Yamaha Motorcycle FJR1300(N) User manual

Yamaha Motorcycle FJR1300(N) User manual
2001
FJR1300(N)
5JW1-AE1
SERVICEMANUAL
FJR1300R
5JW9-AE1
5JW–28197–20
SERVICE MANUAL
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
@
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
1
EAS00008
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical system
9 Troubleshooting
CHAS
5
6
ENG
COOL
7
8
FI
–
ELEC
9
Symbols 0 to G indicate the following.
0
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum disulfide oil
K Wheel bearing grease
L Lithium soap base grease
M Molybdenum disulfide grease
New
N Apply locking agent (LOCTITE®)
O Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
FI
7
–
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
Notice: This enhanced version has been prepared for persons who already own a copy of
the FJR Service Manual. The enhancements are distributed as freeware for the FJR
Owner's community. If you find them useful, please donate 5 or 10 units of your local
currency to a motorcycle charity or related event.
GEN
INFO
1
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL CODE .......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE ...................................................................................................1-2
FI SYSTEM................................................................................................1-3
COMPONENTS......................................................................................... 1-5
FUEL INJECTION SYSTEM.................................................................... 1-17
THREE-WAY CATALYTIC CONVERTER SYSTEM...............................1-26
AIR INDUCTION SYSTEM...................................................................... 1-30
COMPONENTS....................................................................................... 1-31
IMPORTANT INFORMATION ....................................................................... 1-35
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-35
REPLACEMENT PARTS.........................................................................1-35
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-35
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-36
BEARINGS AND OIL SEALS .................................................................. 1-36
CIRCLIPS ................................................................................................1-36
CHECKING THE CONNECTIONS.......................................................... 1-37
SPECIAL TOOLS .......................................................................................... 1-38
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL CODE
The model code label 1 is affixed to the
frame. This information will be needed to order
spare parts.
1-1
FEATURES
GEN
INFO
FEATURES
OUTLINE
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 that
is used in the respective chamber.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to
realize cleaner exhaust gases.
1 Ignition coil
2 Air filter case
3 Intake temperature
sensor
4 Fuel delivery hose
5 Fuel tank
6 Fuel pump
7 Fuel return hose
8 Intake air pressure
sensor
9 Throttle position sensor
0 Fuel injector
A O2 sensor
B Catalytic converter
C Crankshaft position
sensor
D Coolant temperature
sensor
E Spark plug
F Cylinder identification sensor
G Pressure regulator
H Battery
I ECU
J Atmospheric pressure
sensor
K Fuel injection system
relay
1-2
L Engine trouble warning light
M Lean angle cut-off
switch
N Air cut-off valve
FEATURES
GEN
INFO
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the injector at only 2.55 kg/cm2 higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the 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 injector is energized (injection duration),
the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the 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, atmospheric
pressure sensor, intake temperature sensor, coolant temperature 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 and the cylinder identification 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.
#4 #3 #2 #1
1 Fuel pump
2 Pressure regulator
3 Fuel injector
4 Throttle body
5 Intake temperature
sensor
6 Throttle position sensor
7 Intake air pressure
sensor
8 ECU
9 Atmospheric pressure
sensor
0 Coolant temperature
sensor
A O2 sensor
B Cylinder identification
sensor
C Crankshaft position
sensor
1-3
È Fuel system
É Air system
Ê Control system
FEATURES
GEN
INFO
Fuel control block
The fuel control block consists of the following main components:
Control block
Sensor block
Actuator block
Component
Function
ECU
Total FI system control
Throttle body
Air volume control
Pressure regulator
Fuel pressure detection
Intake air pressure sensor
Intake air pressure detection
Atmospheric pressure sensor
Atmospheric pressure detection
Coolant temperature sensor
Coolant temperature detection
Intake temperature sensor
Intake temperature detection
Throttle position sensor
Throttle angle detection
O2 sensor
Gas emission O2 concentration detection
Cylinder identification sensor
Reference position detection
Crankshaft position sensor
Crankshaft position detection and engine
RPM detection
Speed sensor
Speed detection
Injector
Fuel injection
Fuel pump
Fuel feed
Air Induction system, air cut valve
Induction of secondary air
An FI warning light is provided on meter panel.
1-4
FEATURES
GEN
INFO
COMPONENTS
ECU (Electronic Control Unit)
The ECU is mounted underneath the seat, below the toolbox. The main functions of the ECU are
ignition control, fuel control, self-diagnosis, and load control.
• ECU’s internal construction and functions
The main components and functions of the ECU can be broadly divided into the following four
items:
A. Power supply circuit
The power supply circuit obtains power from the battery (12 V) to supply the power (5 V) that is
required for operating the ECU.
B. Input interface circuits
The input interface circuits convert the signals output by all the sensors into digital signals,
which can be processed by the CPU, and input them into the CPU.
C. CPU (Central Processing Unit)
The CPU determines the condition of the sensors in accordance with the level of the signal that
is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the
CPU. Based on those stored signals and the basic processing program on the ROM, the CPU
calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits.
D. Output interface circuits
The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the
indicator and relay output circuits as needed.
ECU
Input
interface circuit
Hall sensor
signal
(for cylinder
identification)
Pickup coil signal
(for identifying the
crankshaft position)
Switches
Waveform
shaping circuit
Battery
Power
supply
circuit
CPU
Output
interface circuit
Injector drive
output circuit
Injector
Waveform
shaping circuit
Ignition output circuit
Digital input circuit
Lamp drive
output circuit
Indicating lamp
Relay drive
output circuit
Relay
Ignition coil
RAM/ROM
MEMORY
Sensors
A/D converter
input circuit
1-5
FEATURES
GEN
INFO
• Ignition control
The ignition control function of the ECU controls the ignition timing and the duration of ignition
energizing. The ignition timing control uses the signals from the throttle position sensor (to detect
the angle of the throttle), and the crankshaft position sensor and speed sensor (to detect the
speed of the engine). This control establishes an ignition timing that suits the operating condition
of the engine through compensations made to the basic ignition timing control map. The ignition
energizing duration control establishes the energizing duration to suit the operating conditions by
calculating the energizing duration in accordance with the signal received from the crankshaft
position sensor and the battery voltage.
• Fuel control
The fuel control function of the ECU controls the injection timing and injection duration. The injection timing control controls the injection timing during the starting of the engine and the injection
timing during the normal operation of the engine, based on the signals received from the crankshaft position sensor and the cylinder identification sensor. The injection duration control determines the duration of injection based on the signals received from the atmospheric pressure
sensors, temperature sensors, and the position sensors, to which compensations are made to suit
various conditions such as the weather, atmospheric pressure, starting, acceleration, and deceleration.
• Load control
The ECU effects load control in the following manner:
1. Stopping the fuel pump and injectors when the motorcycle overturns
The ECU turns OFF the fuel injection system relay when the lean angle cut-off switch is tripped.
2. Operating the headlight illumination relay
On the model for Europe, the ECU causes the headlight relay 2 to output a constant ON signal,
provided that the main switch is ON. On the model for Australia, the ECU controls the headlight
relay 2 in accordance with the engine speed as required by the daytime illumination specification.
3. Operating the radiator fan motor in accordance with the coolant temperature
The ECU controls the radiator fan motor relay ON/OFF in accordance with the coolant temperature.
4. Operating the AI system solenoid valve
The ECU controls the energizing of the solenoid valve in accordance with the driving conditions.
• Self-diagnosis function
The ECU is equipped with a self-diagnosis function to ensure that the engine control system is
operating normally. The ECU mode functions include a diagnosis mode in addition to the normal
mode.
Normal mode
• To check for any blown bulbs, this mode illuminates a warning light while the main switch is
turned ON, and while the starter switch is being pressed.
• If the starting disable warning is activated, this mode alerts the rider by blinking the warning light
while the start switch is being pressed.
• If a malfunction occurs in the system, this mode provides an appropriate substitute characteristic
operation, and alerts the rider of the malfunction by illuminating a warning light. After the engine
is stopped, this mode displays a fault code on the clock LCD.
Diagnosis mode
• In this mode, a diagnostic code is input into the ECU through the operation of the operating
switch on the meter, and the ECU displays the values output by the sensors or actuates the
actuators in accordance with the diagnostic code. Whether the system is operating normally can
be checked by observing the illumination of the warning light, the values displayed on the meter,
or the actuating state of the actuators.
1-6
FEATURES
GEN
INFO
Fuel pump
The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it
to the injector.
A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel
system downstream of the pump.
The pump consists of a pump unit, electric motor, filter, and valves.
The pump unit is a Wesco type rotary pump that is connected to the motor shaft.
A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose
becomes clogged. This valve opens when the fuel pressure at the discharge outlet reaches
between 440 and 640 kpa, and returns the fuel to the fuel tank.
1 Fuel filter
2 Fuel inlet strainer
3 Outlet
È Fuel
1-7
FEATURES
GEN
INFO
Pressure regulator
It regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order
to maintain a constant pressure difference with the pressure in the intake manifold.
The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator
and exerts pressure on the diaphragm in the direction for opening the valve.
A spring that is provided in the spring chamber exerts pressure on the diaphragm in the direction for
closing the valve, in contrast to the pressure of the fuel. Thus, the valve cannot open unless the fuel
pressure overcomes the spring force.
An intake vacuum is applied to the spring chamber via a pipe. When the pressure of the fuel
exceeds the sum of the intake vacuum and the spring force, the valve that is integrated with the diaphragm opens, allowing the fuel to return from the fuel outlet to the fuel tank, via the fuel return
hose.
As a result, because the intake vacuum fluctuates in accordance with the changes in the operating
conditions in contrast to the constant volume of fuel supplied by the pump, the valve opening/closing pressure also changes to regulate the return fuel volume. Thus, the difference between the fuel
pressure and the intake manifold pressure remains constant at a prescribed pressure.
1 Spring chamber
2 Spring
3 Diaphragm
4 Fuel inlet
5 Fuel outlet
6 Fuel chamber
7 Valve
8 Intake manifold vacuum pressure
1-8
È Spring pressure
É Fuel pressure
Ê Vacuum pressure
FEATURES
GEN
INFO
Fuel injector
Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the
core is pressed downward by the force of the spring, as illustrated. The needle that is integrated
with the bottom of the core keeps the fuel passage closed.
