY)
Br
R
B
R
B
Y
Br
A B
Br L
ON
OFF
(BLACK)
R
R
B
L
Br L L/B
L/Y
B
R
L
A
L
B
Br/L
Y
A
Y
R/W
R
Br
R
B
L WW B
(BLACK)
W B /W
R/W B/R
G L L/B
B
B
R
(BLACK)
BR RW
L B G/L
Y
Br
R/Y
Br/L
L
B
Br/L
B
R
R/G
R
RB
B
R
R
L Y
R
R
R
L
R/Y
L
R/Y
Br
R/Y
Y
R/W
R W R/W R/W R/W
RY
B/R
RY
L
R/W
W/B
L/W
LW
B/Y
L
B
LB
LB
G/L
B
W L
B B
L Y/G B/L
(BLACK)
BL PY L
(BLACK)
BL
(BLACK)
L Y B
B
B
Sb
Sb
Sb W
B L/B
RL
L/Y L R
R
b
R/W
L/G
L
Y
L
B
BL
YG
L
L
P/Y
B/L
L
PW
B/L
B
Y
L
Gy B/L
R
BR
E B
E Y
E L
L
Y
B G
B
G
GL
(GRAY)
B /W
(GRAY)
Ch Dg
P B
R
(GRAY)
B
Y
Br
(BLACK)
B B
B
B B
GYGB
Y B
B/L
B
Y/B
B
Br
B
B
(BLACK)
L/Y B Y
G
B
GW
W L
B
Br
RY
R/Y
G/L
L WY
BL
(BLACK)
(BLUE)
Y
(BLACK)
(GRAY)
Br W
Dg h
B P
YR
(GRAY)
(GRAY)
B/Y L Y
G/B G/Y
(BLACK)
B
Y
(BLUE)
G
G/L
B
B/L
Gy
(BLUE)
R/L
R/W L W R/L
Sb B/Y Sb/W
Br W B/L
L G L/Y
B L/G
B
(BLUE)
B Gy
B
B
L R R/Y
LG
B/R
R/W
B
Ch
YB
G/L
Br
Br/W
Y
Br
G
(L)
N
(R)
B
Dg
Br/W
Ch
Br
Y/G
B/Y
RL
L/R
R/B
R/B
B /W
Br
P/W
P/Y
L/W
B/L
Y
L
WY
R/W
L/B
Gy
Y/R
Br/W Y/R
B
Ch A Ch
Dg A Dg
Dg
GL
BL
L
WY
G/W B
R/L B
B
B
G /R
G
Gy Y/B G /R
O
O
B
B
W Y Y/R
P
Br
B /W
W/Y
PUSH
B
Ch L
G/B
G/Y
P
Br
(BLACK)
B/Br B
B/Br B
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
Y/B
Gy/G
Gy W
Y/L
WR
B/G
B/R
R/G
P/L
W/G
B /L
O
O
Gy/R
Gy/R
RG
PL
W/G
Br/L
B
Dg L
R/B
R/B
D D
R/B
R/B
R/B
R/B
B
BW
W G R B R/G
Br/ R B P L
R/G
P/L
WG
Br/L
L Dg
Dg L
B
B
(BLACK) (BLACK)
R/G
P/L
W/G
Br L
Gy R C Gy R
Gy R C Gy R
Gy G L B
Br W P/Y W R L
R/L R/W R/B B/Br P/L B/L R/G B Y
LW WY
Y G Br
Gy R/B B/Br Y L Y Br L W/G
P/W L R
Gy W B/R
B/G
G
B
B G
G
Gy
B
G
G
Gy
B/G
B/R
Gy/R
BR
Gy/R
BR
O
BR
W
BL
Gy/W
(BLACK)
Gy W R L
Gy/G B L
RL
B B
W L
W Gy
(GRAY)
W G
B
(DARK GRAY)
W B
W
W
L
R
(BLACK)
L WR
BG
Gy/G
Gy
G
L
W/R
B/L
B/R
B/R
O
BR
W
W
Y
Dg
Ch
L
G/B
RG
Y/L
GW
G
RW
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
G Gy
W W
B
L
(BLACK)
R G R/B W G
P L R/B Br/L
(BLACK)
G/Y
G/B
(BLACK)
G/B
G/Y
(BLACK)
R G G/W Y/L
B G
Y L G/W R/G
G B
(BLACK)
Dg L Y
Ch Sb W R W
Sb/W
SUB W RE HARNESS2
L Y
B
SUB W RE HARNESS4
D
Y L Dg
R/W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W G R/B R/G
Br L R/B P/L
SUB W RE HARNESS3
(BLACK)
W RE HARNESS
y R B/R Gy R
(BLACK)
C
SUB W RE HARNESS2
Br
B
SUB W RE HARNESS1
A
Gy R B/R y R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
ELECTRIC STARTING SYSTEM
EAS27160
ELECTRIC STARTING SYSTEM
EAS27170
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
3. Main switch
4. Main fuse
6. Battery
8. Starter relay
9. Starter motor
10.Diode 1
11.Relay unit
12.Starting circuit cut-off relay
14.Neutral switch
15.Diode 2
16.Sidestand switch
27.ECU (electronic control unit)
54.Clutch switch
68.Engine stop switch
69.Start switch
77.Ignition fuse
81.ECU fuse
7-8
ELECTRIC STARTING SYSTEM
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits 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 circuit is closed).
• The clutch lever is pulled to the handlebar (the clutch switch circuit is closed) and the sidestand is up
(the sidestand switch circuit is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay stays open so current cannot reach
the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off
relay is closed and the engine can be started by pushing the start switch “ ”.
14
13
1
2
17
3
4
15
5
6
7
8
8
9
8
b
10
16
7-9
a
11
12
ELECTRIC STARTING SYSTEM
a. WHEN THE TRANSMISSION IS IN
NEUTRAL
b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Diode 2
7. Relay unit (starting circuit cut-off relay)
8. Relay unit (diode)
9. Clutch switch
10. Sidestand switch
11. Neutral switch
12. Start switch
13. Starter relay
14. Starter motor
15. ECU fuse
16. ECU (electronic control unit)
17. Diode 1
7-10
ELECTRIC STARTING SYSTEM
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Headlight assembly
1. Check the fuses.
(Main, ignition and ECU)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the starter motor operation.
Refer to “CHECKING THE STARTER MOTOR OPERATION” on page
7-85.
OK →
Starter motor is OK. Perform the electric
starting system troubleshooting, starting
with step 5.
NG ↓
4. Check the starter motor.
Refer to “CHECKING THE STARTER MOTOR” on page 5-79.
NG →
Repair or replace the starter motor.
OK ↓
5. Check the relay unit (starting circuit
cut-off relay).
Refer to “CHECKING THE RELAYS” on page 7-79.
NG →
Replace the relay unit.
OK ↓
6. Check the relay unit (diode).
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the relay unit.
OK ↓
7. Check the diode 1.
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the diode 1.
OK ↓
8. Check the diode 2.
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the diode 2.
OK ↓
7-11
ELECTRIC STARTING SYSTEM
9. Check the starter relay.
Refer to “CHECKING THE RELAYS” on page 7-79.
NG →
Replace the starter relay.
OK ↓
10.Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the main switch.
OK ↓
11.Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The engine stop switch is faulty. Replace
the right handlebar switch.
OK ↓
12.Check the neutral switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the neutral switch.
OK ↓
13.Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the sidestand switch.
OK ↓
14.Check the clutch switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the clutch switch.
OK ↓
15.Check the start switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
16.Check the entire starting system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-7.
NG →
Properly connect or repair the starting system wiring.
OK ↓
The starting system circuit is OK.
7-12
(GRAY)
WW W
W
W
W
7-13
Br
(GRAY)
L/Y L/B
R
Br/L
B
L B L/Y
(GRAY)
Br
R
B
R
Br/L
ON
OFF
(BLACK)
R
R
Br/L L/B
L/Y
R
R
R
R/Y
R
R/W
Br
Br/L
Br/L
L
B
Br/L
B
R/B
B
R
R/G
R
B
R
R
R
R
B
L
R/Y
L
R/Y
R/Y
R/W R/W R/W R/W
R R/Y
R/Y
L
R/W
L/W
B/Y
L
R/L
L/Y L/R
R
B
L Y/G B/L
(BLACK)
B/L P/Y L
(BLACK)
B L P/W L
(BLACK)
L Y B
B
B
Sb
Sb
Sb/W
Sb
R/W
L/G
L
Y
L
B
B/L
Y/G
L
L
P/Y
B/L
L
P/W
B/L
B
Y
L
Gy B/L
R
B/R
E B
E Y
E L
L
B L/G
B
B/L
Gy
B/L
Br
(BLACK)
Br B
B
(BLACK)
B B
B
G/W
W L
B
Y/B
Br
R/Y
R/Y
G/L
L W/Y
B/L
B
R/L
R/W L/W R/L
Sb B/Y Sb/W
Br/W B/L
L/G L/Y
(BLUE)
B Gy
B
B B
(BLUE)
L/R R/Y
L/G
B/R
R/W
Br
Y/B
G/L
Br B Br
Br/W
B/L
L
W/Y
G/W B
RL B
Br/W Y/R
B
Br
Y/G
B/Y
R/L
L/R
R/B
R/B
Br/W
Br
P/W
P/Y
L/W
B/L
Y
L
W/Y
R/W
L/B
Gy
B
B
Br
B
Br/W
W/Y Y/R
W/Y
Br/W P/Y W/R
Y/G Br
Gy/W B R
BG
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
CHARGING SYSTEM
1.
2.
4.
6.
AC magneto
Rectifier/regulator
Main fuse
Battery
7-14
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Rectifier/regulator cover
3. Lead cover
1. Check the fuse.
(Main)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse.
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the stator coil.
Refer to “CHECKING THE STATOR
COIL” on page 7-85.
NG →
Replace the stator coil.
OK ↓
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTIFIER/REGULATOR” on page 7-85.
NG →
Replace the rectifier/regulator.
OK ↓
5. Check the entire charging system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-13.
NG →
Properly connect or repair the charging
system wiring.
OK ↓
The charging system circuit is OK.
7-15
CHARGING SYSTEM
7-16
(GRAY)
WW W
7-17
B
Br
W
W
W
Br B
B R/
Br
(GRAY)
/Y /B
R
B /L
B
B
(BLACK)
Y Br
(BLACK)
B
/B L/Y
(GRAY)
Br
R
B
R
B
Y
Br
A B
Br L
ON
OFF
(BLACK)
R
R
B
L
Br L L/B
L/Y
B
R
L
A
L
B
Br/L
Y
A
Y
R/W
R
Br
R
B
L WW B
(BLACK)
B
W B /W
R/W B/R
G L L/B
B
R
L
R/Y
L
R/Y
Br
R/Y
Y
R/W
R W R/W R/W R/W
R RY
(BLACK)
B/R R W
L B G/L
Y
Br
R/Y
Br/L
L
B
Br/L
B
R
RG
R
RB
B
R
R
L Y
R
R
B/R
RY
L
R/W
W/B
L/W
LW
B/Y
L
B
LB
LB
G/L
B
B B
L Y/G B/L
(BLACK)
BL PY L
(BLACK)
B/L P W L
(BLACK)
L Y B
B
B
Sb
Sb
Sb W
B L/B
RL
L/Y L R
R
Sb
R/W
L/G
L
Y
L
B
B/L
YG
L
L
P/Y
B/L
L
PW
B/L
B
Y
L
Gy B/L
R
BR
E B
E Y
E L
L
Y
B G
B
G
GL
(GRAY)
B /W
(GRAY)
Ch Dg
P B
YR
(GRAY)
B
Y
Br
(BLACK)
B B
B
B B
GYGB
Y B
B/L
B
Y/B
B
Br
B
B
(BLACK)
L/Y B Y
G
B
GW
W L
B
Br
RY
R/Y
G/L
L WY
B/
(BLACK)
(BLUE)
Y
(BLACK)
(GRAY)
rW
Dg h
B P
R
(GRAY)
(GRAY)
B/Y L Y
G/B G/Y
(BLACK)
B
Y
(BLUE)
G
G/L
B
B/L
Gy
(BLUE)
R/L
R/W L W R/L
Sb B/Y Sb/W
Br W B/L
L G L/Y
B L/G
B
(BLUE)
B Gy
B
B
L R R/Y
LG
B/R
R/W
B
Ch
YB
G/L
Br
Br/W
Y
Br
G
(L)
N
(R)
B
Dg
Br/W
Ch
Br
Y/G
B/Y
RL
L/R
R/B
R/B
B /W
Br
P/W
P/Y
L/W
BL
Y
L
WY
R/W
L/B
Gy
Y/R
Br/W Y/R
B
Ch A Ch
Dg A Dg
Dg
GL
BL
L
W/Y
G/W B
R/L B
B
B
Gy R
G
Gy Y/B Gy R
O
O
B
B
W Y Y/R
P
Br
Br W
W/Y
PUSH
B
Ch L
G/B
GY
P
Br
(BLACK)
B/Br B
B/Br B
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
Y/B
Gy/G
Gy W
Y/L
WR
B/G
B/R
R/G
P/L
W/G
B /L
O
O
Gy/R
Gy/R
RG
PL
W/G
B /L
B
Dg L
R/B
R/B
D D
R/B
R/B
R/B
R/B
B
BW
WGRB RG
/ RB PL
R/G
P/L
WG
Br/L
L Dg
Dg L
B
B
(BLACK) (BLACK)
R/G
P/L
WG
Br L
Gy R C Gy R
Gy R C Gy R
Gy G L B
Br W P/Y W R L
R/L R/W R/B B/Br P L B/L R/G B Y
LW WY
Y G Br
Gy R/B B/Br Y L Y Br L W/G
P/W L R
Gy W B/R
B/G
G
B
B G
G
Gy
B
G
G
Gy
B/G
B/R
Gy/R
BR
Gy/R
BR
O
BR
W
BL
Gy/W
(BLACK)
Gy W R L
Gy/G B L
RL
B B
W L
W Gy
(GRAY)
B
(DARK GRAY)
W B
W
W
W G
(BLACK)
L WR BL
BG R
Gy/G
Gy
G
L
W/R
B/L
B/R
B/R
O
BR
W
W
Y
Dg
Ch
L
G/B
RG
Y/L
GW
G
RW
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
Br
B
G Gy
W W
B
L
(BLACK)
R G R/B W G
P L R/B B /L
L Y
B
(BLACK)
G/Y
G/B
(BLACK)
G/B
G/Y
(BLACK)
R/G G/W Y/L
B G
Y L G/W R G
G B
(BLACK)
Dg L Y
Ch Sb W R W
Sb/W
SUB W RE HARNESS2
E
SUB W RE HARNESS4
D
Y L Dg
R/W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W G R/B R/G
Br L R/B P/L
SUB W RE HARNESS3
(BLACK)
W RE HARNESS
y R B/R Gy R
(BLACK)
C
SUB W RE HARNESS2
B
SUB W RE HARNESS1
A
Gy R B/R y R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
LIGHTING SYSTEM
3. Main switch
4. Main fuse
6. Battery
27.ECU (electronic control unit)
44.Meter light
47.High beam indicator light
52.Headlight relay
55.Dimmer switch
59.Front right turn signal/position light
60.Front left turn signal/position light
64.Headlight (high beam)
65.Headlight (low beam)
70.Accessory light switch
71.Accessory light (OPTION)
72.Tail/brake light
73.License plate light
78.Headlight fuse
79.Signaling system fuse
80.Taillight fuse
81.ECU fuse
7-18
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light,
taillight, license light, position light, meter light or accessory light (OPTION).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Headlight assembly
1. Check the condition of each bulb
and bulb socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
7-74.