When the current flows to the coil in accordance with the signal from the ECU, the core is drawn
upward, allowing the flange that is integrated with the needle to move to the spacer. Since the distance of the movement of the needle is thus kept constant, the opening area of the fuel passage
also becomes constant. Because the pressure difference of the fuel to the intake manifold pressure
is kept constant by the pressure regulator, the fuel volume varies in proportion to the length of time
the coil is energized. The injector that has been recently adopted has a four-hole type injection orifice that enhances the atomization of fuel and improves combustion efficiency.
1 Fuel
2 Coil
3 Core
4 Spacer
5 Needle
6 Inject
7 Flange
1-9
FEATURES
GEN
INFO
F
5˚
W
5J
5
7T
56
Crankshaft position sensor
The crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side
of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the
projections on the rotor to pass by the pickup coil, an electromotive force is generated in the coil.
The voltage of this force is then input into the ECU, which calculates the position of the crankshaft
and the speed of the engine. The ignition timing is then determined in accordance with the calculated data, in order to determine the corresponding injection timing. Based on the changes in the
time intervals of the signals generated by the pickup coil, the ECU calculates the ignition timing
advance to suit the operating conditions. The injection timing is also advanced in accordance with
the ignition timing in order to supply fuel to the engine at an optimal timing.
180˚
180˚
180˚
1 Pickup rotor
È Direction of rotation
É #1 cylinder compression stroke, 5° BTDC
Ê Pickup signal
Ë Trigger pole
1 - 10
180˚
FEATURES
GEN
INFO
Cylinder identification sensor
The cylinder identification sensor is mounted on the exhaust head cover of the #4 cylinder. When
the exhaust cam of the #4 cylinder rotates and the lift of the cam passes by the sensor, the sensor
generates a signal and sends it to the ECU. Based on this signal and the signal from the crankshaft
position sensor, the ECU then actuates the injector of the cylinder that is currently in order to supply
fuel.
180˚
180˚
180˚
180˚
#1
#2
#4
#3
1 Cylinder identification
sensor
2 Cam
È Cam lift
É Crankshaft position
sensor signal
Ê Cylinder identification
sensor signal
Ë Cylinder firing order
Ì #4 cam lobe onto
exhaust camshaft
Í Combustion
1 - 11
Î Exhaust
Ï Injection
Ð Intake
Ñ Compression
Ò Ignition
FEATURES
GEN
INFO
Throttle position sensor
The throttle position sensor measures the intake air volume by detecting the position of the throttle
valve. It detects the mechanical angle of the throttle valve through the positional relationship
between the moving contact that moves in unison with the throttle shaft and the resistor board. In
actual operation, the ECU supplies 5 V power to both ends of the resistor board and the voltage that
is output by the throttle position sensor is used to determine the angle of the throttle valve.
50
40
30
20
10
0.68 V
10°
5°
95°
100°
110°
1 Moving contact
2 Resistor board
3 Spring
È Output voltage
É Idling output position
Ê Mechanical stopper
Ë Mechanical stopper
Ì Effective electrical
angle
Í Sensor operating
angle
1 - 12
5°
FEATURES
GEN
INFO
Intake air pressure sensor and atmospheric pressure sensor
• Intake air pressure sensor
The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of
every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be
measured by measuring the intake air pressure. The intake air pressure sensor converts the measured intake air pressure into electrical signals and sends those signals to the ECU. When the intake
air pressure is introduced into the sensor unit, which contains a vacuum chamber on one side of the
silicon diaphragm, the silicon chip that is mounted on the silicon diaphragm converts the intake air
pressure into electrical signals. Then, an integrated circuit (IC) amplifies and adjusts the signals and
makes temperature compensations, in order to generate electrical signals that are proportionate to
the pressure.
• Atmospheric pressure sensor
The atmospheric pressure sensor is used for making compensations to the changes in the air
density caused by the changes in the atmospheric pressure (particularly at high altitudes). The
operating principle and function of the atmospheric pressure sensor are the same as those of the
aforementioned intake air pressure sensor.
(V)
P
1 EMI shield
2 Sensor unit
3 Through condenser
4 Hybrid IC
5 Cap
6 Silicon diaphragm
7 Vacuum chamber
8 Solder
9 Silicon chip
0 Gold wire
A Lead pin
È Output voltage
B Stem
É Input pressure
C Pressure induction pipe
D Atmospheric pressure,
intake air pressure
1 - 13
GEN
INFO
FEATURES
Coolant temperature sensor
The signals from the coolant temperature sensor are used primarily for making fuel volume compensations during starting and warm-up. The coolant temperature sensor converts the temperature of
the coolant into electrical signals and sends them to the ECU.
15.5
0.322
-20
1 Connector
2 Terminal
3 Tube
4 Thermistor
0
20
40
5 Holder
60
80
È Resistance kΩ
É Temperature °C
Intake temperature sensor
The intake temperature sensor corrects the deviation of the air-fuel mixture that is associated with
the changes in the intake air density, which are created by the changes in the intake air temperature
that occur due to atmospheric temperatures. This sensor uses a semi-conductor thermistor that has
a large resistance at low temperatures and a small resistance at high temperatures. The thermistor
converts the temperature-dependent changes in resistance into electrical resistance values, which
are then input into the ECU.
6.0
0.34
-20
1 Connector
2 Terminal
3 Tube
4 Thermistor
5 Holder
È Resistance kΩ
É Temperature °C
1 - 14
0
20
40
60
80
FEATURES
GEN
INFO
O2 sensor
The O2 sensor has been adopted to enable the catalyst to function at a high degree of efficiency by
maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirconia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concentration levels. In actual operation, a zirconia tube made of solid electrolyte is exposed in the exhaust
gas, so that the exterior of the zirconia tube is in contact with the exhaust gas and the interior is in
contact with the atmosphere whose oxygen concentration level is known. When a difference in the
oxygen concentration level is created between the outside and the inside of the zirconia tube, the
oxygen ion passes through the zirconia element and generates an electromotive force. The electromotive force increases when the oxygen concentration level is low (rich air-fuel ratio) and the electromotive force decreases when the oxygen concentration level is high (lean air-fuel ratio). As
electromotive force is generated in accordance with the concentration of the exhaust gas, the resultant voltage is input into the ECU in order to correct the duration of the injection of fuel.
1 Inner cover
2 Outer cover
3 Zirconia tube
4 Exhaust gas
5 Atmosphere
È Atmosphere
É Inner electrode
Ê Zirconia element
1 - 15
Ë Outer electrode
Ì Porous ceramic layer
Í Exhaust gas
FEATURES
GEN
INFO
Lean angle cut-off switch
The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns.
When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approximately 1.0 V (low level). When the motorcycle tilts, the float in the switch tilts in proportion to the tilt
of the motorcycle. However, the voltage output to the ECU remains unchanged at the low level.
When the tilt of the motorcycle exceeds 70 degrees (according to the tilt of the float), the signal from
the sensor increases to approximately 4.0 V (high level). When the ECU receives the high-level voltage, it determines that the motorcycle has overturned, and stops the delivery of fuel to the engine by
turning OFF the fuel injection system relay that powers the fuel pump and the injectors. Once the
cut-off switch is tripped, the ECU maintains this state; therefore, even if the motorcycle has recovered its upright position, this state will not be canceled unless the main switch is turned OFF, and
then turned back ON.
°
70
V
4.0
1.0
20° 40° 60° 80°
70°
1 Thyristor
2 IC unit
3 O-ring
4 Shaft
5 Float
È Output voltage
É High level
Ê Low level
Ë Cut-off switch tilt angle
Ì Fuel injection system
relay OFF
1 - 16
70
°
FEATURES
GEN
INFO
FUEL INJECTION SYSTEM
Operation and control
The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are controlled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volume
through the signals from the intake air pressure sensor, throttle position sensor, cylinder identification sensor, and crankshaft position sensor.
Furthermore, the ECU calculates the final injection timing by adding the following compensations to
the aforementioned basic injection duration: those obtained from the state of acceleration, as well
as those based on the signals from various sensors such as the coolant temperature, intake temperature, atmospheric, and exhaust pipe oxygen concentration level. At the same time, the ECU
assesses the crankshaft position through the signals from the cylinder identification sensor and the
crankshaft position sensor. Then, when the ECU determines that it is time to inject fuel, it sends an
injection command to the injectors. Furthermore, the ECU also controls the length of time the coil is
energized by calculating the ignition timing and the coil energizing duration based on the signals
from these sensors.
Determining the basic injection duration
The intake air volume determines the basic injection duration. In order to operate the engine in an
optimal condition, it is necessary to supply fuel at an air-fuel ratio that corresponds appropriately to
the volume of intake air that is constantly changing, and to ignite it an appropriate timing. The ECU
controls the basic injection duration based on the intake air volume and engine speed data.
Detection of intake air volume
The intake air volume is detected primarily through the signals from the throttle position sensor and
the intake air pressure sensor. The intake air volume is determined in accordance with the signals
from the atmospheric pressure sensor, intake temperature sensor, and the engine speed data.
Composition of basic injection duration
È RPM
É Injection duration
Ê Cranking
Ë Warm-up
Ì Idle
Í Acceleration
Î Constant
Ï Deceleration
Ð Start
1 - 17
Ñ After start
Ò Basic injection duration
Ó Voltage compensation
duration
FEATURES
GEN
INFO
Determining the final injection duration
The intake air volume determines the basic injection duration. However, at a given intake air volume, the volume of fuel that is required varies by the engine operating conditions such as acceleration or deceleration, or by weather conditions. This system uses various sensors to precisely check
these conditions, applies compensations to the basic injection duration, and determines the final
injection duration based on the operating condition of the engine.
Intake air pressure
Engine rpm
Degree of
opening of
throttle
Atmospheric
pressure
Basic injection
quantity
Compensation
Water
temperature
Battery voltage
Injection
command
Intake air
temperature
The fuel is cut off under conditions that do not require fuel, in order to stop the injection.
1 - 18
FEATURES
GEN
INFO
Composition of final injection duration
1 Injection at start *1
2 After-start enrichment
*2
3 Warm-up enrichment
*3
4 Acceleration compensation *5
5 Oxygen feedback *6
6 Fuel cut-off
Deceleration compensation *5
7 Basic injection duration
8 Voltage compensation
duration
Ð Start
Ñ After start
È RPM
É Injection duration
Ê Cranking
Ë Warm-up
Ì Idle
Í Acceleration
Î Constant
Ï Deceleration
Reactive injection duration:
A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time
the injector actually opens. Therefore, the ECU calculates this lag in advance before sending the
actuation signal to the injector. The battery voltage determines the reactive injection duration.