NG →
Replace the bulb(s) and bulb socket(s).
OK ↓
2. Check the fuses.
(Main, headlight, signaling system,
taillight and ECU)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse(s).
OK ↓
3. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
4. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the main switch.
OK ↓
5. Check the dimmer switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the accessory light switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The accessory light switch is faulty. Replace the right handlebar switch.
OK ↓
7. Check the headlight relay.
Refer to “CHECKING THE RELAYS” on page 7-79.
NG →
Replace the headlight relay.
OK ↓
7-19
LIGHTING SYSTEM
8. Check the entire lighting system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-17.
NG →
Properly connect or repair the lighting system wiring.
OK ↓
The lighting system circuit is OK.
7-20
(GRAY)
WW W
7-21
B
Br
W
W
W
Br B
B R/L
Br
(GRAY)
Y L/B
R
Br L
B
B
(BLACK)
Y Br
(BLACK)
B
L/B L/Y
(GRAY)
Br
R
B
R
B
Y
Br
A B
Br/L
ON
OFF
(BLACK)
R
R
B
L
Br/L L B
LY
B
L
A
L
B
Br L
Y
A
Y
RW
R
Br
R
B
L/W W/B
(BLACK)
B
W/B L W
RW R
G/L L B
B
R
L
RY
L
RY
Br
RY
Y
RW
R/W R W R W R/W
R R/Y
(BLACK)
B/R R/W
L/B G L
Y
Br
RY
Br L
L
B
Br L
B
R
RG
R
R/B
B
R
R
R
L Y
R
R
BR
R/Y
L
R/W
WB
LW
L/W
B/Y
L
B
L/B
L/B
G/L
B
(BLACK)
L Y B
B
B
Sb
Sb
Sb/W
L Y G B/L
(BLACK)
B/L P/Y L
(BLACK)
B/L P/W L
B L/B
/B B
R/L
L/Y L/R
R
Sb
R/W
LG
L
Y
L
B
B/L
Y/G
L
L
P/Y
BL
L
P/W
BL
B
Y
L
Gy B L
R
B/R
B
Y
L
L
Y
Y
B G
G
G/L
Y B
Br W
(GRAY)
Ch Dg
P B
Y/R
(GRAY)
(GRAY)
B B
G/Y G/B
B
Y
Br
(BLACK)
Br B
B
(BLACK)
(BLUE)
Y
BL
YB
B
Br
B
B
(BLACK)
L/Y B/Y
G
B
G/W
W L
B
Br
R/Y
RY
GL
L WY
B/L
B
RL
R W L/W R/L
Sb B Y b W
B /W B L
B B
(BLACK)
(GRAY)
B /W
Dg Ch
B P
Y/R
(GRAY)
(GRAY)
B
BL
Gy
B Y L/Y
GB GY
(BLUE)
G
GL
(BLACK)
B
B L/G
L/G L Y
(BLUE)
B Gy
B
B B
(BLUE)
L/R R/Y
L/G
BR
R/W
B
Ch
Y/B
GL
Br
Br W
Y
Br
G
(L)
N
(R)
B
Ch A Ch
Dg
Dg
G/L
B/L
L
W/Y
GW B
R/L B
Dg
Ch
Dg
B /W
YR
Br W Y R
B
Br
YG
B/Y
R/L
LR
R/B
R/B
Br/W
Br
PW
P/Y
L/W
B/L
Y
L
W/Y
RW
LB
Gy
B
B
B
B
W/Y Y R
P
Br
PUSH
B
Ch L
GB
G/Y
P
Br
(BLACK)
B Br B
B Br B
Br/W
W/Y
O
O
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
YB
Gy/G
Gy/W
Y/L
W/R
BG
BR
R/G
PL
WG
Br/L
O
O
Gy/R
Gy/R
B
Dg L
RB
RB
D
RB
RB
RB
RB
B
B/W
W/G R/B R/G
Br L R/B P/L
RG
P/L
W/G
B /L
Gy/R
Gy/R
L Dg
Dg L
B
B
(BLACK) (BLACK)
R/G D R G
P/L D P L
W G D W/G
Br L D Br/L
Gy/R
Gy/R
y/G L/B
R L R W R B B B P/L B L R G B/Y
L/W W/Y
Gy R B B B Y/L Y B /L W G
Gy/R
G
Gy Y B Gy/R
B /W P Y W/R L
Y/G Br
P W L/R
Gy/W B R
BG
G
B
B G
G
Gy
B
G
G
Gy
B/G
B/R
Gy/R
B/R
Gy/R
B/R
O
B/R
W
B/L
Gy/W
(BLACK)
G /W R/L
Gy G B/L
R/L
B B
W L
W Gy
(GRAY)
(DARK GRAY)
W
W
W
W G
(BLACK)
L W/R B/L
B/G B/R
Gy G
Gy
G
L
WR
BL
B/R
B/R
C
O
B/R
W
W
Y
Dg
Ch
L
G/B
R/G
Y/L
G/W
G
R/W
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
Br
B
G Gy
W W
B
L
L Y
B
(BLACK)
/Y
GB
Y
(BLACK)
B
(BLACK)
R/G G W Y L
B G
Y/L G/W R/G
G B
(BLACK)
Dg L Y
Ch Sb/W R/W
Sb/W
SUB W RE HARNESS2
E
SUB W RE HARNESS4
(BLACK)
R/G R B W/G
P/L R B Br L
Y L Dg
R W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W/G R B R G
B /L R B P L
SUB W RE HARNESS3
(BLACK)
W RE HARNESS
Gy R B R Gy R
(BLACK)
C
SUB W RE HARNESS2
B
SUB W RE HARNESS1
A
Gy R B/R Gy R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS27280
CIRCUIT DIAGRAM
SIGNALING SYSTEM
3. Main switch
4. Main fuse
5. Backup fuse (odometer and clock)
6. Battery
11.Relay unit
14.Neutral switch
18.Fuel sender (fuel pump)
24.Speed sensor
27.ECU (electronic control unit)
39.Neutral indicator light
40.Multi-function meter
43.Fuel level warning light
45.Left turn signal indicator light
46.Right turn signal indicator light
48.Fuel sender (fuel tank)
49.Horn 1
50.Horn 2
51.Turn signal relay
56.Turn signal switch
57.Horn switch
59.Front right turn signal/position light
60.Front left turn signal/position light
61.Rear right turn signal light
62.Rear left turn signal light
67.Front brake light switch
72.Tail/brake light
74.Rear brake light switch
77.Ignition fuse
79.Signaling system fuse
81.ECU fuse
7-22
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel level gauge fails to operate.
• The speedometer fails to operate.
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Rider seat bracket assembly
4. Headlight assembly
5. Fuel tank
1. Check the fuses.
(Main, backup, ignition, signaling
system and ECU)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the main switch.
OK ↓
4. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
Check the condition of each of the signaling system’s circuits. Refer to
“Checking the signaling system”.
Checking the signaling system
The horn fails to sound.
1. Check the horn switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
OK ↓
7-23
The horn switch is faulty. Replace the left
handlebar switch.
SIGNALING SYSTEM
2. Check the horns.
Refer to “CHECKING THE
HORNS” on page 7-86.
NG →
Replace the horn(s).
OK ↓
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.
1. Check the front brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the rear brake light switch.
OK ↓
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the condition of each bulb
and bulb socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
7-74.
NG →
Replace the bulb(s) and bulb socket(s).
OK ↓
2. Check the turn signal switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the turn signal relay.
Refer to “CHECKING THE TURN
SIGNAL RELAY” on page 7-80.
NG →
Replace the turn signal relay.
OK ↓
7-24
SIGNALING SYSTEM
4. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
This circuit is OK.
The neutral indicator light fails to come on.
1. Check the neutral switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the neutral switch.
OK ↓
2. Check the relay unit (diode).
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the relay unit.
OK ↓
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
This circuit is OK.
The fuel level gauge fails to operate.
1. Check the fuel sender (fuel tank).
Refer to “CHECKING THE FUEL
SENDER (FUEL TANK)” on page
7-87.
NG →
Replace the fuel sender.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
Replace the meter assembly.
The fuel level warning light fails to come on.
1. Check the fuel level warning light.
Refer to “CHECKING THE FUEL
LEVEL WARNING LIGHT” on page
7-88.
NG →
Replace the meter assembly or fuel pump
assembly.
OK ↓
7-25
SIGNALING SYSTEM
2. Check the fuel sender (fuel pump).
Refer to “CHECKING THE FUEL
SENDER (FUEL PUMP)” on page
7-88.
NG →
Replace the fuel pump assembly.
OK ↓
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
This circuit is OK.
The speedometer fails to operate.
1. Check the speed sensor.
Refer to “CHECKING THE SPEED
SENSOR” on page 7-88.
NG →
Replace the speed sensor.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-21.
NG →
Properly connect or repair the signaling
system wiring.
OK ↓
Replace the meter assembly.
7-26
(GRAY)
WW W
7-27
B
Br
W
W
W
Br B
B R/
Br
(GRAY)
/Y B
R
Br L
B
B
(BLACK)
Y B
(BLACK)
B
B Y
(GRAY)
Br
R
B
R
B
Y
Br
A B
Br L
ON
OFF
(BLACK)
R
R
B
L
Br L L/B
L/Y
B
R
L
A
L
B
Br/L
Y
Y
R/W
R
Br
R
B
L W W/B
(BLACK)
B
W/B /W
R/W B/R
G/ L/B
B
R
L
R/Y
L
R/Y
Br
R/Y
Y
R/W
R/W R/W R/W R/W
R RY
(BLACK)
B/R R W
L/B G/L
Y
Br
R/Y
Br/L
L
B
Br/L
B
R
R/G
R
R/B
B
R
R
L Y
R
R
B/R
RY
L
R/W
WB
L/W
L/W
BY
L
B
L/B
L/B
B
(BLACK)
L Y B
B
B
Sb
Sb
Sb W
L Y/G B L
(BLACK)
B/L P Y L
(BLACK)
B/L P W L
B LB
LB B
G/L
R/L
L/Y L R
R
Sb
RW
LG
L
Y
L
B
B/L
YG
L
L
P/Y
B/L
L
PW
B/L
B
Y
L
Gy B/L
R
B/R
B
Y
L
L
Y
B G
B
G
/L
B /W
(GRAY)
Ch Dg
P B
Y/R
(GRAY)
B
Y
Br
(BLACK)
B B
B
B B
G Y /B
(GRAY)
Y B
B/L
B
Y/B
B
Br
B
B
(BLACK)
L/Y B Y
G
B
GW
W L
B
Br
R/Y
R/Y
G/L
L W/Y
B/L
(BLACK)
(BLUE)
Y
(BLACK)
(GRAY)
B /W
Dg Ch
B P
YR
(GRAY)
(GRAY)
B/Y L/Y
G/B G/Y
(BLACK)
B
Y
(BLUE)
G
GL
B
B/L
Gy
(BLUE)
R/L
R/W L W R/L
Sb B/Y Sb W
Br W B/L
L G L/Y
B L/G
B
(BLUE)
B Gy
B
B
L/R R/Y
LG
B/R
R/W
B
Ch
Y/B
G/L
Br
Br/W
Y
Br
G
(L)
N
(R)
B
Dg
Br/W
Ch
Br
Y/G
BY
RL
L/R
RB
RB
Br W
Br
P/W
PY
L/W
BL
Y
L
WY
R/W
L/B
Gy
YR
B /W Y/R
B
Ch A Ch
Dg A Dg
Dg
GL
B/L
L
W/Y
G/W B
RL B
B
B
G
Gy Y/B
yR
yR
O
O
B
B
WY YR
P
Br
Br W
W/Y
PUSH
B
Ch L
G/B
GY
P
Br
(BLACK)
B/Br B
B/Br B
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
YB
Gy/G
Gy/W
YL
WR
B/G
B/R
R/G
P/L
W/G
Br L
O
O
Gy/R
Gy/R
RG
P/L
W/G
B /L
B
Dg L
R/B
R/B
D D
R/B
R/B
R/B
R/B
B
B/W
W/G R B R G
/L R B P L
R/G
PL
W/G
Br/L
L Dg
Dg L
B
B
(BLACK) (BLACK)
R/G
P/L
WG
Br L
Gy R C Gy R
Gy R C Gy R
Gy G L/B
Br W P Y W/R L
R L R W R/B B Br P L B/L R G B/Y
L W W/Y
Y G Br
Gy R/B B Br Y L Y Br/L W/G
P/W L R
Gy W B/R
B/G
G
B
B G
B
G
G B G
Gy B Gy
B/G
B/R
Gy R
BR
Gy R
BR
O
BR
W
BL
Gy/W
(BLACK)
Gy/W R L
Gy/G B L
R/L
B B
W L
WG
(GRAY)
B
(DARK GRAY)
W B
W
W
W G
(BLACK)
L W/R B L
G BR
Gy/G
Gy
G
L
W/R
B/L
B/R
B/R
O
BR
W
W
Y
Dg
Ch
L
G/B
R/G
Y/L
G/W
G
RW
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
Br
B
G Gy
W W
B
L
(BLACK)
R G R/B W/G
P L R/B B /L
L Y
B
(BLACK)
GY
G/B
(BLACK)
GB
G/Y
(BLACK)
R/G G/W Y/L
B G
Y/L G W R G
G B
(BLACK)
Dg L Y
Ch Sb W /W
Sb/W
SUB W RE HARNESS2
E
SUB W RE HARNESS4
D
Y L Dg
R/W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W G R B R/G
Br L R/B P L
SUB W RE HARNESS3
(BLACK)
W RE HARNESS
y R B/R Gy R
(BLACK)
C
SUB W RE HARNESS2
B
SUB W RE HARNESS1
A
Gy B R Gy R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
FUEL INJECTION SYSTEM
EAS27330
FUEL INJECTION SYSTEM
EAS27340
CIRCUIT DIAGRAM
FUEL INJECTION SYSTEM
3. Main switch
4. Main fuse
6. Battery
7. Fuel injection system fuse
11.Relay unit
12.Starting circuit cut-off relay
13.Fuel pump relay
14.Neutral switch
15.Diode 2
16.Sidestand switch
17.Fuel pump
19.Crankshaft position sensor
20.Throttle position sensor
21.Cylinder-#1 intake air pressure sensor
22.Cylinder-#2 intake air pressure sensor
23.Lean angle sensor
24.Speed sensor
25.Air temperature sensor
26.Engine temperature sensor
27.ECU (electronic control unit)
28.Cylinder-#1 left ignition coil
29.Cylinder-#1 right ignition coil
30.Cylinder-#2 left ignition coil
31.Cylinder-#2 right ignition coil
32.Spark plug
33.ISC (idle speed control) unit
34.EXUP servo motor
35.Injector #1
36.Injector #2
37.O2 sensor
40.Multi-function meter
41.Reset switch
42.Engine trouble warning light
52.Headlight relay
55.Dimmer switch
58.Select switch
64.Headlight (high beam)
65.Headlight (low beam)
68.Engine stop switch
77.Ignition fuse
78.Headlight fuse
79.Signaling system fuse
81.ECU fuse
7-28
FUEL INJECTION SYSTEM
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the odometer/tripmeter/fuel reserve tripmeter/clock LCD. Once a fault code has been displayed, it remains stored in the
memory of the ECU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication
Flashing*
Remains on
ECU operation
Fuel injection operation
Vehicle operation
Warning provided
when unable to start
engine
Operation stopped
Cannot be operated
Malfunction detected
Operated with substitute characteristics in
accordance with the
description of the malfunction
Can or cannot be operated depending on the
fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch
is pushed:
Lean angle sensor
12:
Crankshaft position sensor
41:
(open or short-circuit)
19:
Blue/black ECU lead
(broken or disconnected)
30:
Lean angle sensor
(latch up detected)
50:
ECU internal malfunction
(memory check error)
Checking the engine trouble warning light
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light (LED) may be defective.
a
b
c
a.
b.
c.
d.
d
Main switch “OFF”
Main switch “ON”
Engine trouble warning light off
Engine trouble warning light on for 1.4
seconds
7-29
c
FUEL INJECTION SYSTEM
EAS27380
SELF-DIAGNOSTIC FUNCTION TABLE
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic Function table
Fault
code No.
Item
Symptom
Able / unable to start
Able / unable to
drive
12
Crankshaft position
sensor
No normal signals are received
from the crankshaft position sensor.
Unable
Unable
13
Cylinder-#1 intake air
pressure sensor
(open or short circuit)
Cylinder-#1 intake air pressure
sensor: open or short circuit detected.
Able
Able
14
Cylinder-#1 intake air
pressure sensor
(hose system)
Cylinder-#1 intake air pressure
sensor: hose system malfunction
(clogged or detached hose).
Able
Able
15
Throttle position sensor
(open or short circuit)
Throttle position sensor: open or
short circuit detected.
Able
Able
17
EXUP servo motor
circuit
(open or short circuit)
EXUP servo motor circuit: open or
Able
short circuit detected.
Able
18
EXUP servo motor
(lock)
EXUP servo motor is stuck.
Able
Able
19
Blue/black ECU lead
(broken or disconnected)
A break or disconnection of the
blue/black lead of the ECU is detected.
Unable
Unable
22
Air temperature sensor
(open or short circuit)
Air temperature sensor: open or
short circuit detected.
Able
Able
24
O2 sensor
No normal signal is received from
the O2 sensor.
Able
Able
25
Cylinder-#2 intake air
pressure sensor
(open or short circuit)
Cylinder-#2 intake air pressure
sensor: open or short circuit detected.
Able
Able
26
Cylinder-#2 intake air
pressure sensor
(hose system)
Cylinder-#2 intake air pressure
sensor: hose system malfunction
(clogged or detached hose).
Able
Able
28
Engine temperature
sensor
(open or short circuit)
Engine temperature sensor: open
or short circuit detected.
Able
Able
30
Lean angle sensor
(latch up detected)
The vehicle has overturned.
Unable
Unable
7-30
FUEL INJECTION SYSTEM
Fault
code No.
Item
Symptom
Able / unable to start
Able / unable to
drive
Cylinder-#1 left or
right ignition coil
(faulty ignition)
Able
(depending
Malfunction detected in the primaon the
ry wire of the cylinder-#1 left or
number of
right ignition coil.
faulty cylinders)
Able
(depending
on the
number of
faulty cylinders)
Cylinder-#2 left or
right ignition coil
(faulty ignition)
Able
(depending
Malfunction detected in the primaon the
ry wire of the cylinder-#2 left or
number of
right ignition coil.
faulty cylinders)
Able
(depending
on the
number of
faulty cylinders)
Cylinder-#1 left or
right ignition coil
(faulty ignition)
Able
(depending
Malfunction detected in the primaon the
ry wire of the cylinder-#1 left or
number of
right ignition coil.
faulty cylinders)
Able
(depending
on the
number of
faulty cylinders)
36
Cylinder-#2 left or
right ignition coil
(faulty ignition)
Able
(depending
Malfunction detected in the primaon the
ry wire of the cylinder-#2 left or
number of
right ignition coil.
faulty cylinders)
Able
(depending
on the
number of
faulty cylinders)
37
ISC valve (stuck fully
open)
Engine speed is high when the enAble
gine is idling.
Able
41
Lean angle sensor
(open or short circuit)
Lean angle sensor: open or short
circuit detected.
Unable
Unable
Speed sensor
No normal signals are received
from the speed sensor.
Open or short circuit is detected in
the neutral switch.
Able
Able
Neutral switch
43
Fuel system voltage
(monitoring voltage)
The ECU is unable to monitor the
battery voltage
Able
(an open or short circuit in the line
to the ECU).
Able
44
Error in writing the
amount of CO adjustment on EEPROM
Error is detected while reading or
writing on EEPROM (CO adjustment value).
Able
Able
46
Vehicle system power
Power supply to the fuel injection
supply
system is not normal.
(Monitoring voltage)
Able
Able
50
Faulty ECU memory. (When this
ECU internal malfuncmalfunction is detected in the
tion
ECU, the fault code number might
(memory check error)
not appear on the meter.)
Unable
Unable
33
34
35
42
7-31
FUEL INJECTION SYSTEM
Fault
code No.
70
Item
Engine idling stop
Symptom
Engine has been left idling. (The
ECU automatically stops the engine after 20 minutes if it is left
idling.)
Able / unable to start
Able
Able / unable to
drive
Able
Communication error with the meter
Fault
code No.
Item
Symptom
Able / unable to start
Able / unable to
drive
Er-1
ECU internal malfuncNo signals are received from the
tion
ECU.
(output signal error)
Unable
Unable
Er-2
ECU internal malfuncNo signals are received from the
tion
ECU within the specified duration.
(output signal error)
Unable
Unable
Er-3
ECU internal malfuncData from the ECU cannot be retion
ceived correctly.
(output signal error)
Unable
Unable
Er-4
ECU internal malfuncNon-registered data has been retion
ceived from the meter.
(input signal error)
Unable
Unable
2. Check and repair the probable cause of malfunction.
EAS27400
TROUBLESHOOTING METHOD
Fault code No.
The engine operation is not normal and the
engine trouble warning light comes on.
1. Check:
• Fault code number
Check and repair.
Refer to “TROUBLESHOOTING DETAILS” on page 7-40.
Monitor the operation of the sensors
and actuators in the
diagnostic mode. Refer to “Sensor operation table” and
“Actuator operation
table”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on
the meter.
b. Identify the faulty system with the fault code.
Refer to “Self-Diagnostic Function table”.
c. Identify the probable cause of the malfunction. Refer to “Diagnostic code table”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
No fault code No.
Check and repair.
Refer to “Self-Diagnostic Function table”.
3. Perform ECU reinstatement action.
Refer to “Reinstatement method” of table in
“TROUBLESHOOTING DETAILS”.
4. Turn the main switch to “OFF” and back to
“ON”, then check that no fault code number is
displayed.
NOTE:
If fault codes are displayed, repeat steps (1) to
(4) until no fault code number is displayed.
7-32
FUEL INJECTION SYSTEM
5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation table
(Diagnostic code No. 62)”.
The engine operation is not normal but the
engine trouble warning light does not come
on.
1. Check the operation of following sensors and
actuators in the Diagnostic mode. Refer to
“Sensor operation table” and “Actuator operation table”.
01: Throttle position sensor (throttle angle)
30: Cylinder-#1 ignition coil
31: Cylinder-#2 ignition coil
32: Cylinder-#1 ignition coil
33: Cylinder-#2 ignition coil
36: Injector #1
37: Injector #2
NOTE:
Turning the main switch to “OFF” will not erase
the malfunction history.
If a malfunction is detected in the sensors or
actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors
and actuators, check and repair inner parts of
the engine.
EAS27420
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Press and hold the “RESET” switch, turn the main switch to “ON”, and continue to press the switch
for 8 seconds or more.
“SELECT”
“RESET”
NOTE:
• All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip
meter/clock displays.
• “dIAG” appears on the odometer/trip meter/fuel reserve trip meter/clock LCD.
4. Simultaneously press the “SELECT” and “RESET” switches for 2 seconds or more to activate the
diagnostic mode. The diagnostic code number “d01” appears on the clock LCD.
5. Set the engine stop switch to “ ”.
6. Select the diagnostic code number corresponding to the fault code number by pressing the “SELECT” and “RESET” switches.
NOTE:
• To decrease the selected diagnostic code number, press the “RESET” switch. Press the “RESET”
switch for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “SELECT” switch. Press the “SELECT”
switch for 1 second or longer to automatically increase the diagnostic code numbers.
7-33
FUEL INJECTION SYSTEM
“d01 d70”
“d70 d01”
7. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appears on the odometer/trip meter/fuel reserve trip meter/clock LCD.