• High voltage → short reactive injection duration
• Low voltage → long reactive injection duration
LIST OF FUEL INJECTION COMPENSATIONS
Compensation item
Starting injection *1
Check item
Sensor used
Coolant temperature
Coolant temperature sensor
After-start enrichment *2
Coolant temperature
Coolant temperature sensor
Warm-up enrichment *3
Coolant temperature
Coolant temperature sensor
Intake temperature compensation *4
Intake temperature
Intake temperature sensor
Acceleration compensation/decelera- Intake air pressure
tion compensation *5
Intake air pressure sensor
After-start injection:
Throttle position
Throttle position sensor
Coolant temperature
Coolant temperature sensor
Air-fuel ratio feedback compensation Exhaust gas residual oxy- O2 sensor
*6
gen concentration
1 - 19
GEN
INFO
FEATURES
Fuel control during normal driving
In synchronous injection during normal driving, fuel is injected on a cylinder-by-cylinder basis when
all of the conditions below are met:
1 Other than the stop mode
2 Cylinder identification completed
3 Other than overrun
To determine the injection timing, the ECU calculates the injection timing through the use of the 3D
control map provided in the ECU, which is based on the throttle position and the engine speed.
The injection duration is based on the basic injection duration (obtained through the throttle position,
intake air pressure, and engine speed) to which injection duration compensation (based on the signals from various sensors such as the intake temperature sensor, atmospheric pressure sensor,
and O2 sensor) is added to determine the final injection duration. As a result, fuel is supplied to the
cylinders.
• Normal synchronous injection
#2
1 Injector #1
2 Injector #2
3 Injector #3
#4
#3
#1
4 Injector #4
È Cylinder identification
signal
#2
#4
#3
É Crankshaft identification signal
Ê Injection
#1
Ë Stop
• Fuel injection control during normal driving
È #1 cylinder fuel injection timing
É Basic injection duration
Ê Various types of fuel
Ë Synchronous injection
injection duration comduration (final injecpensations
tion duration)
1 - 20
FEATURES
GEN
INFO
Fuel injection compensation control
• Starting injection control
The coolant temperature is used for determining the injection duration in order to ensure proper
start ability. To suit the engine’s operating conditions, the starting injection duration is determined by
applying a starting compensation coefficient to the basic injection duration, which forms the basis of
the injection duration.
(Starting injection duration = basic injection duration × injection compensation coefficient)
During starting, injection cylinder control is effected together with injection duration compensation.
To effect injection cylinder control, the injectors of all the cylinders inject fuel only once immediately
upon receiving the signals from the sensors during the cranking of the engine. This is called asynchronous injection, in contrast to synchronous injection, which is a normal cylinder injection that is
effected on a cylinder-by-cylinder basis.
After the asynchronous injection is completed, and until the ECU receives signals from the cylinder
identification sensor, the injectors are actuated in pairs in sync with the signals from the crankshaft
position sensor: cylinders #1 and 4, and cylinders #2 and 3. Controlling both the injection duration
and the injection cylinders in this manner enables a precise supply of fuel in accordance with the
starting conditions of the engine.
• Starting injection duration
0
1 Basic injection duration
2 After-start compensation injection duration
3 Low
4 High
È Injection duration
É Coolant temperature
Ê Extended duration
1 - 21
(˚C)
FEATURES
GEN
INFO
• Starting cylinder control
#1/4
1 Injectors #1,4
2 Injectors #2,3
3 Starting asynchronous injection
4 Group injection
È Cylinder identification
sensor
É Crankshaft position
sensor
Ê Injection
Ë Stop
Ì Synchronous injection
• After-start enrichment
After-start enrichment provides enrichment compensation during a prescribed duration following the
starting (firing) of the engine. While the amount of fuel enrichment is determined by the after-start
enrichment coefficient, the coefficient varies by the coolant temperature. Although the coolant temperature determines the initial starting enrichment coefficient, the coefficient subsequently changes
in accordance with the damping factor. The enrichment ratio is the highest immediately after the
engine is started, and diminishes gradually. The enrichment of fuel in this manner ensures a stable
engine operation immediately after the engine is started.
Changes in compensation coefficient and compensation injection duration
Engine speed
Stopped
Long
Injection
duration
Cranking
Initial starting enrichment
coefficient
(determined by coolant
temperature)
After-start enrichment
Basic injection
duration
Short
Starting enrichment coefficient
Changes in compensation coefficient
1 - 22
Duration
Compensation injection
duration
FEATURES
GEN
INFO
• Warm-up enrichment
When the coolant temperature is low, a warm-up coefficient is applied in accordance with the signals from the coolant temperature sensor in order to effect fuel enrichment. Because the coolant
temperature determines the coefficient, the coefficient changes with the fluctuations in the coolant
temperature. The coefficient increases with the decrease in the coolant temperature, and decreases
with the increase in the coolant temperature. The ratio of fuel enrichment also changes with the
changes in the coefficient.
Small
Enrichment
coefficient
Large
Changes in compensation coefficient and compensation injection duration
Long
Short
1.0
60
Injection
duration
Warm-up enrichment
Basic injection duration
Duration
(˚C)
Coolant temperature
Low
High
Changes in compensation coefficient
1 - 23
Compensation injection duration
FEATURES
GEN
INFO
• Acceleration enrichment
Acceleration enrichment is provided in accordance with the signals from the throttle position sensor.
As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throttle position sensor actuates in unison with the accelerator. The ECU interprets that acceleration has
taken place through the throttle position sensor signal and executes acceleration enrichment. The
enrichment volume is determined by the acceleration enrichment coefficient. The coefficient
increases with the changes in the throttle position sensor, which also increases the actual enrichment volume. The enrichment volume is executed in accordance with the acceleration enrichment
coefficient when the movement of the throttle position sensor has met the acceleration condition as
defined by the ECU. Thereafter, the enrichment volume is regulated by the coefficient that changes
in accordance with the damping rate.
(Acceleration injection duration = basic injection duration × acceleration compensation coefficient)
Changes in compensation coefficient and compensation injection duration
Changes in acceleration
compensation coefficient
Acceleration enrichment volume
Large
Long
Changes in
throttle position
sensor angle
Injection
duration
Small
Basic injection duration
Short
Duration
Duration
Starting of acceleration
Starting of acceleration
Compensation injection duration
1 - 24
FEATURES
GEN
INFO
• Deceleration control
Deceleration control is effected in accordance with the signals from the throttle position sensor. As
the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position
sensor acutates in unison with the accelerator. When the engine speed is greater than a prescribed
value with the throttle fully closed (thus applying engine braking), the ECU executes a deceleration
fuel cut-off. The injection of fuel to all the cylinders is stopped when fuel cut-off control is executed,
thus improving fuel economy.
È Engine speed
É Duration
Ê Fuel cut-off control (stopping fuel injection)
Ë Basic injection duration
Ì Basic injection duration
• Over-revving control
This function effects fuel cut-off control when the engine speed becomes greater than the prescribed value. The fuel cut-off control regulates the engine speed by stopping the injection of fuel
into two cylinders when the engine speed becomes greater than the specified value. If the engine
speed increases further, this control stops the injection of fuel to all the cylinders. Thus, the overrevving control effects fuel cut-off control in two stages.
1 - 25
FEATURES
GEN
INFO
THREE-WAY CATALYTIC CONVERTER SYSTEM
System outline
This is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint
effort by the FI system, O2 sensor, and the three-way catalytic converter system. By effecting comprehensive control of the air-fuel ratio in this manner, this system reduces the CO, HC, and NOx in
the exhaust gases.
The FI system controls the mixture to an optimal air-fuel ratio (basic air-fuel ratio) that matches the
operating condition of the engine in order to realize an ideal combustion.
Furthermore, an O2 sensor that detects the concentration of oxygen that remains in the exhaust gas
is provided in the exhaust pipe for the purpose of maximizing the performance of the three-way catalytic converter and to clean the exhaust gas at a high degree of efficiency. Based on this data, the
ECU applies more precise compensation to the basic air-fuel ratio, in order to maintain the mixture
in the vicinity of the stoichiometric air-fuel ratio of 14.7:1.
Through the joint effort of these control systems, the exhaust gas is cleaned in a highly efficient
manner without sacrificing engine performance.
Three-way catalytic converter system diagram
1 Ignition coil
2 Injector
3 Intake temperature
sensor
4 Throttle position sensor
5 Intake air pressure 9 Cylinder identification
sensor
sensor
0 Spark plug
6 Crankshaft position
sensor
A ECU
7 O2 sensor
8 Coolant temperature
sensor
1 - 26
B Igniter
C Atmospheric pressure
sensor
D Catalytic converter
FEATURES
GEN
INFO
Functions of components
Three-way catalytic
converter system
Equipment
Functions
Main components
Catalyzer (honeycomb
type)
Simultaneously reduces
CO, HC, and NOx emissions.
• Catalytic converter
• Catalyst case
Air-fuel compensation
equipment
Reduces CO, HC, and NOx • O2 sensor
emissions. The catalyst pri- • ECU
marily cleans the exhaust
gases in order to ensure
the stoichiometric air-fuel
ratio.
Fuel cut-off equipment
Reduces CO and HC emis- • Throttle position sensor
sions, improves fuel econ- • ECU
omy, and cuts off fuel
during deceleration.
Catalyst
Because the conditions in which NOx is generated are directly opposed to those of CO and HC,
there is a limit to the extent to which the concentration levels of these harmful elements can be
reduced in the combustion stage. Hence, the function of the catalyst is to clean the exhaust gas at a
high degree of efficiency by removing CO, HC, and NOx in the exhaust stage.
This model has adopted a monolith type metallic catalyst with a honeycomb construction, which
achieves a low exhaust resistance through the large surface area of the catalyst body (with a high
level of cleaning efficiency).
Catalytic substances consisting of precious metals such as platinum and rhodium are adhered to
the wall surface of these honeycomb cells, which are enclosed in the exhaust pipe. As the exhaust
gas comes in contact with these catalytic substances, the chemical reactions of oxidation and
reduction advance in order to clean the exhaust gas.
• The CO and HC oxidize with the oxidation function of platinum, and are converted into harmless
carbon dioxide (CO2) and water (H2O), resulting in cleaner exhaust gases.
CO + 1/2 O2
HC + O2
CO2
CO2 + H2O
• The NOx is reduced by the reduction function of rhodium, which converts NOx into harmless nitrogen (N2) and oxygen (O2), resulting in cleaner exhaust gases.
NOx
N2 + O2
To clean the exhaust gases at a high rate of efficiency through the maximization of these catalytic
capacities, it is necessary to maintain and control the mixture in the vicinity of the stoichiometric airfuel ratio of (14.7:1) at all times. As a means of maintaining the stoichiometric ratio, this system has
adopted an O2 feedback compensation method that uses an O2 sensor, which will be described in
the next section.