• Actuator operation
Set the engine stop switch to “ ” to operate the actuator.
NOTE:
If the engine stop switch is set to “
”, set it to “
”, and then set it to “
” again.
8. Turn the main switch to “OFF” to cancel the diagnostic mode.
Diagnostic code table
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
12
No normal signals are received from the crankshaft
position sensor.
• Open or short circuit in wire harness.
• Defective crankshaft position sensor.
• Malfunction in crankshaft position sensor
rotor.
• Malfunction in ECU.
• Improperly installed sensor.
—
13
• Open or short circuit in wire harness.
Cylinder-#1 intake air pres• Defective cylinder-#1 intake air pressure
sure sensor: open or short
sensor.
circuit detected.
• Malfunction in ECU.
03
14
Cylinder-#1 intake air pres• Cylinder-#1 intake air pressure sensor hose
sure sensor: hose system
is detached, clogged, kinked, or pinched.
03
malfunction (clogged or de• Malfunction in ECU.
tached hose).
15
• Open or short circuit in wire sub lead.
Throttle position sensor:
• Open or short circuit in wire harness.
open or short circuit detect- • Defective throttle position sensor.
01
ed.
• Malfunction in ECU.
• Improperly installed throttle position sensor.
17
EXUP servo motor circuit: • Open or short circuit in wire harness.
open or short circuit detect- • Defective EXUP servo motor (potentiomeed.
ter circuit).
53
18
• Open or short circuit in wire harness.
EXUP servo motor is stuck. • Stuck EXUP servo motor (mechanism).
• Stuck EXUP servo motor (motor).
53
7-34
FUEL INJECTION SYSTEM
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
19
A break or disconnection of
• Open circuit in wire harness (ECU coupler).
the blue/black lead of the
20
• Malfunction in ECU.
ECU is detected.
22
• Open or short circuit in wire harness.
Air temperature sensor:
• Defective air temperature sensor.
open or short circuit detect05
• Malfunction in ECU.
ed.
• Improperly installed air temperature sensor.
24
No normal signal is received from the O2 sensor.
25
• Open or short circuit in wire sub lead.
Cylinder-#2 intake air pres- • Open or short circuit in wire harness.
sure sensor: open or short • Defective cylinder-#2 intake air pressure
circuit detected.
sensor.
• Malfunction in ECU.
26
Cylinder-#2 intake air pres• Cylinder-#2 intake air pressure sensor hose
sure sensor: hose system
is detached, clogged, kinked, or pinched.
04
malfunction (clogged or de• Malfunction in ECU.
tached hose).
28
Engine temperature sensor: open or short circuit
detected.
• Open or short circuit in wire sub lead.
• Open or short circuit in wire harness.
• Defective engine temperature sensor.
• Malfunction in ECU.
• Improperly installed sensor.
11
30
The vehicle has overturned.
• Overturned.
• Malfunction in ECU.
08
33
• Open or short circuit in wire harness.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igniprimary wire of the cylintion coil.
der-#1 left or right ignition
• Malfunction in ECU.
coil.
• Malfunction in a component of ignition cutoff circuit system.
30
32
34
• Open or short circuit in wire sub lead.
• Open or short circuit in wire harness.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igniprimary wire of the cylintion coil.
der-#2 left or right ignition
• Malfunction in ECU.
coil.
• Malfunction in a component of ignition cutoff circuit system.
31
33
35
• Open or short circuit in wire harness.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igniprimary wire of the cylintion coil.
der-#1 left or right ignition
• Malfunction in ECU.
coil.
• Malfunction in a component of ignition cutoff circuit system.
30
32
• Open or short circuit in wire harness.
• Defective O2 sensor.
• Malfunction in ECU.
• Improperly installed sensor.
7-35
—
04
FUEL INJECTION SYSTEM
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
36
• Open or short circuit in wire sub lead.
• Open or short circuit in wire harness.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igniprimary wire of the cylintion coil.
der-#2 left or right ignition
• Malfunction in ECU.
coil.
• Malfunction in a component of ignition cutoff circuit system.
37
• Open circuit in wire harness.
• Malfunction in throttle body.
• Malfunction in throttle cables.
• ISC valve is stuck fully open due to disconnected ISC unit hose or coupler. (High enEngine speed is high when
gine idle speed is detected with the ISC
54
the engine is idling.
valve stuck fully open even though signals
for the valve to close are continuously being
transmitted by the ECU.)
• Malfunction in ECU.
• ECU fuse is blown.
41
• Open or short circuit in wire harness.
Lean angle sensor: open or
• Defective lean angle sensor.
short circuit detected.
• Malfunction in ECU.
42
• Open circuit in wire harness.
• Defective speed sensor.
No normal signals are re• Malfunction in vehicle speed sensor detectceived from the speed sened.
07
sor.
• Defective neutral switch.
21
Open circuit is detected in
• Malfunction in the engine side of the neutral
the neutral switch.
switch.
• Malfunction in ECU.
43
The ECU is unable to monitor the battery voltage (an • Open or short circuit in wire harness.
open or short circuit in the • Malfunction in ECU.
line to the ECU).
44
Error is detected while
• Malfunction in ECU. (The CO adjustment
reading or writing on EEvalue is not properly written on or read from 60
PROM (CO adjustment valthe internal memory).
ue).
46
Power supply to the fuel inMalfunction in the charging system. Refer to
jection system is not nor“CHARGING SYSTEM” on page 7-13.
mal.
50
Faulty ECU memory.
(When this malfunction is
detected in the ECU, the
fault code number might
not appear on the meter.)
• Malfunction in ECU. (The program and data
are not properly written on or read from the —
internal memory.)
No signals are received
from the ECU.
• Open or short circuit in wire harness.
• Malfunction in meter.
• Malfunction in ECU.
• Defective wire connection of the ECU coupler.
Er-1
7-36
31
33
08
09
—
—
FUEL INJECTION SYSTEM
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
Er-2
No signals are received
from the ECU within the
specified duration.
• Improper connection in wire harness.
• Malfunction in meter.
• Malfunction in ECU.
—
Er-3
Data from the ECU cannot
be received correctly.
• Improper connection in wire harness.
• Malfunction in meter.
• Malfunction in ECU.
—
Er-4
Non-registered data has
been received from the
meter.
• Improper connection in wire harness.
• Malfunction in meter.
• Malfunction in ECU.
—
Sensor operation table
Diagnostic
code
No.
01
Item
Meter display
Checking method
Throttle angle
• Fully closed position
12–22
Check with throttle fully
closed.
• Fully opened position
87–107
Check with throttle fully
open.
03
Pressure difference
Displays the cylinder-#1 in(atmospheric pressure and take air pressure.
cylinder-#1 intake air pressure)
Set the engine stop switch
to “ ”, and then push the
start switch “ ”. (If the display value changes, the
performance is OK.)
04
Pressure difference
Displays the cylinder-#2 in(atmospheric pressure and take air pressure.
cylinder-#2 intake air pressure)
Set the engine stop switch
to “ ”, and then push the
start switch “ ”. (If the display value changes, the
performance is OK.)
05
Air temperature
Displays the air temperature. Compare the actually measured air temperature with
the meter display value.
07
Vehicle speed pulse
0–999
08
Lean angle sensor
Check that the number increases when the rear
wheel is rotated. The number is cumulative and does
not reset each time the
wheel is stopped.
• Upright
0.4–1.4
• Overturned
3.7–4.4
7-37
Remove the lean angle
sensor and incline it more
than 65 degrees.
FUEL INJECTION SYSTEM
Diagnostic
code
No.
Item
Meter display
Checking method
09
Fuel system voltage
(battery voltage)
Approximately 12.0
11
Engine temperature
Displays the engine tempera- Compare the actually meature.
sured engine temperature
with the meter display value.
20
Sidestand switch
21
• Stand retracted
ON
• Stand extended
OFF
Set the engine stop switch
to “ ”, and then compare
with the actually measured
battery voltage. (If the battery voltage is lower, perform recharging.)
Set on/off the sidestand
switch (with the transmission in gear).
Neutral switch
Shift the transmission.
• Neutral
ON
• In gear
OFF
53
EXUP servo motor
Displays the operating angle. —
Engine trouble warning light
comes on twice: once when
the EXUP valve is closing
and once when it is opening.
60
EEPROM fault code display
61
62
—
• No history
00
• History exists
01 or 02 (Cylinder fault code)
• (If both cylinders are defective, the display alternates
every two seconds.)
Malfunction history code
display
—
• No history
00
• History exists
Fault codes 12-70
• (If more than one code
number is detected, the display alternates every two
seconds to show all the detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
Malfunction history code
erasure
• No history
0
—
• History exists
Up to 25 fault codes
To erase the history, set the
engine stop switch to “ ”.
7-38
FUEL INJECTION SYSTEM
Diagnostic
code
No.
70
Item
Control number
Meter display
0–255
Checking method
—
Actuator operation table
Diagnostic
code
No.
30
31
32
33
36
37
50
Item
Actuation
Checking method
Cylinder-#1 left or right ignition coil
Actuates the cylinder-#1 left
or right ignition coil five times Check the spark five times.
at one-second intervals.
• Connect an ignition
Illuminates the engine trouchecker.
ble warning light.
Cylinder-#2 left or right ignition coil
Actuates the cylinder-#2 left
or right ignition coil five times Check the spark five times.
at one-second intervals.
• Connect an ignition
Illuminates the engine trouchecker.
ble warning light.
Cylinder-#1 left or right ignition coil
Actuates the cylinder-#1 left
or right ignition coil five times Check the spark five times.
at one-second intervals.
• Connect an ignition
Illuminates the engine trouchecker.
ble warning light.
Cylinder-#2 left or right ignition coil
Actuates the cylinder-#2 left
or right ignition coil five times Check the spark five times.
at one-second intervals.
• Connect an ignition
Illuminates the engine trouchecker.
ble warning light.
Injector #1
Actuates the injector #1 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Check the operating sound
of the injector #1 five times.
Injector #2
Actuates the injector #2 five
times at one-second intervals.
Illuminates the engine trouble warning light.
Check the operating sound
of the injector #2 five times.
Fuel pump relay
Actuates the fuel pump relay
five times at one-second intervals.
Illuminates the engine trouCheck the operating sound
ble warning light.
of the fuel pump relay five
(The engine trouble warning
times.
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
7-39
FUEL INJECTION SYSTEM
Diagnostic
code
No.
52
54
Item
Actuation
Checking method
Headlight relay
Actuates the headlight relay
for five cycles of five seconds. (ON 2 seconds, OFF 3 Check the operating sound
seconds)
of the headlight relay five
Illuminates the engine troutimes.
ble warning light and headlight.
ISC valve
Actuates and fully closes the
ISC valve, then opens it to
the standby opening position
when the engine is started.
The ISC unit vibrates when
This operation takes approxithe ISC valve operates.
mately 12 seconds until it is
completed.
Illuminates the engine trouble warning light.
EAS27460
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service
the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 7-33.
7-40
FUEL INJECTION SYSTEM
Fault code No.
12
Diagnostic code No.
Symptom No normal signals are received from the crankshaft position sensor.
—
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of crankshaft position sensor.
Check for looseness or pinching.
Cranking the
engine.
2
Connections
• Crankshaft position sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU coupler.
(gray–gray)
(black/blue–black/blue)
4
Defective crankshaft position sensor.
• Replace if defective.
Refer to “CHECKING THE
CRANKSHAFT POSITION
SENSOR” on page 7-84.
7-41
FUEL INJECTION SYSTEM
Fault code No.
13
Diagnostic code No.
Symptom Cylinder-#1 intake air pressure sensor: open or short circuit detected.
03
Cylinder-#1 intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#1 intake air pressure sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#1 intake air
pressure sensor coupler and
ECU coupler
(black/blue–black/blue)
(pink/white–pink/white)
(blue–blue)
3
Defective cylinder-#1 intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.03)
• Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 7-90.
7-42
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
14
Diagnostic code No.
Symptom Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose).
03
Cylinder-#1 intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Cylinder-#1 intake air pressure sensor • Check the cylinder-#1 intake air Starting the enhose
pressure sensor hose condition. gine and oper• Repair or replace the sensor
ating it at idle.
hose.
2
Cylinder-#1 intake air pressure sensor • Check and repair the connecmalfunction at intermediate electrical
tion.
potential.
• Replace it if there is a malfunction.
3
Connections
• Cylinder-#1 intake air pressure sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
4
Defective cylinder-#1 intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.03)
• Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 7-90.
7-43
FUEL INJECTION SYSTEM
Fault code No.
15
Diagnostic code No.
Symptom Throttle position sensor: open or short circuit detected.
01
Throttle position sensor
Order Item/components and probable
cause
Check or maintenance job
1
Installed condition of throttle position
sensor.
• Check for looseness or pinchTurning the
ing.
main switch to
• Check that the sensor is in“ON”.
stalled in the specified position.
2
Connections
• Throttle position sensor coupler
• Main wire harness ECU coupler
• Sub-wire harness 2 coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
3
Open or short circuit in wire harness
and/or sub lead.
• Repair or replace if there is an
open or short circuit.