1 - 27
FEATURES
GEN
INFO
Large amounts of both CO and HC are generated when the mixture is rich (as indicated by insufficient O2 region A). Conversely, large amounts of NOx are generated when the mixture is lean (as
indicated by excessive O2 region B). Under these conflicting characteristics, the system maintains
the mixture within an extremely narrow range C of stoichiometric ratio (14.7:1). As a result, the
function of the catalyst is maximized, making it possible to clean the exhaust gases at a high degree
of efficiency.
100
NOx
Conv. (%)
80
60
40
HC
20
CO
14.7
0 13
13.5
14
14.5
1 - 28
15
15.5
16
FEATURES
GEN
INFO
Air-fuel ratio compensation equipment
An O2 sensor is provided in the exhaust pipe upstream of the catalyst, to enable the catalyst to
operate at a high degree of efficiency. The O2 sensor detects the level of concentration of the oxygen remaining in the exhaust gases.
A high level of oxygen concentration signifies a lean air-fuel mixture, and when the O2 sensor
detects this condition, it inputs a lean signal into the ECU. Conversely, when the level of oxygen
concentration is low, the O2 sensor inputs a rich signal into the ECU.
The ECU system applies minute corrections to these signals so that the injection volume (the duration of the current applied to the injectors) comes to be within the vicinity of the stoichiometric ratio.
Thus, the system is designed to maximize the cleaning function of the catalyst.
Feedback compensation circuit
Illustration is for reference only.
Prolongs the duration of the current
applied to the injectors
Injection duration correction circuit
Shortens the duration of the current
applied to the injectors
Air-fuel ratio
judged as
lean
Air-fuel ratio
judged as
rich
Lean signal
Rich signal
Basic injection duration circuit
Signal from
various sensors
Injector
O2 sensor
È The ECU determines the basic injection volume based on the signals that are input from various sensors
and regulates the duration of the current applied to the injectors.
É Current is applied to the injectors, enabling them to inject fuel.
Ê The engine undergoes combustion and exhaust.
Ë The O2 sensor detects the level of oxygen concentration in the exhaust gases, and outputs a lean or rich
air-fuel ratio signal in accordance with the detected data.
Ì In accordance with the signals from the O2 sensor, the ECU applies minute corrections to the basic injection duration, determines the subsequent injection volume, and provides instructions to the injectors.
The above processes are repeated in order to maintain the mixture at the stoichiometric ratio.
1 - 29
FEATURES
GEN
INFO
1
2
3
4
AIR INDUCTION SYSTEM
The air induction system (AI system) introduces fresh air into the exhaust port in order to burn the
unburned gas (which is present in the exhaust gas) in the exhaust pipe. The burning of the
unburned gases in this manner enhances the efficiency of the catalyst and results in cleaner
exhaust gases.
The AI system takes a portion of the air from the air cleaner, sends it to the reed valve via the air
cut-off valve, and introduces it directly into the exhaust port through the reed valve.
The air cut-off valve is controlled by the signals from the ECU in accordance with the combustion
conditions. Ordinarily, the air cut-off valve opens to allow the air to flow during idle and closes to cut
off the flow when the motorcycle is being driven. However, if the coolant temperature is below the
specified value, the air cut-off valve remains open and allows the air to flow into the exhaust pipe
until the temperature becomes higher than the specified value.
The reed valve is provided on the cylinder head cover above the cylinders, and sends air to the
exhaust pipe through the inside of the cylinder head.
1 Air cut-off valve
2 Reed valve
3 Exhaust port
4 Resonator
1 - 30
FEATURES
GEN
INFO
COMPONENTS
1.Air cut-off valve
The air cut-off valve consists of a plunger that is mounted inside the core of a solenoid coil, and a
valve at the end of the plunger for opening and closing the air passage. Due to the force of a spring,
the valve is in constant contact with valve block A, and thus keeps the air passage open. As a result,
the air from the air cleaner passes through the air passage and flows into the reed valves of the cylinders. When the current flows to the solenoid coil in accordance with a signal from the ECU, the
plunger in the core becomes attracted towards the coil. When this attraction force overcomes the
pressure of the spring, the valve is pulled in along with the plunger, comes in contact with valve
block B, and closes the air passage. The ECU controls the operation of the air cut-off valve so that it
operates in an optimal condition to suit the driving conditions.
1 Valve block A
2 Valve
3 Spring
4 Coil
5 Core
6 Valve block B
1 - 31
È To reed valve
É From air cleaner
FEATURES
GEN
INFO
Instrument panel
Function indication
The indications of the self-diagnosis function can be checked and inspection operations can be performed through the use of the multi-function meter on the instrument panel.
Based on the signals received from the sensors, the ECU inputs the signals into the multi-function
meter. Then, the conditions of the sensors appear on the clock and trip/odometer display of the
multi-function meter.
1. ECU transmission data and meter display
Mode
Common to all
modes
Normal mode
ECU transmission data
Vehicle speed
Engine warning
indicator lamp
Self-diagnostic fault
code
Coolant temperature
CO/DIAG mode
selection
CO adjustment
mode
CO/DIAG selection
Meter indication
Trip meter
Indicator lamp
Clock LCD
Shows trouble code in numbers
Coolant temperature meter LCD
Clock LCD
CO adjustment
cylinder No.
CO adjustment volume
Clock LCD
Diagnostic code
Clock LCD
Diagnosis sensor value
Trip LCD
Display description
4 digits including decimals
ON/OFF
Coolant temperature
Shows CO or DIAG in letters
Shows adjustment cylinder No.
in numbers
Shows adjustment volume in
numbers
Shows diagnostic code in numbers
Shows data for sensors
Trip LCD
DIAG mode
Note: If the exchange of data between the ECU and the meters is abnormal, the clock LCD shows
error “Er-1~4”. The clock LCD reverts to showing the time after the error has been corrected.
180
200
220
240
F
260
280
L
Km/h
H
TRIP
km
mile
km
mile
TRIP
E ODO
SELECT
1 Fuel meter
2 Clock
3 Coolant temperature
meter
4 TRIP meter
RESET
5 TRIP/ODO meter
6 RESET button
7 SELECT button
1 - 32
8 Engine trouble warning light
9 Oil level warning light
FEATURES
GEN
INFO
2. DIAG and CO mode inspection and adjustment (multi-function meter)
Mode Selection (Make sure to disconnect the coupler from the fuel pump.)
CO/DIAG mode
1. While keeping both the SELECT and
RESET buttons pressed, turn “ON” the
main switch. Keep the buttons pressed for
8 seconds or more.
* All the segments are “OFF” except the
clock and the trip LCD.
* “DIAG” appears on the clock LCD.
Normal mode
Turn “ON” the main switch.
* The self-diagnostic function starts a system check.
System normal
Normal meter display
Switching between CO adjustment mode and
DIAG mode
1. Press the SELECT button in order to
switch the display to “CO” or “DIAG”.
2. Simultaneously press the SELECT and
RESET buttons for 2 seconds or more to
select an item.
CO adjustment mode
Enables the adjustment of CO for any of the
four cylinders by pressing the SELECT and
RESET buttons.
1. Adjustment cylinder selection
* Press the SELECT and RESET buttons to
select the cylinder.
* The adjustment cylinder appears on the
clock LCD.
* RESET button = decrement
* SELECT button = increment
* Execute the selection of the cylinder by simultaneously pressing the SELECT and RESET
buttons for approximately 2 seconds.
2. CO adjustment
* After selecting the adjustment cylinder,
change the adjustment volume by pressing
the SELECT and RESET buttons.
* The adjustment volume appears on the trip
LCD.
* RESET button = decrement
* SELECT button = increment
* The selection is executed upon releasing
the finger from the switch.
* Simultaneously press the SELECT and
RESET buttons to return to the cylinder
selection.
Cancel the mode by turning “OFF” the main
switch.
Malfunction detection
A fault code number
appears on the clock
LCD.
The engine trouble
warning light illuminates.
(The engine cannot be started in this mode.)
Diagnosis mode
Enables the verification of the operation of the
actuator and various sensors.
* Turn the engine stop switch to “OFF”.
(Turn it “ON” when the diagnostic code is
09 or 03.)
1. Press the SELECT and RESET buttons to
select the Diagnosis mode.
* RESET button = decrement
* SELECT button = increment
* A diagnostic code number appears on the
clock LCD.
2. Checking the operation of the actuator
* Turn “ON” the engine stop switch to start
the operation.
3. Checking the operation of various sensors
* The condition of the operation appears on
the TRIP LCD.
1 - 33
FEATURES
180
200
220
240
260
F
280
L
Km/h
H
TRIP
km
mile
km
mile
TRIP
E ODO
SELECT
1 Clock
2 TRIP meter
3 RESET button
4 SELECT button
5 Engine trouble warning light
1 - 34
RESET
GEN
INFO
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment. Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
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.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1 - 35
IMPORTANT INFORMATION
GEN
INFO
EAS00023
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.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium soap base grease.
Oil bearings liberally when installing, if appropriate.
1 Oil seal
CAUTION:
@
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1 - 36
IMPORTANT INFORMATION
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
@
4.
•
•
•
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
@
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
@
1 - 37
SPECIAL TOOLS
GEN
INFO
EAS00027
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.
Tool No.
Bolt
90890-01083
Weight
90890-01084
Tool name/Function
Slide hammer bolt
Weight
These tools are needed to remove the
main axle assembly.
Coupling gear/middle shaft tool
90890-01229
This tool is needed when removing or
installing the coupling gear nut.
Final gear backlash band
90890-01230
This tool is needed when measuring the
final gear backlash.
Rotor holding tool
90890-01235
This tool is needed to hold the camshaft
sprocket when loosen or tighten the
camshaft sprocket bolts.
Piston pin puller set
90890-01304
This tool is used to remove the piston
pin.
Tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Radiator cap tester adapter
This tester and its adapter are needed
for checking the cooling system.
Flywheel puller
Puller
90890-01362
This tool is needed to remove the rotor.
1 - 38
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Steering nut wrench
90890-01403
This tool is needed to loosen and
tighten the steering stem ring nut.
Oil filter wrench
90890-01426
This tool is needed to remove and
install the oil filter.
Fork seal driver
90890-01442
This tool is needed when installing the
slide metal, oil seal and dust seal into
the fork.
Gear lash measurement tool
90890-01467
This tool is needed when measuring the
middle gear backlash.
Damper rod holder
90890-01447
This tool is needed to hold the damper
rod assembly when loosen or tighten
the damper rod assembly bolt.
Pivot shaft wrench
90890-01471
This tool is needed to loosen or tighten
the spacer bolt.
Sheave holder
90890-01701
Gauge
90890-03081
Adapter
90890-04136
This tool is needed to hold the rotor
when removing or installing the rotor
bolt, starter clutch and pickup coil rotor
bolt.
Compression gauge
Compression gauge adapter
These tools are needed to measure
engine compression.
1 - 39
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Vacuum gauge
90890-03094
This gauge is needed for throttle bodies
synchronization.
Dial gauge
90890-03097
This tool is used to measure the middle
gear backlash.
Pocket tester
90890-03112
This instrument is needed for checking
the electrical system.
Pocket tester
90890-03132
This instrument is needed for checking
the engine oil temperature.
Exhaust attachment
90890-03134
This tool is needed for checking the CO.
Timing light
90890-03141
This tool is necessary for checking ignition timing.
Gauge
90890-03153
Oil pressure adaptor B
90890-03124
Compressor
90890-04019
Attachment
90890-04108
Pressure gauge
Oil pressure adaptor B
These tools are needed to measure
engine oil pressure.
Valve spring compressor
Valve spring compressor attachment
These tools are needed to remove and
install the valve assemblies.
1 - 40
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Bearing retainer wrench
90890-04050
This tool is needed when removing or
installing the final drive housing bearing
retainer.
Bearing retainer wrench
90890-04057
Driver
90890-04058
Installer
90890-04078
This tool is needed when removing or
installing the middle drive shaft bearing
retainer.
Middle driven shaft bearing driver
Mechanical seal installer
These tools are needed to install the
water pump seal.
Universal clutch holder
90890-04086
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.
Damper spring compressor
90890-04090
This tool is needed when removing or
installing the damper spring.
Valve guide remover (5 mm)
90890-04097
This tool is needed to remove and
install the valve guide.
Valve guide installer (5 mm)
90890-04098
This tool is needed to install the valve
guide.
Valve guide reamer (5 mm)
90890-04099
This tool is needed to rebore the new
valve guide.
1 - 41
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve lapper
90890-04101
This tool is needed to remove and
install the valve lifter.
Piston ring compressor
90890-05158
This tool is used to compress the piston
rings when installing the piston into the
cylinder.
Ignition checker
90890-06754
This tool is used to check the ignition
system components.
Vacuum/pressure pump gauge set
90890-06756
This tool used to measure the vacuum
pressure.
Engine tachometer
90890-06760
This tool is needed for observing engine
rpm.
Yamaha Bond No. 1215
90890-85505
This sealant (bond) is used on crankcase mating surfaces, etc.
Bearing retainer wrench
90890-04140
This tool is needed when removing or
installing the middle driven shaft bearing retainer.
Fuel pressure adapter
90890-03176
This tool is needed to measure fuel
pressure.
1 - 42
GEN
INFO
Illustration
SPEC
2
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
ENGINE SPECIFICATIONS ..........................................................................2-2
CHASSIS SPECIFICATIONS ....................................................................... 2-11
ELECTRICAL SPECIFICATIONS ................................................................2-15
CONVERSION TABLE ................................................................................. 2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS ..............................2-18
TIGHTENING TORQUES ............................................................................. 2-19
ENGINE TIGHTENING TORQUES ........................................................ 2-19
CHASSIS TIGHTENING TORQUES ......................................................2-23
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-25
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ............... 2-25
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ............2-27
OIL FLOW DIAGRAMS ................................................................................ 2-28
COOLING SYSTEM DIAGRAMS .................................................................2-38
CABLE ROUTING ........................................................................................ 2-42
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
5JW1 (for Europe)
5JW2 (for F)
5JW3 (for Oceania)
----------
2,195 mm
760 mm
1,420 mm
805 mm
1,515 mm
135 mm
3,100 mm
----------------------
268 kg
237 kg
208 kg
----------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Final gear oil
Recommended oil
Total amount
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
1,298 cm3
Forward-inclined parallel 4-cylinder
79.0 × 66.2 mm
10.8 : 1
1,000 ~ 1,100 r/min
33.3 kPa (250 mm Hg)
----------------------
1,600 kPa (16 kg/cm2, 16 bar)
at 400 r/min
----
Regular unleaded gasoline
----
25 L
5L
-------
Wet sump
----
SAE 20W40SE
SAE 10W40SE
-------
4.9 L
3.8 L
-------
4L
30 kPa at 1,000 r/min
(0.30 kg/cm2, 0.30 bar) at 1,000 r/min
490 ~ 570 kPa
(4.90 ~ 5.70 kg/cm2, 4.90 ~ 5.70 bar)
-------
Shaft drive gear oil
(Part No. : 9079E-SH001-00)
0.2 L
----
2-2
----
----
ENGINE SPECIFICATIONS
Item
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Valve relief pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
<From low to full level>
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
Starting system type
Spark plugs
Model (manufacturer) × quantity
Spark plug gap
Cylinder head
Volume
Max. warpage
Standard
Formed type
78.4 ~ 117.6 kPa
(0.78 ~ 1.18 kg/cm2, 0.78 ~ 1.18 bar)
Trochoid
0.09 ~ 0.15 mm
0.03 ~ 0.08 mm
SPEC
Limit
-------
---0.23 mm
0.15 mm
3.2 L
93.3 ~ 122.7 kPa
(0.93 ~ 1.23 kg/cm2, 0.93 ~ 1.23 bar)
4.9 kPa (0.05 kg/cm2, 0.05 bar)
----
360 mm
295.8 mm
27 mm
----------
0.485 L
0.15 L
-------
Single-suction centrifugal pump
75/48 × 25/28 (1.395)
---Electric starter
CR8E/U24ESR-N (NGK/DENSO) × 4
0.7 ~ 0.8 mm
22.74 ~ 23.34 cm3
----
2-3
-------
------0.15 mm
------------0.1 mm
ENGINE SPECIFICATIONS
Item
Standard
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap
clearance
Intake camshaft lobe dimensions
Chain drive (right)
24.500 ~ 24.521 mm
24.472 ~ 24.459 mm
0.028 ~ 0.062 mm
SPEC
Limit
-------------
C
A
B
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
33.05 ~ 33.15 mm
24.997 ~ 25.097 mm
32.05 mm
23.997 mm
33.05 ~ 33.15 mm
24.997 ~ 25.097 mm
----
32.95 mm
24.897 mm
0.03 mm
C
A
B
Measurement A
Measurement B
Max. camshaft runout
2-4
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
SPEC
Limit
RH2015/136
Automatic
-------
0.15 ~ 0.22 mm
0.18 ~ 0.25 mm
-------
B
C
D
A
Head Diameter
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
Seat Width
Margin Thickness
29.9 ~ 30.1 mm
25.9 ~ 26.1 mm
-------
1.2 ~ 2.0 mm
1.2 ~ 2.0 mm
-------
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
1.6 mm
1.6 mm
0.8 ~ 1.2 mm
0.5 ~ 0.9 mm
-------
4.975 ~ 4.990 mm
4.960 ~ 4.975 mm
4.945 mm
4.930 mm
5.000 ~ 5.012 mm
5.000 ~ 5.012 mm
5.05 mm
5.05 mm
0.010 ~ 0.037 mm
0.025 ~ 0.052 mm
----
0.08 mm
0.1 mm
0.01 mm
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
1.6 mm
1.6 mm
2-5
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
Standard
39.7 mm
39.7 mm
SPEC
Limit
37.7 mm
37.7 mm
33 mm
33 mm
-------
136 ~ 158 N (13.9 ~ 16.1 kgf)
136 ~ 158 N (13.9 ~ 16.1 kgf)
-------
-------
2.5° /1.7 mm
2.5° /1.7 mm
Clockwise
Clockwise
2-6
-------
ENGINE SPECIFICATIONS
Item
Standard
Cylinders
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
Pistons
Piston-to-cylinder clearance
Diameter D
SPEC
Limit
Forward inclined parallel 4-cylinder
79.0 × 66.2 mm
10.8 : 1
79.00 ~ 79.01 mm
-------
------------0.05 mm
0.05 mm
0.020 ~ 0.045 mm
78.965 ~ 78.980 mm
0.012 mm
----
H
D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
5 mm
----
19.004 ~ 19.015 mm
0.5 mm
Intake side
19.045 mm
-------
18.991 ~ 19.000 mm
0.004 ~ 0.024 mm
18.971 mm
0.074 mm
Barrel
1.0 × 2.8 mm
0.35 ~ 0.45 mm
0.03 ~ 0.07 mm
------0.7 mm
0.12 mm
Taper
1.0 × 2.9 mm
0.75 ~ 0.85 mm
0.02 ~ 0.06 mm
------1.2 mm
0.12 mm
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2-7
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
Small end inside diameter
Crankshaft
F
C
C
2.0 × 2.5 mm
0.2 ~ 0.6 mm
0.06 ~ 0.15 mm
----------
0.031 ~ 0.048 mm
----
1 = Blue 2 = Black 3 = Brown 4 = Green
5 = Yellow 6 = Pink
19.005 ~ 19.018 mm
-------
C
E
D
A
B
Width A
Width B
Max. runout C
Big end side clearance D
Big end radial clearance
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
Position of thrust bearing
Balancer
Balancer drive method
Clutch
Clutch type
Clutch release method
Operation
Clutch cable free play (at the end of
the clutch lever)
Friction plates
Thickness
Plate quantity
61.6 ~ 63.2 mm
325.1 ~ 326.3 mm
---0.160 ~ 0.262 mm
0.031 ~ 0.048 mm
0.027 ~ 0.045 mm
------0.03 mm
----------
2 = Black 3 = Brown 4 = Green
5 = Yellow 6 = Pink 7 = Red 8 = White
#3 JOURNAL
----
Gear
----
Wet, multiple disc
Hydraulic inner push
Left-hand operation
1.9 ~ 20.7 mm
-------------
2.9 ~ 3.1 mm
9
2-8
----
2.8 mm
----
ENGINE SPECIFICATIONS
Item
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch spring