• Between throttle position sensor coupler and ECU coupler
(blue–blue)
(yellow–yellow)
(black–black)
4
Throttle position sensor lead wire
open circuit output voltage check.
• Check for open circuit and replace the throttle position sensor.
(black–yellow)
5
Defective throttle position sensor.
Open circuit
item
Output voltage
Ground wire
open circuit
5V
Output wire
open circuit
0V
Power supply
wire open circuit
0V
• Execute the diagnostic mode.
(Code No.01)
• Replace if defective.
Refer to “CHECKING THE
THROTTLE POSITION SENSOR” on page 7-89.
7-44
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
17
Diagnostic code No.
Symptom EXUP servo motor circuit: open or short circuit detected.
53
EXUP servo motor
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• EXUP servo motor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between servo motor coupler
and ECU coupler
(blue–blue)
(white/red–white/red)
(black/blue–black/blue)
3
Defective EXUP servo motor (potenti- • Execute the diagnostic mode.
ometer circuit).
(Code No.53)
• Replace if defective.
Refer to “CHECKING THE
EXUP SERVO MOTOR” on
page 7-90.
Fault code No.
18
Diagnostic code No.
Reinstatement
method
Symptom EXUP servo motor is stuck.
53
EXUP servo motor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• EXUP servo motor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between the EXUP servo motor
coupler and the ECU coupler.
(black/green–black/green)
(black/red–black/red)
Turning the
main switch to
“ON”.
It takes 120
seconds at the
maximum before the original state
returns.
3
Defective EXUP servo motor.
• Execute the diagnostic mode.
(Code No.53)
• Replace if defective.
Refer to “CHECKING THE
EXUP SERVO MOTOR” on
page 7-90.
4
Defective EXUP valve, pulley, cables.
Replace if defective.
7-45
FUEL INJECTION SYSTEM
Fault code No.
19
Diagnostic code No.
Symptom A break or disconnection of the blue/black lead of the
ECU is detected.
20
Sidestand switch
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Main wire harness ECU coupler
• Execute the diagnostic mode.
(Code No.20)
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
If the transmission is in gear,
retracting the
sidestand.
If the transmission is in neutral,
reconnecting
the wiring.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between ECU and blue/black
lead
3
Defective sidestand switch.
• Replace if defective.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
Fault code No.
22
Diagnostic code No.
Symptom Air temperature sensor: open or short circuit detected.
05
Air temperature sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of air temperature
sensor.
Check for looseness or pinching.
2
Connections
• Air temperature sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
Turning the
main switch to
“ON”.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between air temperature sensor coupler and ECU coupler
(brown/white–brown/white)
(black/blue–black/blue)
4
Defective air temperature sensor.
• Execute the diagnostic mode.
(Code No.05)
• Replace if defective.
Refer to “CHECKING THE AIR
TEMPERATURE SENSOR” on
page 7-90.
7-46
FUEL INJECTION SYSTEM
Fault code No.
24
Diagnostic code No.
Symptom No normal signal is received from the O2 sensor.
—
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
Starting the engine and operating it at idle.
1
Installed state of O2 sensor.
Check for looseness or pinching.
2
Connections
• O2 sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between O2 sensor coupler and
ECU coupler.
(gray/white–gray/white)
(red/blue–red/blue)
(gray/green–gray/green)
(black/blue–black/blue)
4
Check fuel pressure.
• Refer to “THROTTLE BODIES”
on page 6-6.
5
Defective O2 sensor.
• Replace if defective.
7-47
FUEL INJECTION SYSTEM
Fault code No.
25
Diagnostic code No.
Symptom Cylinder-#2 intake air pressure sensor: open or short circuit detected.
04
Cylinder-#2 intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#2 intake air pressure sensor coupler
• Main wire harness ECU coupler
• Sub-wire harness 3 coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness
and/or sub lead.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#2 intake air
pressure sensor coupler and
ECU coupler
(black/blue–black/blue)
(pink/yellow–pink/yellow)
(blue–blue)
3
Defective cylinder-#2 intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.04)
• Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 7-90.
7-48
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
26
Diagnostic code No.
Symptom Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose).
04
Cylinder-#2 intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Cylinder-#2 intake air pressure sensor • Check the cylinder-#2 intake air Starting the enhose
pressure sensor hose condition. gine and oper• Repair or replace the sensor
ating it at idle.
hose.
2
Cylinder-#2 intake air pressure sensor • Check and repair the connecmalfunction at intermediate electrical
tion.
potential.
• Replace it if there is a malfunction.
3
Connections
• Cylinder-#2 intake air pressure sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
4
Defective cylinder-#2 intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.04)
• Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 7-90.
7-49
FUEL INJECTION SYSTEM
Fault code No.
28
Diagnostic code No.
Symptom Engine temperature sensor: open or short circuit detected.
11
Engine temperature sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed state of engine temperature
sensor.
Check for looseness or pinching.
2
Connections
• Engine temperature sensor coupler
• Main wire harness ECU coupler
• Sub-wire harness 2 coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
Turning the
main switch to
“ON”.
3
Open or short circuit in wire harness
and/or sub lead.
• Repair or replace if there is an
open or short circuit.
• Between engine temperature
sensor coupler and ECU coupler
(brown–brown)
(black–black)
4
Defective engine temperature sensor. • Execute the diagnostic mode.
(Code No.11)
• Replace if defective.
Refer to “CHECKING THE ENGINE TEMPERATURE SENSOR” on page 7-87.
Fault code No.
30
Diagnostic code No.
Symptom The vehicle has overturned.
08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
The vehicle has overturned.
Raise the vehicle upright.
2
Installed condition of the lean angle
sensor.
Check for looseness or pinching.
3
Connections
• Lean angle sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
Turning the
main switch to
“ON” (however,
the engine cannot be restarted
unless the main
switch is first
turned “OFF”).
4
Defective lean angle sensor.
• Execute the diagnostic mode.
(Code No.08)
• Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 7-84.
7-50
FUEL INJECTION SYSTEM
Fault code No.
33
Diagnostic code No.
Symptom Malfunction detected in the primary wire of the cylinder-#1
left or right ignition coil.
30, 32
Cylinder-#1 left or right ignition coil
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#1 left or right ignition coil
connector (primary coil side)
• Main wire harness ECU coupler
• Check the connector and couStarting the enpler for any pins that may be
gine and operpulled out.
ating it at idle.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#1 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(orange–orange)
3
Defective cylinder-#1 left or right ignition coil.
• Execute the diagnostic mode.
(Code No.30 or 32)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “CHECKING THE IGNITION COILS” on page 7-83.
7-51
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
34
Diagnostic code No.
Symptom Malfunction detected in the primary wire of the cylinder-#2
left or right ignition coil.
31, 33
Cylinder-#2 left or right ignition coil
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#2 left or right ignition coil
connector (primary coil side)
• Main wire harness ECU coupler
• Sub-wire harness 3 coupler
• Check the connector and couStarting the enpler for any pins that may be
gine and operpulled out.
ating it at idle.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness
and/or sub lead.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#2 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(gray/red–gray/red)
3
Defective cylinder-#2 left or right ignition coil.
• Execute the diagnostic mode.
(Code No.31 or 33)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “CHECKING THE IGNITION COILS” on page 7-83.
7-52
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
35
Diagnostic code No.
Symptom Malfunction detected in the primary wire of the cylinder-#1
left or right ignition coil.
30, 32
Cylinder-#1 left or right ignition coil
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#1 left or right ignition coil
connector (primary coil side)
• Main wire harness ECU coupler
• Check the connector and couStarting the enpler for any pins that may be
gine and operpulled out.
ating it at idle.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#1 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(orange–orange)
3
Defective cylinder-#1 left or right ignition coil.
• Execute the diagnostic mode.
(Code No.30 or 32)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “CHECKING THE IGNITION COILS” on page 7-83.
7-53
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
36
Diagnostic code No.
Symptom Malfunction detected in the primary wire of the cylinder-#2
left or right ignition coil.
31, 33
Cylinder-#2 left or right ignition coil
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Cylinder-#2 left or right ignition coil
connector (primary coil side)
• Main wire harness ECU coupler
• Sub-wire harness 3 coupler
• Check the connector and couStarting the enpler for any pins that may be
gine and operpulled out.
ating it at idle.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness
and/or sub lead.
• Repair or replace if there is an
open or short circuit.
• Between cylinder-#2 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(gray/red–gray/red)
3
Defective cylinder-#2 left or right ignition coil.
• Execute the diagnostic mode.
(Code No.31 or 33)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “CHECKING THE IGNITION COILS” on page 7-83.
7-54
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
37
Diagnostic code No.
Symptom Engine speed is high when the engine is idling.
54
ISC valve
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
ECU fuse is blown.
• Check the ECU fuse.
Refer to “CHECKING THE
FUSES” on page 7-75.
2
Throttle valve does not fully close.
• Check the throttle bodies.
Refer to “THROTTLE BODIES”
on page 6-6.
• Check the throttle cables.
Refer to “ADJUSTING THE
THROTTLE CABLE FREE
PLAY” on page 3-8.
3
ISC valve is stuck fully open due to
• Check that the ISC unit hose is
disconnected ISC unit hose or counot disconnected.
pler. (High engine idle speed is de• Check that the ISC unit coupler
tected with the ISC valve stuck fully
is not disconnected.
open even though signals for the valve • The ISC valve is stuck fully
to close are continuously being transopen if it does not operate when
mitted by the ECU.)
the main switch is turned “OFF”.
(Touch the ISC unit with your
hand and check if it is vibrating
to confirm if the ISC valve is operating.)
ISC valve returns to its original position by
turning the
main switch to
“ON” and back
to “OFF”.
Reinstated if
the engine idle
speed is within
specification after starting the
engine.
4
ISC valve is not moving correctly.
• Execute the diagnostic mode.
(Code No.54)
• After the ISC valve is fully
closed, it opens to the standby
opening position when the engine is started. This operation
takes approximately 12 seconds. Start the engine. If the error recurs, replace the throttle
body assembly.
7-55
FUEL INJECTION SYSTEM
Fault code No.
41
Diagnostic code No.
Symptom Lean angle sensor: open or short circuit detected.
08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Lean angle sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in lead wire.
• Repair or replace if there is an
open or short circuit.
• Between lean angle sensor
coupler and ECU coupler.
(blue–blue)
(yellow/green–yellow/green)
(black/blue–black/blue)
3
Defective lean angle sensor.
• Execute the diagnostic mode.
(Code No.08)
• Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 7-84.
7-56
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
42
Diagnostic code No.
Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
A
07
Speed sensor
B
21
Neutral switch
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
A-1
Connections
• Speed sensor coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
A-2
Open or short circuit in speed sensor
lead.
• Repair or replace if there is an
open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white/yellow–white/yellow)
(black/blue–black/blue)
Starting the engine, and activating the
vehicle speed
sensor by operating the vehicle at 20 to 30
km/h.
A-3
Gear for detecting vehicle speed has
broken.
• Replace if defective.
Refer to “TRANSMISSION” on
page 5-107.
A-4
Defective speed sensor.
• Execute the diagnostic mode.
(Code No.07)
• Replace if defective.
Refer to “CHECKING THE
SPEED SENSOR” on page
7-88.
7-57
FUEL INJECTION SYSTEM
Fault code No.
42
Diagnostic code No.
Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
A
07
Speed sensor
B
21
Neutral switch
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
B-1
Connections
• Neutral switch coupler
• Main wire harness ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
B-2
Open circuit in neutral switch lead.
• Repair or replace if there is an
open circuit.
• Between neutral switch coupler
and relay unit coupler (fuel
pump relay).
(sky blue–sky blue)
• Between relay unit coupler and
main switch.
(blue/yellow–blue/yellow)
• Between main switch and ECU
coupler.
(blue/black–blue/black)
Starting the engine, and activating the
vehicle speed
sensor by operating the vehicle at 20 to 30
km/h.
B-3
Faulty shift drum (neutral detection ar- • Replace if defective.
ea).
Refer to “TRANSMISSION” on
page 5-107.
B-4
Defective neutral switch.
• Execute the diagnostic mode.
(Code No.21)
• Replace if defective.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
7-58
FUEL INJECTION SYSTEM
Fault code No.
43
Diagnostic code No.
Symptom The ECU is unable to monitor the battery voltage (an open
or short circuit in the line to the ECU).
09
Fuel system voltage
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Relay unit coupler (fuel pump relay)
• Main wire harness ECU coupler
• Check the coupler for any pins Starting the enthat may be pulled out.
gine and oper• Check the locking condition of
ating it at idle.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in the wire harness.
• Repair or replace if there is an
open or short circuit.
• Between relay unit coupler (fuel
pump relay) and ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
• Between relay unit coupler (fuel
pump relay) and battery terminal.
(red–red)
• Between relay unit coupler (fuel
pump relay) and diode 2 coupler.
(red/white–red/white)
• Between diode 2 coupler and
engine stop switch coupler.
(black/red–black/red)
3
Malfunction or open circuit in relay
unit (fuel pump relay).
• Execute the diagnostic mode.
(Code No. 09)
• Replace if defective.
• If there is no malfunction with
the relay unit (fuel pump relay),
replace the ECU.
Fault code No.