Free length
Spring quantity
Min. length
Push rod bending limit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Max. main axle runout
Max. drive axle runout
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Installed shift rod length
Air filter type
Fuel pump
Pump type
Model (manufacturer)
Consumption amperage
<max>
Output pressure
Standard
SPEC
Limit
1.9 ~ 2.1 mm
8
----
------0.1 mm
6.78 mm
1
-------
------6.44 mm
0.2 mm
Constant mesh, 5-speed
Helical gear
75/48 (1.563)
Shaft drive
35/36 × 21/27 × 33/9 (2.773)
Left-foot operation
-------------------
43/17 (2.529)
39/22 (1.773)
31/23 (1.348)
28/26 (1.077)
26/28 (0.929)
-------
---------------0.08 mm
0.08 mm
Shift drum and guide bar
---209 mm
Dry element
---0.1 mm
-------
Electrical
5JW1 (DENSO)
5.5 A
294 kPa (2.94 kg/cm2, 2.94 bar)
2-9
-------------
ENGINE SPECIFICATIONS
Item
Throttle bodies
Model (manufacturer) × quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Shaft drive
Final gear backlash
Standard
SPEC
Limit
42EHS (MIKUNI) × 4
33.3 kPa (250 mmHg)
3 ~ 5 mm
----------
5JW1
----
0.1 ~ 0.2 mm
----
2 - 10
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 208 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
26°
109 mm
----------
Cast wheel
----
17 × MT3.50
Aluminum
135 mm
----------
-------
1 mm
0.5 mm
Cast wheel
----
17 × MT5.50
Aluminum
125 mm
----------
-------
1 mm
0.5 mm
Tubeless
120/70ZR 17 (58W)
MEZ4B FRONT (METZELER)/
BT020F N (BRIDGESTONE)
----------
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
----
---------1.6 mm
2 - 11
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 208 kg
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Brake lever free play (at lever end)
Recommended fluid
Brake discs
Diameter × thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position (below the top
of the rider footrest)
Brake pedal free play
Recommended fluid
Brake discs
Diameter × thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Clutch
Recommended fluid
Master cylinder inside diameter
Release cylinder inside diameter
Standard
Tubeless
180/55ZR 17 (73W)
MEZ4J (METZELER)/
BT020R N (BRIDGESTONE)
250 kPa (2.5 kgf/cm2, 2.5 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
---Dual-disc brake
Right-hand operation
2.2 ~ 11.2 mm
DOT 4
SPEC
Limit
----------
---------1.6 mm
-------------
298 × 5 mm
------5.5 mm
14 mm
30.2 mm and 27 mm
---4.5 mm
0.1 mm
0.5 mm
-------
Single-disc brake
Right-foot operation
42 mm
----------
4.7 ~ 9.9 mm
DOT 4
-------
282 × 6 mm
------5.8 mm
14 mm
41.3 mm
DOT 4
14 mm
33.6 mm
2 - 12
---5.5 mm
0.15 mm
0.8 mm
----------------
CHASSIS SPECIFICATIONS
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully compressed, and without the fork
spring)
Inner tube outer diameter
Inner tube bearing
Damper adjusting rod locknut distance
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum
*from the fully turned-in position
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Standard
Telescopic fork
Coil spring/oil damper
135 mm
SPEC
Limit
----------
270 mm
143.5 mm
258 mm
7.35 N/mm (0.735 kgf/mm)
0 ~ 135 mm (0 ~ 13.5 kgf/mm)
No
Yamaha fork oil 10 WT
Suspension oil “01” or equivalent
700 cm3
79 mm
264.6 mm
----------------------------
48 mm
---12 mm
---0.2 mm
----
6
3
1
----------
17
12
1
----------
21
12
1
----------
Angular
34°
34°
----------
2 - 13
CHASSIS SPECIFICATIONS
Item
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Upper spring
Free length
Installed length
Lower spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Spring rate (K2)
Spring stroke (K2)
Optional spring available
Standard spring preload gas/air pressure
Spring preload adjusting positions
Rider only
With passenger or cargo
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
Standard
Swingarm (link suspension)
Coil spring/gas-oil damper
60 mm
SPEC
Limit
----------
159 mm
138.1 mm
155.82 mm
----
74 mm
65.4 mm
71.6 N/mm (7.16 kgf/mm)
0 ~ 31.3 mm
102 N/mm (10.2 kgf/mm)
31.3 ~ 60.0 mm
No
1,200 kPa (12.0 kg/cm2, 12.0 bar)
72.52 mm
----------------------
SOFT
HARD
-------
20
10
3
----------
-------
0 mm
0 mm
2 - 14
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug caps
Material
Resistance
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance/color
Voltage regulator
Regulator type
Model (manufacturer)
No-load regulated voltage
Rectifier
Model (manufacturer)
Rectifier capacity
Withstand voltage
Battery
Battery type (manufacturer)
Battery voltage/capacity
Specific gravity
Ten hour rate amperage
Headlight type
Indicator light
(voltage/wattage × quantity)
Neutral indicator light
Turn signal indicator light
Oil level warning light
High beam indicator light
Engine trouble warning light
Standard
Limit
12 V
----
Transistorized coil ignition (digital)
5° BTDC at 1,050 r/min
Electric
420.8 ~ 569.3 Ω/Gy–B
F8T911 (MITSUBISHI)
----------------
J0313 (DENSO)
6 mm
1.87 ~ 2.53 Ω
12 ~ 18 kΩ
-------------
Resin
10 kΩ
-------
AC magneto
TLNZ79 (DENSO)
14 V/490 W at 5,000 r/min
0.15 ~ 0.23 Ω/W–W
-------------
Semiconductor, short circuit
FH001 (SHINDENGEN)
14.1 ~ 14.9 V
----------
FH001 (SHINDENGEN)
35 A
200 V
----------
GT14B-4 (GS)
12 V/12 AH
1.320
1.2 A
Halogen bulb
----------------
14 V 1.12 W × 1
14 V 1.4 W × 2
14 V 1.12 W × 1
14 V 1.12 W × 1
14 V 1.12 W × 1
----------------
2 - 15
ELECTRICAL SPECIFICATIONS
Item
Bulbs (voltage/wattage × quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Meter light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Horn
Horn type
Model (manufacturer) × quantity
Max. amperage
Performance
Coil resistance
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Oil level switch model (manufacturer)
Fuel sender
Model (manufacturer)
Resistance
Sidestand relay
Model (manufacturer)
Coil resistance
Headlight relay 2
Model
Standard
SPEC
Limit
12 V 60 W/55 W × 2
12 V 5 W × 2
12 V 5 W/21 W × 2
12 V 21 W × 4
14 V 1.12 W × 1
----------------
Constant mesh
----
5JW (YAMAHA)
0.8 kW
-------
10.8 mm
5.28 ~ 7.92 N (528 ~792 g)
0.024 ~ 0.030 Ω
24.5 mm
1.5 mm
3.65 mm
------23.5 mm
----
2768079-A (JIDECO)
180 A
4.18 ~ 4.62 Ω
----------
Plane
YF-12 (NIKKO) × 2
3A
105 ~ 113 db/2 m
1.15 ~ 1.25 Ω
----------------
Full-transistor
FE246BH (DENSO)
No
75 ~ 95 cycles/min.
21 W × 2 + 3.4 W
5JW (DENSO)
-------------------
5JW (DENSO)
20 ~ 140 Ω at 25 °C
-------
G8R-30Y-N (OMRON)
180 Ω
-------
ACM33211 M05
----
2 - 16
ELECTRICAL SPECIFICATIONS
Item
Fuel pump maximum amperage
Fuel injection system relay model
(manufacturer)
Radiator fan
Model
Running rpm
Fan motor relay
Model
Atmospheric pressure sensor
Thermostat type (manufacturer)
Valve opening temperature
Valve full open temperature
Valve lift – full open
Intake air temperature sensor
Model (manufacturer)
Resistance
Coolant temperature sender
Model (manufacturer)
Resistance
Fuses (amperage × quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Hazard lighting fuse
Parking lighting fuse
Backup fuse (odometer and clock)
Windshield motor fuse
Reserve fuse
Standard
SPEC
Limit
5.5 A
ACM33211 M05
-------
5JW
3,300 r/min
-------
ACM33211 M05
----
4FM (NIPPON THERMOSTAT)
69 ~ 73 °C
85 °C
8 mm
-------------
25978 (MITSUBISHI)
5.4 ~ 6.6 Ω at 80 °C
-------
8CC (MITSUBISHI)
5.21 ~ 6.37 kΩ at 0 °C
0.290 ~ 0.354 kΩ at 80 °C
----------
50 A × 1
15 A
25 A × 1
15 A × 1
10 A × 1
15 A × 1
7.5 A
10 A
10 A
2A
25 A, 15 A, 10 A, 7.5 A, 2 A × 1
----------------------------------
2 - 17
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EB201000
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightening torque m·kg
cm·kg
cm·kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu-in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
Misc.
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: Width across flats
B: Thread diameter
A
(nut)
2 - 18
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
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Part to be tightened
Spark plug
Camshaft sensor
Cylinder head cover
Camshaft cap
Camshaft sprocket
Timing chain tensioner
Timing chain tensioner cap
Cylinder head
Cylinder head
Cylinder head
Oil gallery bolt
Generator cover
Generator rotor
Starter clutch
Stator assembly
Stator assembly lead holder
Pickup coil rotor cover
Ignition timing check bolt
Crankshaft position sensor
Pickup coil rotor
Clutch cover
Damper cover
Oil guide plate
Clutch spring plate retainer
Thread
Part name
Q’ty
size
Tightening
torque
Nm
m·kgf
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Stud bolt
—
Bolt
Bolt
Bolt
Screw
Screw
Bolt
—
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
M10
M6
M6
M6
M7
M6
M6
M10
M6
M8
M8
M6
M12
M8
M6
M6
M6
M8
M5
M10
M6
M6
M6
M6
4
13
1.3
1
10
1.0
8
10
1.0
20
10
1.0
4
24
2.4
2
10
1.0
1
10
1.0
10 See NOTE.*1
2
12
1.2
8
15
1.5
1
20
2.0
8
12
1.2
1
130 13.0
3
32
3.2
3
10
1.0
1
6
0.6
8
12
1.2
1
15
1.5
2
4
0.4
1
45
4.5
10
12
1.2
4
12
1.2
2
10
1.0
6
8
0.8
Clutch boss
Nut
M20
1
90
9.0
Shift arm pinch bolt
Shift rod
—
Nut
M6
M6
1
1
10
7
1.0
0.7
Shift rod
Nut
M6
1
7
0.7
Shift rod joint
Shift pedal
Oil baffle plate
Shift shaft spring stopper
Engine oil drain bolt
Oil filter cartridge
Oil filter bolt
Oil level switch
Oil pan
Oil delivery pipe
Bolt
Bolt
Bolt
Bolt
—
—
—
Bolt
Bolt
Bolt
M6
M8
M6
M8
M14
M20
M20
M6
N6
M6
1
1
3
1
1
1
1
2
20
1
10
30
10
22
43
17
70
10
12
10
1.0
3.0
1.0
2.2
4.3
1.7
7.0
1.0
1.2
1.0
2 - 19
Remarks
LT
E
E
E
LT
LT
LT
LT
Use a lock
washer.
Left-hand
threads
LT
LT
LT
LT
TIGHTENING TORQUES
Part to be tightened
Thread
Part name
Q’ty
size
Oil pipe
Oil strainer
Oil pump assembly
Oil pump housing cover
Left middle gear cover
Right middle gear cover
Middle driven shaft assembly
Middle driven pinion gear
Bearing retainer (middle driven shaft)
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
—
M6
M6
M6
M6
M6
M6
M8
M28
M68
Middle drive pinion gear
Nut
M22
—
Bolt
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
Torx screw
Nut
Bolt
Torx screw
Bolt
—
—
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
M88
M6
M10
M6
M9
M8
M6
M6
M6
M8
M6
M6
M8
M6
M6
M6
M4
M12
M4
M5
M6
M6
M6
M6
M6
M6
M6
M12
Bearing retainer (middle drive shaft)
Oil pump drive chain guide
Neutral switch
Speed sensor
Crankcase
Crankcase
Crankcase
Crankcase
Rear balancer cover
Balancer lever
Balancer shaft pinch bolt
Plate
Connecting rod
Shift drum retainer
Main axle assembly
Air filter case
Air filter case joint clamp screw
Intake air temperature sensor
Throttle body joint clamp screw
Intake air pressure sensor
Air cut-off valve assembly
Reed valve cover
Radiator
Conduit
Water jacket joint
Oil cooler
Thermostat assembly inlet pipe
Coolant temperature sensor
2 - 20
2
2
3
3
9
3
3
1
1
SPEC
Tightening
torque
Nm
10
10
12
12
12
12
25
110
110
Remarks
m·kgf
LT
1.0
LT
1.0
LT
1.2
1.2
1.2
1.2
LT
2.5
LT Stake
11.0
11.0 Stake
E
Use a
1
110 11.0
lock washer.
1
110 11.0 Stake
LT
2
10
1.0
1
20
2.0
LT
1
10
1.0
*2
E
10 See NOTE.
E
2
24
2.4
E
2
12
1.2
E
17
10
1.0
4
12
1.2
2
14
1.4
2
10
1.0
LT
2
12
1.2
*3
M
8 See NOTE.
LT
2
10
1.0
LT Stake
3
12
1.2
2
7
0.7
4
4
0.4
1
18
1.8
8
3
0.3
2
5
0.5
1
10
1.0
LT
6
14
1.4
3
10
1.0
1
10
1.0
LT
2
10
1.0
LT
4
12
1.2
2
10
1.0
1
18
1.8
TIGHTENING TORQUES
Part to be tightened
Thermostat assembly
Thermostat housing cover
Water pump
Water pump housing cover
Coolant drain bolt
Muffler joint
Muffler
Exhaust pipe
Exhaust pipe
Exhaust check bolt
O2 sensor
Starter motor
Thread
Part name
Q’ty
size
Torx screw M6
Bolt
M6
Bolt
M6
Bolt
M6
—
M6
Bolt
M8
Bolt
M10
Nut
M8
Bolt
M8
—
M6
—
M18
Bolt
M6
1
2
3
1
1
2
2
8
2
4
1
2
SPEC
Tightening
torque
Nm
m·kgf
10
10
12
10
10
20
25
20
17
10
45
10
1.0
1.0
1.2
1.0
1.0
2.0
2.5
2.0
1.7
1.0
4.5
1.0
Remarks
NOTE:
*1:Tighten the cylinder head bolts to 25 Nm (2.5 m • kg) in the proper tightening sequence, loosen
and retighten the cylinder head bolts to 25 Nm (2.5 m • kg) in the proper tightening sequence,
and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper
tightening sequence.
*2:Tighten the crankcase bolts to 20 Nm (2.0 m • kg) in the proper tightening sequence, loosen and
retighten the crankcase bolts to 20 Nm (2.0 m • kg) in the proper tightening sequence, and then
tighten the crankcase bolts further to reach the specified angle 120° in the proper tightening
sequence.
*3:Tighten the connecting rod nuts to 20 Nm (2.0 m • kg), and then tighten the connecting rod nuts
further to reach the specified angle 120°.
2 - 21
TIGHTENING TORQUES
Cylinder head tightening sequence:
Crankcase tightening sequence:
2 - 22
SPEC
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Thread
size
Part to be tightened
Engine mounting:
Rear lower mounting bolt
Spacer bolt
Rear upper mounting bolt and nut
Front mounting bolt
Pinch bolt
Bolt (engine bracket 1 and frame)
Bolt (engine bracket 1 and engine)
Bolt (engine bracket 2 and engine)
Bolt (engine bracket 2 and frame)
Front wheel axle
Front wheel axle pinch bolt
Brake disc and wheel
Front brake caliper
Front brake hose holder and front fork
Brake caliper bleed screw
Rear wheel axle nut
Rear wheel axle pinch bolt
Brake torque rod
Rear brake caliper retaining bolt
Brake hose union bolt
Front brake master cylinder
Right rider footrest bracket and frame
Rear master cylinder and right rider footrest bracket
Rear brake hose holder and brake torque rod
Clutch master cylinder
Clutch hose union bolt
Clutch release cylinder
Clutch release cylinder bleed screw
Front fender
Upper bracket pinch bolt
Lower bracket pinch bolt
Front fork cap bolt and inner tube
Front fork cap bolt and nut
Front fork damper rod assembly bolt
Handlebar and upper bracket
Grip end
Steering stem nut
Lower ring nut (steering stem)
2 - 23
M10
M16
M10
M12
M8
M10
M8
M10
M8
M18
M8
M6
M10
M6
M8
M18
M8
M8
M10
M10
M6
M8
M8
M6
M6
M10
M6
M8
M6
M8
M8
M45
M10
M10
M6
M6
M28
M30
Tightening
torque
Remarks
Nm
m·kgf
45
18
45
55
24
32
16
36
16
72
23
18
40
7
6
125
16
16
26
30
10
28
18
10
10
30
10
6
6
30
23
25
25
35
23
4
115
18
4.5
1.8
4.5
5.5
2.4
3.2
1.6
3.6
1.6
7.2
2.3
LT
1.8
4.0
0.7
0.6
12.5
1.6
1.6
2.6
3.0
1.0
2.8
1.8
1.0
1.0
3.0
1.0
0.6
0.6
3.0
2.3
2.5
2.5
LT
3.5
2.3
0.4
11.5
1.8 See NOTE.
TIGHTENING TORQUES
Thread
size
Part to be tightened
Connecting arm and swingarm
Connecting arm and relay arm
Rear shock assembly and relay arm
Rear shock assembly and frame
Relay arm and frame
Swingarm pivot shaft and frame
Swingarm pivot shaft and locknut
Swingarm pivot shaft and pivot shaft nut
Locknut retainer
Final drive housing oil filler bolt
Final drive housing oil drain bolt
Final drive assembly and swingarm
Left rider footrest bracket and frame
Left rider footrest bracket and engine
Left rider footrest bracket, sidestand bracket and frame
Ring gear bearing housing and final drive housing
Ring gear bearing housing and final drive housing
Stopper bolt
Gear coupling and final drive pinion gear
Final drive pinion gear bearing retainer
Sidestand and sidestand bracket
Centerstand bracket and frame
Centerstand and centerstand bracket
Rear frame and main frame (upper)
Rear frame and main frame (lower)
T-bar and frame
Fuel pump and fuel tank
Battery bracket and frame
Battery holder and battery bracket
Ignition coil
M10
M10
M10
M12
M10
M18
M28
M18
M6
M14
M14
M10
M8
M10
M10
M10
M8
M10
M16
M65
M10
M10
M10
M8
M10
M10
M5
M6
M6
M6
SPEC
Tightening
torque
Nm
m·kgf
48
48
40
64
40
7
115
125
10
23
23
42
28
49
63
40
23
9
110
110
58
55
56
28
48
78
4
10
10
10
4.8
4.8
4.0
6.4
4.0
0.7
11.5
12.5
1.0
2.3
2.3
4.2
2.8
4.9
6.3
4.0
2.3
0.9
11.0
11.0
5.8
5.5
5.6
2.8
4.8
7.8
0.4
1.0
1.0
1.0
Remarks
NOTE:
1.First, tighten the lower ring nut approximately 52 Nm (5.2 m • kg) by using the torque wrench, then
loosen the ring nut completely.
2.Retighten the lower ring nut to specification.