44
Diagnostic code No.
Reinstatement
method
Symptom Error is detected while reading or writing on EEPROM (CO
adjustment value).
60
EEPROM improper cylinder indication
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
• Execute the diagnostic mode.
(Code No. 60)
1. Check the faulty cylinder. (If
multiple cylinders are defective, the number of the faulty
cylinders appears alternately at 2-second intervals.)
• Replace ECU if defective.
Turning the
main switch to
“ON”.
Malfunction in ECU.
7-59
FUEL INJECTION SYSTEM
Fault code No.
46
Diagnostic code No.
Symptom Power supply to the fuel injection system is not normal.
—
—
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Main wire harness ECU coupler
• Check the coupler for any pins Starting the enthat may be pulled out.
gine and oper• Check the locking condition of
ating it at idle.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Faulty battery.
• Replace or charge the battery
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
3
Malfunction in rectifier/regulator
• Replace if defective.
Refer to “CHARGING SYSTEM” on page 7-13.
4
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between battery and main fuse
(red–red)
• Between main fuse and main
switch
(red–red)
• Between main switch and ignition fuse
(brown/blue–brown/blue)
• Between ignition fuse and ECU
(red/white–red/white)
Fault code No.
50
Diagnostic code No.
Reinstatement
method
Symptom Faulty ECU memory. (When this malfunction is detected in
the ECU, the fault code number might not appear on the
meter.)
—
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Replace the ECU.
Turning the
main switch to
“ON”.
Malfunction in ECU.
NOTE:
Do not perform this procedure
with the main switch turned to
“ON”.
7-60
FUEL INJECTION SYSTEM
Fault code No.
Er-1 Symptom No signals are received from the ECU.
Diagnostic code No.
—
—
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Main wire harness ECU coupler
• Main wire harness meter assembly
coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between meter assembly coupler and ECU coupler
(yellow/blue–yellow/blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
Fault code No.
Reinstatement
method
Er-2 Symptom No signals are received from the ECU within the specified
duration.
Diagnostic code No.
—
—
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Main wire harness ECU coupler
• Main wire harness meter assembly
coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between meter assembly coupler and ECU coupler
(yellow/blue–yellow/blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
7-61
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
Er-3 Symptom Data from the ECU cannot be received correctly.
Diagnostic code No.
—
—
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Main wire harness ECU coupler
• Main wire harness meter assembly
coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between meter assembly coupler and ECU coupler
(yellow/blue–yellow/blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
Fault code No.
Reinstatement
method
Er-4 Symptom Non-registered data has been received from the meter.
Diagnostic code No.
—
—
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Main wire harness ECU coupler
• Main wire harness meter assembly
coupler
• Check the coupler for any pins Turning the
that may be pulled out.
main switch to
• Check the locking condition of
“ON”.
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between meter assembly coupler and ECU coupler
(yellow/blue–yellow/blue)
3
Malfunction in meter assembly.
Replace the meter assembly.
4
Malfunction in ECU.
Replace the ECU.
7-62
Reinstatement
method
(GRAY)
WW W
7-63
B
Br
W
W
W
Br B
B R/
Br
B
(BLACK)
Y Br
B
R
B
Y
Br
A B
Br L
ON
OFF
(BLACK)
(BLACK)
B
Br
LB LY
(GRAY)
/Y L B
(GRAY)
R
R
Br L
B
R
R
B
L
Br L L/B
L/Y
B
R
L
A
L
B
Br/L
Y
A
Y
R/W
R
Br
R
B
L W W/B
(BLACK)
B
W/B L W
R/W B R
G/ L/B
B
R
L
R/Y
L
RY
Br
R/Y
Y
R/W
R/W R/W R/W R/W
R R/Y
(BLACK)
B/R R W
L/B G/L
Y
Br
RY
Br/L
L
B
Br/L
B
R
R/G
R
R/B
B
R
R
L Y
R
R
B/R
RY
L
R/W
WB
L/W
L/W
BY
L
B
L/B
L/B
B
(BLACK)
L Y B
B
B
Sb
Sb
Sb W
L Y/G B L
(BLACK)
B/L P/Y L
(BLACK)
B/L P W L
B LB
LB B
G/L
R/L
L/Y L R
R
Sb
RW
LG
L
Y
L
B
B/L
Y/G
L
L
P/Y
B/L
L
PW
B/L
B
Y
L
Gy B/L
R
B/R
B
Y
L
L
Y
Y
B G
G
/L
B /W
(GRAY)
Ch Dg
P B
Y/R
(GRAY)
B
Y
Br
(BLACK)
B B
G Y /B
(GRAY)
Y B
B
Br B
B
(BLACK)
Br W B/L
B/L
Y/B
B
Br
B
B
(BLACK)
L/Y B Y
G
B
GW
W L
B
Br
R/Y
R/Y
GL
L W/Y
B/L
B
R/L
R/W L W R/L
Sb B/Y Sb W
(BLUE)
Y
(BLACK)
(GRAY)
B /W
Dg Ch
B P
Y/R
(GRAY)
(GRAY)
B
B/L
Gy
B/Y L/Y
G B G/Y
(BLUE)
G
GL
(BLACK)
B
B L/G
L G L/Y
(BLUE)
B Gy
B
B B
(BLUE)
L/R R/Y
LG
B/R
R/W
B
Ch
Y/B
G/L
Y
Br B Br
B /W
G
Ch
GL
B/L
L
W/Y
G/W B
RL B
B
Dg
Ch
Dg
(L)
N
(R)
Dg
Ch
Dg
Br/W
YR
B /W Y/R
B
Br
Y/G
BY
RL
L/R
RB
RB
Br W
Br
P/W
PY
L/W
BL
Y
L
W/Y
R/W
L/B
Gy
B
B
G
Gy Y B
yR
yR
O
O
B
B
WY YR
P
Br
Br W
W/Y
PUSH
B
Ch L
G/B
GY
P
Br
(BLACK)
B/Br B
B/Br
B
P
Br
L Ch
Ch L
B
B
(GRAY) (GRAY)
G
Gy
YB
Gy/G
Gy/W
YL
WR
B/G
BR
R/G
P/L
WG
Br L
O
O
Gy/R
Gy/R
B
Dg L
R/B
R/B
R/B
R/B
R/B
R/B
B
B/W
W/G R B G
/L R B P L
RG
PL
W/G
Br/L
L Dg
Dg L
B
B
(BLACK) (BLACK)
R/G D R/G
P/L D P/L
W/G D W G
B /L D Br/L
Gy/R C Gy R
Gy/R C Gy R
Gy G L/B
Br W P Y W/R L
R L R W R/B B Br P L B/L R G B/Y
L W W/Y
Y G Br
Gy R/B B Br Y L Y Br/L W/G
P/W L R
Gy W B/R
B/G
G
B
B G
B
G
G B G
Gy B Gy
B/G
B/R
Gy R
B/R
Gy R
B/R
O
W
Gy/W
R/L
(BLACK)
Gy/W R L
Gy/G B L
BL
B B
W L
WG
(GRAY)
B
(DARK GRAY)
W B
W
W
W G
(BLACK)
L W/R B L
BG BR
Gy/G
Gy
G
L
WR
B/L
B/R
B/R
C
B/R
O
B/R
W
W
Y
Dg
Ch
L
G/B
R/G
Y/L
G/W
G
R/W
G/Y
B
L
Dg
B
G
W
Br
B
Dg
B
L
Ch
Y
Br
B
G Gy
W W
(BLACK)
B
L
(BLACK)
R G R/B W/G
P L R/B B /L
(BLACK)
GY
G/B
(BLACK)
(BLACK)
GB
GY
(BLACK)
Dg L Y
Ch Sb W R/W
R/G G W Y/L
B G
Y/L G W R G
G B
Sb/W
SUB W RE HARNESS2
L Y
B
SUB W RE HARNESS4
D
Y L Dg
R W Sb Ch
W RE HARNESS
Y
W RE HARNESS
(BLACK)
W G R B R/G
Br/L R B P L
SUB W RE HARNESS3
Gy R B/R Gy R
W RE HARNESS
(BLACK)
C
SUB W RE HARNESS2
B
SUB W RE HARNESS1
A
Gy B R Gy R
W RE HARNESS
Gy
W
W RE HARNESS
Ch
Y
FUEL PUMP SYSTEM
EAS27550
FUEL PUMP SYSTEM
EAS27560
CIRCUIT DIAGRAM
FUEL PUMP SYSTEM
3. Main switch
4. Main fuse
6. Battery
7. Fuel injection system fuse
11.Relay unit
13.Fuel pump relay
15.Diode 2
17.Fuel pump
27.ECU (electronic control unit)
68.Engine stop switch
77.Ignition fuse
81.ECU fuse
7-64
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Rider seat bracket assembly
4. Left side cover
5. Headlight assembly
1. Check the fuses.
(Main, fuel injection system, ignition
and ECU)
Refer to “CHECKING THE FUSES” on page 7-75.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
Replace the main switch.
OK ↓
4. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 7-71.
NG →
The engine stop switch is faulty. Replace
the right handlebar switch.
OK ↓
5. Check the relay unit (fuel pump relay).
Refer to “CHECKING THE RELAYS” on page 7-79.
NG →
Replace the relay unit.
OK ↓
6. Check the diode 2.
Refer to “CHECKING THE DIODES” on page 7-81.
NG →
Replace the diode 2.
OK ↓
7. Check the fuel pump.
Refer to “CHECKING THE FUEL
PUMP” on page 7-89.
NG →
Replace the fuel pump assembly.
OK ↓
7-65
FUEL PUMP SYSTEM
8. Check the entire fuel pump system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-63.
NG →
Properly connect or repair the fuel pump
system wiring.
OK ↓
Replace the ECU.
7-66
ELECTRICAL COMPONENTS
EAS27970
ELECTRICAL COMPONENTS
3
4
6
1
5
2
7
8
14
9
13
10
12
11
7-67
ELECTRICAL COMPONENTS
1. Cylinder-#2 right ignition coil
2. Cylinder-#2 left ignition coil
3. Fuel sender
4. Engine temperature sensor
5. Cylinder-#1 left ignition coil
6. Cylinder-#1 right ignition coil
7. ECU (electronic control unit)
8. EXUP servo motor
9. Speed sensor
10. Rectifier/regulator
11. Neutral switch
12. Horn 2
13. Horn 1
14. ISC (idle speed control) unit
7-68
ELECTRICAL COMPONENTS
2
4
3
5
1
6
18
10
8
17
11
12
13
7
14
16
15
9
7-69
ELECTRICAL COMPONENTS
1. Air temperature sensor
2. Main switch
3. Cylinder-#2 intake air pressure sensor
4. Throttle position sensor
5. Cylinder-#1 intake air pressure sensor
6. Fuse box
7. Starter relay
8. Fuel injection system fuse
9. Battery
10. Diode 2
11. Turn signal relay
12. Headlight relay
13. Relay unit
14. Diode 1
15. Main fuse
16. Lean angle cut-off switch
17. Crankshaft position sensor
18. Rear brake light switch
7-70
ELECTRICAL COMPONENTS
EAS27980
CHECKING THE SWITCHES
1
R Br L/Y L/B
R
ON
Br
OFF
L/B L/Y
(GRAY)
13
Y
G
G/L
(BLUE)
Ch Br/W Dg B Y/R
B
2
B
R/W B/R
(L)
B B
G/Y G/B
(GRAY)
(R)
R/W B/R
G/L L/B
3
P B
Y/R
(GRAY)
12
G/Y G/B
L/W W/B
L/W W/B
(BLACK)
4
Ch Dg
Br/W
(GRAY)
PUSH
11
L/B G/L
Y G/L G
5
10
B P
9
Br
Y
L/Y B/Y
B
B
(BLACK)
6
B
B
8
7
B B
(BLACK)
B
B B
(BLUE)
7-71
ELECTRICAL COMPONENTS
1. Main switch
2. Engine stop switch
3. Start switch
4. Accessory light switch
5. Front brake light switch
6. Neutral switch
7. Sidestand switch
8. Rear brake light switch
9. Clutch switch
10. Horn switch
11. Dimmer switch
12. Select switch
13. Turn signal switch
7-72
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“
”. There is continuity between red and brown, blue/yellow and blue/black when the switch is
set to “ON”.
b
R Br L/Y L/B
a
ON
OFF
R
Br
7-73
L/B L/Y
ELECTRICAL COMPONENTS
1. Remove:
• Bulb
EAS27990
CHECKING THE BULBS AND BULB
SOCKETS
EW1D71009
WARNING
NOTE:
Do not check any of the lights that use LEDs.
Since headlight bulbs get extremely hot,
keep flammable products and your hands
away from them until they have cooled
down.
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity
between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb, bulb
socket or both.
EC1D71006
CAUTION:
• Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
• Avoid touching the glass part of a 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.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration.
• Bulbs “a” and “b” are used for the headlights
and usually use a bulb holder that must be detached before removing the bulb. The majority
of these types of bulbs can be removed from
their respective socket by turning them counterclockwise.
• Bulbs “c” are 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.
2. Check:
• Bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
7-74
ELECTRICAL COMPONENTS
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. If the pocket tester indicates “∞”, replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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.
3. Replace:
• Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Fuses
Amperage
rating
Q’ty
Main
50 A
1
Ignition
25 A
1
Headlight
20 A
1
Fuel injection system
15 A
1
Signaling system
10 A
1
Taillight
10 A
1
ECU
10 A
1
Backup (odometer and
clock)
10 A
1
Auxiliary DC connector
3A
1
Spare
25 A
1
Spare
20 A
1
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28000
CHECKING THE FUSES
The following procedure applies to all of the fuses.
Spare
15 A
1
CAUTION:
Spare
10 A
1
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.
Spare
3A
1
EC1D71019
EWA13310
WARNING
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Fuse
Never use a fuse with an amperage rating
other than that specified. Improvising or using a fuse with the wrong amperage rating
may cause extensive damage to the electri-
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a. Connect the pocket tester to the fuse and
check the continuity.
7-75
ELECTRICAL COMPONENTS
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
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NOTE:
4. Install:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
EAS28030
CHECKING AND CHARGING THE BATTERY
EWA13290
WARNING
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• ECU band “1”
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
1
3. Remove:
• Coupler tray “1”
1
4. Disconnect:
• Battery leads
(from the battery terminals)
EC1D71020
CAUTION:
ECA13640
CAUTION:
• This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries.
The MF battery should be charged according to the instructions for the charging
method. If the battery is overcharged, the
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
7-76
ELECTRICAL COMPONENTS
1
2
5. Remove:
• Battery
6. Check:
• Battery charge
A. Open-circuit voltage (V)
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
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a. Connect a pocket tester to the battery terminals.
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal
7. Charge:
• Battery
(refer to the appropriate charging method illustration)
NOTE:
Do not quick charge a battery.
EWA13300
WARNING
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
ECA13670
CAUTION:
• Never remove the MF battery sealing caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause battery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehicle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded battery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
7-77
ELECTRICAL COMPONENTS
• If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached
Replace the battery.
d. Adjust the voltage so that the current is at the
standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
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A.
B.
C.
D.
E.
Open-circuit voltage (V)
Time (minutes)
Charging
Ambient temperature 20 °C (68 °F)
Check the open-circuit voltage.
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Charging method using a constant voltage charger
a. Measure the open-circuit voltage prior to
charging.
NOTE:
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Voltage should be measured 30 minutes after
the engine is stopped.
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
b. Connect a charger and ammeter to the battery and start charging.
c. Make sure that the current is higher than the
standard charging current written on the battery.
NOTE:
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the battery and start charging.
NOTE:
If the current is lower than the standard charging
current written on the battery, this type of battery
charger cannot charge the MF battery. A variable voltage charger is recommended.
NOTE:
Set the charging voltage at 16–17 V. If the setting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
d. Charge the battery until the battery’s charging voltage is 15 V.
c. Make sure that the current is higher than the
standard charging current written on the battery.
NOTE:
NOTE:
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
Set the charging time at 20 hours (maximum).
If the current is lower than the standard charging
current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the
amperage for 3–5 minutes to check the battery.
7-78
ELECTRICAL COMPONENTS
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
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8. Install:
• Battery
9. Connect:
• Battery leads
(to the battery terminals)
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminals as shown.
Check the relay operation.
Out of specification → Replace.
ECA13630
CAUTION:
Starter relay
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
3
NOTE:
R
Be sure to route the negative battery lead towards the front of the vehicle and to install the
negative terminal cover “3” securely.
R
R/Y
L
B
2
2
1
4
3
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
1
Result
Continuity
(between “3” and “4”)
10.Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
11.Lubricate:
• Battery terminals
Relay unit (starting circuit cut-off relay)
3
Recommended lubricant
Dielectric grease
1 2
4
12.Install:
• Coupler tray
• ECU band
NOTE:
Make sure the leads are routed correctly.
1.
2.
3.
4.
13.Install:
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity
(between “3” and “4”)
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, replace the relay.
7-79
+
ELECTRICAL COMPONENTS
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Relay unit (fuel pump relay)
3
1.
2.
3.
4.
1
2
a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown.
4
+
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
brown “1”
• Negative tester probe →
ground
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity
(between “3” and “4”)
Headlight relay
3
4
b. Turn the main switch to “ON”.
c. Measure the turn signal relay input voltage.
+
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2
2. Check:
• Turn signal relay output voltage
Out of specification → Replace.
1
Y/B
Br
G/L
R/Y
1.
2.
3.
4.
Turn signal relay output voltage
DC 12 V
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
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a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Result
Continuity
(between “3” and “4”)
• Positive tester probe →
brown/white “1”, yellow/red “2” or white/yellow “3”
• Negative tester probe →
ground
ET1D71011
CHECKING THE TURN SIGNAL RELAY
1. Check:
• Turn signal relay input voltage
Out of specification → The wiring circuit from
the main switch to the turn signal relay coupler is faulty and must be repaired.
Turn signal relay input voltage
DC 12 V
7-80
ELECTRICAL COMPONENTS
Continuity
Positive tester probe → sky blue
“1”
Negative tester probe →
black/yellow “2”
No continuity
Positive tester probe →
black/yellow “2”
Negative tester probe → sky
blue “1”
Continuity
Positive tester probe → sky blue
“1”
Negative tester probe →
blue/yellow “3”
No continuity
Positive tester probe →
blue/yellow “3”
Negative tester probe → sky
blue “1”
Continuity
Positive tester probe → sky blue
“1”
Negative tester probe → sky
blue/white “4”
No continuity
Positive tester probe → sky
blue/white “4”
Negative tester probe → sky
blue “1”
Continuity
Positive tester probe →
blue/green “5”
Negative tester probe →
blue/yellow “3”
No continuity
Positive tester probe →
blue/yellow “3”
Negative tester probe →
blue/green “5”
b. Turn the main switch to “ON”.
c. Measure the turn signal relay output voltage.
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EAS28050
CHECKING THE DIODES
Relay unit (diode)
1. Check:
• Relay unit (diode)
Out of specification → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
The pocket tester or the analog pocket tester
readings are shown in the following table.
5 3 1
2 4
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a. Disconnect the relay unit from the wire harness.
b. Connect the pocket tester (Ω × 1) to the relay
unit terminals as shown.
7-81
ELECTRICAL COMPONENTS
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continuity.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
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Diode 1
1. Check:
• Diode 1
Out of specification → Replace.
NOTE:
The pocket tester and the analog pocket tester
readings are shown in the following table.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Continuity
Positive tester probe →
red/white “1”
Negative tester probe →
black/red “2”
No continuity
Positive tester probe →
black/red “2”
Negative tester probe →
red/white “1”
NOTE:
The pocket tester and the analog pocket tester
readings are shown in the following table.
Continuity
Positive tester probe → red/yellow “1”
Negative tester probe →
red/white “2” or red/white “3”
No continuity
Positive tester probe →
red/white “2” or red/white “3”
Negative tester probe → red/yellow “1”
1
R/W
B/R
2
2
3
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a. Disconnect the diode 2 from the wire harness.
b. Connect the pocket tester (Ω × 1) to the diode
2 terminals as shown.
c. Check the diode 2 for continuity.
d. Check the diode 2 for no continuity.
R/W R/W
R/Y
1
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a. Disconnect the diode 1 from the wire harness.
b. Connect the pocket tester (Ω × 1) to the diode
1 terminals as shown.
c. Check the diode 1 for continuity.
d. Check the diode 1 for no continuity.
ET1D71012
CHECKING THE IGNITION SPARK GAP
1. Check:
• Ignition spark gap
Out of specification → Perform the ignition
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
7-4.
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Diode 2
1. Check:
• Diode 2
Out of specification → Replace.
Minimum ignition spark gap
6.0 mm (0.24 in)
NOTE:
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
7-82
ELECTRICAL COMPONENTS
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a. Disconnect the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as shown.
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
c. Measure the spark plug cap resistance.
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EAS28100
CHECKING THE IGNITION COILS
The following procedure applies to all of the ignition coils.
1. Check:
• Primary coil resistance
Out of specification → Replace.
2. Spark plug cap
Primary coil resistance
2.16–2.64 Ω
c. Turn the main switch to “ON” and engine stop
switch to “ ”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the start switch
“ ” and gradually increase the spark gap until a misfire occurs.
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a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the ignition coil as shown.
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Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EAS28070
CHECKING THE SPARK PLUG CAPS
The following procedure applies to all of the
spark plug caps.
1. Check:
• Spark plug cap resistance
Out of specification → Replace.
• Positive tester probe →
black/red “1”
• Negative tester probe →
orange or gray/red “2”
Resistance
10.0 kΩ
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a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
c. Measure the primary coil resistance.
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2. Check:
• Secondary coil resistance
Out of specification → Replace.
7-83
ELECTRICAL COMPONENTS
• Positive tester probe →
gray “1”
• Negative tester probe →
black “2”
Secondary coil resistance
8.64–12.96 kΩ
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a. Disconnect the spark plug cap from the ignition coil.
b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
B Gy
2
• Negative tester probe →
black/red “1”
• Positive tester probe →
spark plug lead “2”
1
b. Measure the crankshaft position sensor resistance.
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EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
• Lean angle sensor
2. Check:
• Lean angle sensor output voltage
Out of specification → Replace.
Lean angle sensor output voltage
Less than 65°: 0.4–1.4 V
More than 65°: 3.7–4.4 V
c. Measure the secondary coil resistance.
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a. Connect the lean angle sensor coupler to the
wire harness.
b. Connect the pocket tester (DC 20 V) to the
lean angle sensor coupler as shown.
EAS28120
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crankshaft position sensor.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
yellow/green “1”
• Negative tester probe →
black/blue “2”
Crankshaft position sensor resistance
248–372 Ω
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a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
7-84
ELECTRICAL COMPONENTS
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
• Stator coil coupler
(from the rectifier/regulator)
2. Check:
• Stator coil resistance
Out of specification → Replace the stator coil.
Stator coil resistance
0.112–0.168 Ω
c. Turn the lean angle sensor to 65°.
d. Measure the lean angle sensor output voltage.
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a. Connect the pocket tester (Ω × 1) to the stator
coil coupler as shown.
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Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
ET1D71013
CHECKING THE STARTER MOTOR
OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 5.
Refer to “TROUBLESHOOTING” on page
7-11.
• Positive tester probe →
white “1”
• Negative tester probe →
white “2”
• Positive tester probe →
white “1”
• Negative tester probe →
white “3”
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a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING
• Positive tester probe →
white “2”
• Negative tester probe →
white “3”
• 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 no flammable gas or
fluid is in the vicinity.
W W W
1 2 3
b. Measure the stator coil resistance.
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EAS28170
b. Check the starter motor operation.
CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltage
Out of specification → Replace the rectifier/regulator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-85
ELECTRICAL COMPONENTS
• Positive tester probe →
horn terminal “1”
• Negative tester probe →
horn terminal “2”
Charging voltage
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the cylinder-#1
left spark plug lead or right spark plug lead.
b. Connect the pocket tester (DC 20 V) to the
rectifier/regulator coupler as shown.
A
1
2
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
red “1”
• Negative tester probe →
black “2”
R
W W W
1
B
B
1
2
A. Horn 1
B. Horn 2
2
c. Measure the horn resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Start the engine and let it run at approximately 5000 r/min.
d. Measure the charging voltage.
2. Check:
• Horn sound
Faulty sound → Adjust or replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS28180
a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b”
until the horn sound is obtained.
CHECKING THE HORNS
1. Check:
• Horn resistance
Out of specification → Replace.
Coil resistance
0.94–0.98 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn 1 connectors and horn 2
coupler from the horn terminals.
b. Connect the pocket tester (Ω × 1) to the horn
terminals.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
7-86
ELECTRICAL COMPONENTS
A
3
a
b
1
2
b. Immerse the engine temperature sensor “1”
in a container filled with water “2”.
B
NOTE:
a
b
Make sure that the engine temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to
the specified temperature.
e. Measure the engine temperature sensor resistance.
A. Horn 1
B. Horn 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Engine temperature sensor
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28210
T.
CHECKING THE ENGINE TEMPERATURE
SENSOR
1. Remove:
• Engine temperature sensor
(from the front cylinder head)
R
Engine temperature sensor
20 Nm (2.0 m·kg, 14 ft·lb)
ET1D71014
CHECKING THE FUEL SENDER (FUEL
TANK)
1. Remove:
• Fuel sender
(from the fuel tank)
2. Check:
• Fuel sender resistance
Out of specification → Replace.
EWA14140
WARNING
• Handle the engine temperature sensor with
special care.
• Never subject the engine temperature sensor to strong shocks. If the engine temperature sensor is dropped, replace it.
2. Check:
• Engine temperature sensor resistance
Out of specification → Replace.
Fuel sender (fuel tank)
Sender unit resistance (full)
9–11 Ω
Sender unit resistance (empty)
213–219 Ω
Engine temperature sensor resistance
0.90–1.10 kΩ at 100 °C (212 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
fuel sender coupler as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1 k) to the engine temperature sensor terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
7-87
ELECTRICAL COMPONENTS
• Positive tester probe →
green “1”
• Negative tester probe →
black “2”
2
b. Move the fuel sender float to maximum
“3”/minimum “4” level position.
1
G/W
B
R/L
B
3
1
2
b. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
G B
ET1D71044
CHECKING THE FUEL LEVEL WARNING
LIGHT
This model is equipped with a self-diagnosis device for the fuel level detection circuit.
1. Check:
• Fuel level warning light “1”
(Turn the main switch to “ON”.)
Warning light comes on for a few seconds,
then goes off → Warning light is OK.
Warning light does not come on → Replace
the meter assembly.
Warning light flashes eight times, then goes
off for three seconds in a repeated cycle (malfunction detected in fuel sender or thermistor)
→ Replace the fuel pump assembly.
4
c. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71015
CHECKING THE FUEL SENDER (FUEL
PUMP)
1. Drain the fuel.
2. Disconnect:
• Fuel pump coupler
(from the fuel pump)
3. Remove:
• Fuel pump
(from the sub-fuel tank)
4. Check:
• Fuel sender resistance
Out of specification → Replace the fuel pump
assembly.
Fuel sender resistance
0.90–2.05 kΩ
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the fuel
sender terminals as shown.
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
Out of specification → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
• Positive tester probe →
green/white “1”
• Negative tester probe →
black “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown.
7-88
ELECTRICAL COMPONENTS
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2
• Positive tester probe →
white “1”
• Negative tester probe →
black “2”
1
B Y L
b. Measure the throttle position sensor maximum resistance.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
W
L
3. Install:
• Throttle position sensor
L W/Y
B
NOTE:
B/ L
When installing the throttle position sensor, adjust its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page
6-12.
2
b. Turn the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage of white and black. With
each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V
to 0.6 V to 4.8 V.
EAS28350
CHECKING THE FUEL PUMP
EWA13850
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28300
CHECKING THE THROTTLE POSITION
SENSOR
1. Remove:
• Throttle position sensor
(from the throttle body)
2. Check:
• Throttle position sensor maximum resistance
Out of specification → Replace the throttle
position sensor.
Resistance
4.0–6.0 kΩ/blue-black
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 refueling.
• 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
the engine is completely cool before performing the following test.
1. Disconnect:
• Fuel pump coupler
(from the fuel pump)
2. Check:
• Fuel pump operation
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the
throttle position sensor terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose “1” into an open
container.
c. Connect the battery (DC 12 V) to the fuel
pump terminals as shown.
• Positive tester probe →
blue “1”
• Negative tester probe →
black “2”
7-89
ELECTRICAL COMPONENTS
ECA14390
• Positive battery lead →
red/blue “2”
• Negative battery lead →
black “3”
3
CAUTION:
To prevent damaging the EXUP servo motor,
perform this test within a few seconds of
connecting the battery.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28410
CHECKING THE INTAKE AIR PRESSURE
SENSOR
The following procedure applies to both of the intake air pressure sensors.
1. Check:
• Intake air pressure sensor output voltage
Out of specification → Replace.
B
G/W B
R/L
1
d. Check the fuel pump operation.
Intake air pressure sensor output
voltage
3.75–4.25 V
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28360
CHECKING THE EXUP SERVO MOTOR
1. Check:
• EXUP servo motor operation
Out of specification → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
a. Disconnect the EXUP cables from the EXUP
servo motor pulley.
b. Disconnect the EXUP servo motor coupler
from the wire harness.
c. Connect the battery leads to the EXUP servo
motor terminals as shown.
For counterclockwise rotation “a”
• Positive battery lead →
black/green “1”
• Negative battery lead →
black/red “2”
For clockwise rotation “b”
• Positive battery lead →
black/red “2”
• Negative battery lead →
black/green “1”
1
• Positive tester probe →
pink/white “1” or pink/yellow
• Negative tester probe →
black/blue “2”
2
B/L P/W L
2
b. Turn the main switch to “ON”.
c. Measure the intake air pressure sensor output voltage.
b
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
L W/R B/L
B/G B/R
ET1D71016
CHECKING THE AIR TEMPERATURE
SENSOR
1. Remove:
• Air temperature sensor
d. Check that the EXUP servo motor pulley rotates several times in directions “a” and “b”.
7-90
ELECTRICAL COMPONENTS
EW1D71004
WARNING
• Handle the air temperature sensor with
special care.
• Never subject the air temperature sensor to
strong shocks. If the air temperature sensor is dropped, replace it.
2. Check:
• Air temperature sensor resistance
Out of specification → Replace.
Air temperature sensor resistance
290–390 Ω at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the air
temperature sensor terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
3
1
2
b. Immerse the air temperature sensor “1” in a
container filled with water “2”.
NOTE:
Make sure that the air temperature sensor terminals do not get wet.
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to
the specified temperature.
e. Measure the air temperature sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-91
TROUBLESHOOTING
TROUBLESHOOTING .................................................................................... 8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES ............................................................................. 8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY GEAR SHIFTING ....................................................................... 8-2
SHIFT PEDAL DOES NOT MOVE............................................................ 8-2
JUMPS OUT OF GEAR ............................................................................ 8-2
FAULTY CLUTCH ..................................................................................... 8-2
OVERHEATING ........................................................................................ 8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS.................................................................. 8-3
UNSTABLE HANDLING............................................................................ 8-3
FAULTY LIGHTING OR SIGNALING SYSTEM........................................ 8-4
8
TROUBLESHOOTING
• Sucked-in air
EAS28450
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
4. Ignition coil(s)
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
5. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
6. Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections
7. Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty relay unit (starting circuit cut-off relay)
• Faulty starter clutch
EAS28460
GENERAL INFORMATION
NOTE:
The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this
manual for checks, adjustments, and replacement of parts.
EAS28470
STARTING FAILURES
Engine
1. Cylinder(s) and cylinder head(s)
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston(s) and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
EAS28490
INCORRECT ENGINE IDLING SPEED
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel filter
• Clogged fuel tank overflow/breather hose
• Clogged rollover valve
• Clogged rollover valve hose
• Deteriorated or contaminated fuel
2. Fuel pump
• Faulty fuel pump
• Faulty relay unit (fuel pump relay)
3. Throttle body(-ies)
• Deteriorated or contaminated fuel
Engine
1. Cylinder(s) and cylinder head(s)
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Throttle body(-ies)
• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
8-1
TROUBLESHOOTING
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
• Improper throttle cable free play
• Flooded throttle body
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil(s)
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS28550
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
EAS28570
FAULTY CLUTCH
EAS28510
POOR MEDIUM AND HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURES” on page 8-1.
Clutch slips
1. Clutch
• Improperly assembled clutch
• Improperly assembled clutch master cylinder
• Improperly assembled clutch release cylinder
• Incorrect clutch fluid level
• Damaged clutch hose
• Loose or fatigued clutch spring
• Loose union bolt
• Worn friction plate
• Worn clutch plate
• Damaged clutch release cylinder
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
EAS28530
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to “Clutch drags”.
Clutch drags
1. Clutch
• Air in hydraulic clutch system
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
• Damaged clutch release cylinder
• Match marks not aligned
EAS28540
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
8-2
TROUBLESHOOTING
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS28590
OVERHEATING
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
Engine
1. Cylinder head(s) and piston(s)
• Heavy carbon buildup
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Fuel system
1. Throttle body(-ies)
• Faulty throttle body(-ies)
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
EAS28670
UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
EAS28620
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS28660
FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
8-3
TROUBLESHOOTING
• Faulty turn signal relay
• Burnt-out turn signal bulb
EAS28710
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main switch)
• Burnt-out headlight bulb
Horn does not sound
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Headlight bulb life expired
Tail/brake light does not come on
• Wrong tail/brake light LED
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light LED
Tail/brake light LED burnt out
• Wrong tail/brake light LED
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light LED life expired
Turn signal does not come on
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
Turn signal flashes slowly
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
Turn signal remains lit
• Faulty turn signal relay
• Burnt-out turn signal bulb
Turn signal flashes quickly
• Incorrect turn signal bulb
8-4
XV19SW(C)/XV19W(C)/XV19MW(C)/XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C) 2007 WIRING DIAGRAM
15
A
11
12
13
16
WIRE HARNESS SUB WIRE HARNESS1
17
(BLUE)
18
28
32
29
32
B
(BLUE)
C
14
WIRE HARNESS SUB WIRE HARNESS2
C
C
32
31
32
C
4
2
1
30
19
24
(BLACK)
(GRAY)
(BLACK)
D
D
D
D
33
5
D
20
3
E
E
E
27
DD
(BLACK)
7
ON
OFF
(GRAY)
(BLACK)
WIRE HARNESS SUB WIRE HARNESS3
(BLACK)
21
8
6
(GRAY)
(BLACK)
34
22
10
9
(BLACK)
WIRE HARNESS SUB WIRE HARNESS4
(BLACK)
25
(BLACK)
35
(BLACK)
B
B
E
(GRAY)
B
26
WIRE HARNESS SUB WIRE HARNESS2
B
B
36
(BLACK)
(DARK GRAY)
B
23
81
37
(BLACK)
80
79
38
78
76
75
51
77
(BLACK)
49
50
39
48
52
66
74
41
53
55
(BLACK)
68
69
70
(BLUE)
(BLUE)
56
54
57
(BLACK)
58
42
(BLACK)
67
(GRAY)
(GRAY)
(GRAY)
(GRAY)
43
44
(BLACK)
(BLACK)
71
A
45
46
(GRAY)
(GRAY)
47
A
72
63
73
A
A
64
(BLACK)
(BLACK)
65
62
61
60
(GRAY)
A
(BLACK)
PUSH
(L)
N
(R)
(BLACK)
40
59
(GRAY)
(BLACK) (BLACK)
(BLACK)
(BLACK)
EAS28740
WIRING DIAGRAM
XV19SW(C)/XV19W(C)/
XV19MW(C)/XV19CTSW(C)/
XV19CTW(C)/XV19CTMW(C)
2007
1. AC magneto
2. Rectifier/regulator
3. Main switch
4. Main fuse
5. Backup fuse (odometer and
clock)
6. Battery
7. Fuel injection system fuse
8. Starter relay
9. Starter motor
10. Diode 1
11. Relay unit
12. Starting circuit cut-off relay
13. Fuel pump relay
14. Neutral switch
15. Diode 2
16. Sidestand switch
17. Fuel pump
18. Fuel sender (fuel pump)
19. Crankshaft position sensor
20. Throttle position sensor
21. Cylinder-#1 intake air pressure
sensor
22. Cylinder-#2 intake air pressure
sensor
23. Lean angle sensor
24. Speed sensor
25. Air temperature sensor
26. Engine temperature sensor
27. ECU (electronic control unit)
28. Cylinder-#1 left ignition coil
29. Cylinder-#1 right ignition coil
30. Cylinder-#2 left ignition coil
31. Cylinder-#2 right ignition coil
32. Spark plug
33. ISC (idle speed control) unit
34. EXUP servo motor
35. Injector #1
36. Injector #2
37. O2 sensor
38. Meter assembly
39. Neutral indicator light
40. Multi-function meter
41. Reset switch
42. Engine trouble warning light
43. Fuel level warning light
44. Meter light
45. Left turn signal indicator light
46. Right turn signal indicator light
47. High beam indicator light
48. Fuel sender (fuel tank)
49. Horn 1
50. Horn 2
51. Turn signal relay
52. Headlight relay
53. Left handlebar switch
54. Clutch switch
55. Dimmer switch
56. Turn signal switch
57. Horn switch
58. Select switch
59. Front right turn signal/position
light
60. Front left turn signal/position
light
61. Rear right turn signal light
62. Rear left turn signal light
63. Headlight assembly
64. Headlight (high beam)
65. Headlight (low beam)
66. Right handlebar switch
67. Front brake light switch
68. Engine stop switch
69. Start switch
70. Accessory light switch
71. Accessory light (OPTION)
72. Tail/brake light
73. License plate light
74. Rear brake light switch
75. Auxiliary DC coupler
76. Auxiliary DC connector fuse
77. Ignition fuse
78. Headlight fuse
79. Signaling system fuse
80. Taillight fuse
81. ECU fuse
EAS28750
COLOR CODE
B
Br
Ch
Dg
G
Gy
L
O
P
R
Sb
W
Y
B/Br
B/G
B/L
B/R
B/Y
Br/L
Br/W
G/L
G/R
G/W
G/Y
Gy/G
Gy/R
Gy/W
L/B
L/G
L/R
L/W
L/Y
P/L
P/W
P/Y
R/B
R/G
R/L
R/W
R/Y
Sb/W
W/B
W/G
W/R
W/Y
Y/B
Y/G
Y/L
Y/R
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Orange
Pink
Red
Sky blue
White
Yellow
Black/Brown
Black/Green
Black/Blue
Black/Red
Black/Yellow
Brown/Blue
Brown/White
Green/Blue
Green/Red
Green/White
Green/Yellow
Gray/Green
Gray/Red
Gray/White
Blue/Black
Blue/Green
Blue/Red
Blue/White
Blue/Yellow
Pink/Blue
Pink/White
Pink/Yellow
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
Sky blue/White
White/Black
White/Green
White/Red
White/Yellow
Yellow/Black
Yellow/Green
Yellow/Blue
Yellow/Red
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
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