2 - 24
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Oil seal lips
LS
O-rings
LS
Bearings
E
Crankshaft pins
E
Piston surfaces
E
Piston pins
E
Connecting rod bolts and nuts
M
Crankshaft journals
E
Camshaft lobes
M
Camshaft journals
M
Balancer weights and shafts
E
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
E
Water pump impeller shaft
E
Oil pump rotors (inner and outer)
E
Oil pump housing
E
Oil strainer
E
Starter clutch idle gear inner surface
E
Starter clutch assembly
E
Primary driven gear
E
Push rods and ball
LS
Transmission gears (wheel and pinion)
M
Main axle and drive axle
M
Shift drum
E
Shift forks and shift fork guide bars
E
Shift shaft
E
Shift pedal bolt
LS
Damper drive cam and damper driven cam
M
Middle driven gear
M
Middle drive pinion gear and middle drive shaft
E
Middle driven pinion gear and middle driven shaft
E
2 - 25
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
SPEC
Lubricant
Cylinder head cover mating surface
Sealant
Cylinder head cover
Sealant
Crankcase mating surface
Sealant
Clutch cover (crankcase mating surface)
Sealant
Generator cover (crankcase mating surface)
Sealant
Pickup coil rotor cover (crankcase mating surface)
Sealant
Left middle gear cover (crankcase mating surface)
Sealant
2 - 26
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
LS
Front wheel oil seal (right and left)
LS
Rear wheel oil seal
LS
Rear wheel drive hub oil seal
LS
Rear wheel drive hub mating surface
LS
Rear brake pedal pivot
LS
Footrest pivoting point
LS
Centerstand pivoting point and sliding surface
LS
Sidestand pivoting point and metal-to-metal moving parts
LS
Throttle grip inner surface
LS
Brake lever pivot bolt and contact surface
LS
Clutch lever pivot bolt and contact surface
LS
Rear shock absorber assembly oil seal
LS
Rear shock absorber assembly bearing
LS
Rear shock absorber assembly spacer
LS
Pivot shaft
LS
Connecting arm bearing
LS
Spacer (relay arm and connecting arm)
LS
Oil seal (relay arm and connecting arm)
LS
2 - 27
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1 Crankshaft
2 Oil pump
3 Oil pipe
4 Relief valve
5 Oil filter cartridge
6 Main axle
2 - 28
SPEC
OIL FLOW DIAGRAMS
1 Crankshaft
2 Main axle
3 Drive axle
2 - 29
SPEC
OIL FLOW DIAGRAMS
1 Oil nozzle
2 Main gallery bolt
3 Crankshaft
2 - 30
SPEC
OIL FLOW DIAGRAMS
1 Main axle
2 Drive axle
3 Oil delivery pipe
2 - 31
SPEC
OIL FLOW DIAGRAMS
1 Exhaust camshaft
2 Oil check bolt
3 Intake camshaft
2 - 32
SPEC
OIL FLOW DIAGRAMS
1 Oil check bolt
2 Crankshaft
3 Oil cooler
4 Oil pump
5 Oil strainer
6 Oil pipe
2 - 33
SPEC
OIL FLOW DIAGRAMS
1 Crank pin
2 Crankshaft
2 - 34
SPEC
OIL FLOW DIAGRAMS
1 Rear balancer
2 Oil delivery pipe
3 Crankshaft
4 Front balancer
5 Crank pin
2 - 35
SPEC
OIL FLOW DIAGRAMS
1 Oil strainer
2 Oil delivery pipe
3 Oil cooler
4 Engine oil drain bolt
5 Oil level switch
6 Oil filter cartridge
7 Oil pan
8 Oil pipe
9 Oil pump
2 - 36
SPEC
OIL FLOW DIAGRAMS
1 Main axle
2 Drive axle
3 Middle drive shaft
2 - 37
SPEC
COOLING SYSTEM DIAGRAMS
COOLING SYSTEM DIAGRAMS
1 Radiator
2 - 38
SPEC
COOLING SYSTEM DIAGRAMS
1 Water jacket joint
2 Oil cooler
2 - 39
SPEC
COOLING SYSTEM DIAGRAMS
1 Thermostat assembly
2 Coolant reservoir
3 Radiator
4 Oil cooler
2 - 40
SPEC
COOLING SYSTEM DIAGRAMS
1 Coolant reservoir
2 Radiator
3 Water pump
2 - 41
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1 Throttle cable
2 Brake cable
3 Clutch cable
4 Main switch lead
5 Headlight lead
6 Fuse box
7 Thermostat assembly breather hose
8 Coolant reservoir hose
9 Hazard switch
0 Rectifier/regulator
A Plate
B Plunger control unit hose 2
C Radiator
D Radiator fan coupler
2 - 42
CABLE ROUTING
È Pass the right handlebar switch lead under the
handlebar.
É Pass the left handlebar switch lead under the
handlebar.
Ê Pass the wire harness, stator coil lead, coolant
reservoir hose, and thermostat assembly
breather hose through the left slit of the plate.
Ë To the thermostat housing
SPEC
Ì After passing the coolant reservoir hose through
the two hose guides behind the plate, pass the
hose through the right hole of the plate.
Í Pass the plunger control unit hose 2 on the
inside of the plate.
Î To the radiator fan
Ï Pass the radiator fan lead on the outside of the
plate.
2 - 43
CABLE ROUTING
1 Brake cable
2 Right handlebar switch lead
3 Throttle cable
4 Starter relay
5 Battery
6 Positive battery lead
7 Main fuse
8 Front turn signal lead
9 Spark plug lead #4
0 Spark plug lead #1
A Ignition coil lead (#1, #4)
SPEC
B Ignition coil (#1, #4)
C Coolant reservoir
D Coolant reservoir breather hose
E Coolant reservoir hose
F Pickup coil lead
G Starter motor lead
H Spark plug lead #2
I Spark plug lead #3
J Ignition coil (#2, #3)
K Starter relay
L Negative battery lead
2 - 44
CABLE ROUTING
È Fasten the positive battery lead with a plastic
locking tie to the battery stay.
É Fasten the positive battery lead and main fuse
lead with a plastic locking tie to the battery stay.
Ê Insert the front turn signal leads into the inner
panel.
Ë Install the connector so that the ignition coil lead
can be turned outward.
Ì Support the coolant reservoir breather hose with
the hose holder attached to the coolant reservoir.
SPEC
Í Pass the brake cable through the brake cable
guide.
Î Pass the coolant reservoir hose through the hole
of the plate.
Ï Pass the coolant reservoir hose through the
hose guide attached to the coolant reservoir.
Ð Pass the negative battery lead and starter motor
lead through the hose guide attached to the
coolant reservoir.
2 - 45
CABLE ROUTING
Ñ Support the coolant reservoir hose and coolant
reservoir breather hose with the hose holder
located under the coolant reservoir.
Ò Pass the coolant reservoir hose through the hole
of the coolant reservoir hose holder.
Ó Fasten spark plug lead #1 and #4 at the number
tag.
Ô Pass the wire harness, spark plug leads #1, #2,
and #3 through the right slit of the battery
bracket.
SPEC
Õ Pass the starter motor lead, negative battery
lead, and spark plug leads #2 and #3 through
the battery stay. Be sure to pass the starter
motor lead and negative battery lead on the battery stay side.
2 - 46
CABLE ROUTING
1 Tail/brake light lead
2 - 47
SPEC
CABLE ROUTING
1 Main switch lead
2 Left handlebar switch lead
3 Hazard switch
4 Rectifier/regulator
5 Clutch cable
6 Fuel tank overflow hose
7 Fuel tank breather hose
8 Stator coil lead
9 Sidestand switch
0 Sidestand switch lead
SPEC
A Oil level switch lead
B Brake cable
C Coolant reservoir hose
D Thermostat assembly breather hose
E Headlight lead
F Radiator fan lead
G Wire harness
2 - 48
CABLE ROUTING
È To the radiator fan
É Pass the wire harness, stator coil lead, coolant
reservoir hose, and thermostat assembly
breather hose through the left slit of the plate.
Ê To the right side of the frame
Ë Clamp the wire harness with the plastic band
attached to the frame.
Ì To the fuel tank
Í Pass the stator coil lead at the fork of the wire
harness.
SPEC
Î Support the harness holder into the hole on the
rear end of the frame.
Ï Insert the harness holder into the hole on the
rear end of the frame.
Ð Pass the brake cable through the brake cable
guide.
Ñ To the wire harness
Ò Contact the clutch cable to the turn stopper.
2 - 49
CABLE ROUTING
1 ECU
2 Tail/brake light lead
3 Seat lock cable
4 Fuel tank breather hose
5 Fuel tank overflow hose
6 Air filter case breather hose
È To the intake air temperature sensor
É Fasten the wire harness with a plastic band to
the frame.
Ê To the inside of the U-lock storage box
Ë Fasten the tail/brake light lead with a plastic
band to the frame.
SPEC
Ì Pass the tail/brake light lead between the rear
cover and frame.
Í Pass the wire harness on the inside of the seat
lock cable.
Î Support the wire harness and ignitor unit lead
with the cable holder attached to the tray.
Ï Pass the fuel tank breather hose and fuel tank
over flow hose through the hose guide.
Ð Pass the fuel tank breather hose and fuel tank
overflow hose between the swingarm and universal joint.
2 - 50
CABLE ROUTING
1 Air cut-off valve
2 Clutch cable
3 Left handlebar switch lead
4 Headlight lead
5 Main switch lead
6 Throttle cable
7 Right handlebar switch lead
8 T-bar
9 Spark plug lead #3
0 Spark plug lead #2
A Spark plug lead #1
B Spark plug lead #4
C Throttle position sensor
D Sidestand switch lead
E Spark plug lead #1
F Spark plug lead #4
2 - 51
SPEC
CABLE ROUTING
È Connect the wire harness and right handlebar
switch lead.
É Pass the left handlebar switch lead, main switch
lead, headlight lead, and clutch cable through
the hole on the left side of the frame.
Ê Pass the right handlebar and throttle cables
through the hole on the right side of the frame.
Ë To the lower left slit of the plate
SPEC
Ì To the camshaft sensor
Í To the fuel tank
Î Pass the camshaft sensor lead through the lead
guide of throttle body.
Ï After connecting the camshaft sensor lead,
cover it with a rubber cover.
Ð To the sidestand switch lead
Ñ Pass the camshaft sensor lead under the fuel
hose and then to the wire harness.
2 - 52
CABLE ROUTING
Ò Support the throttle cables with the T-bar located
behind the cable guide.
Ó Pass the throttle cables under spark plug leads
#1, #2, #3, and #4, and the wire harness, headlight lead, main switch lead, right handlebar
switch lead, and left handlebar switch lead.
Install the thermostat, heat protector, throttle
cables, spark plug leads, wire harnesses, and
air cut valve under the cable guide in the respective order.
Ô To the left slit of the plate
2 - 53
SPEC
CABLE ROUTING
1 Engine stop switch
2 Starting circuit cut-off relay
3 Atmospheric pressure sensor
4 CYCLELOCK coupler
5 Seat lock cable
2 - 54
SPEC
CABLE ROUTING
È To the rear brake light switch
É Pass the engine stop switch through the lead
guide attached to the frame.
Ê Pass the security lead coupler through the inside
of the storage box of the U-lock.
Ë Pass the security lead coupler through the lead
guide.
Ì Pass the pressure sensor lead and engine stop
switch lead through the lead guide.
Í Pass the wire harnesses under the tray bracket.
2 - 55
SPEC
CHK
ADJ
3
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1
SEATS AND FUEL TANK ............................................................................... 3-3
SEATS....................................................................................................... 3-3
FUEL TANK............................................................................................... 3-4
T-BAR........................................................................................................ 3-5
REMOVING THE FUEL TANK ..................................................................3-6
REMOVING THE FUEL PUMP .................................................................3-6
INSTALLING THE FUEL PUMP................................................................3-7
INSTALLING THE FUEL HOSE ................................................................3-7
INSTALLING THE T-BAR..........................................................................3-7
AIR FILTER CASE .......................................................................................... 3-8
COWLINGS AND COVERS ..........................................................................3-10
COWLINGS ............................................................................................. 3-10
COVERS .................................................................................................3-14
ENGINE .........................................................................................................3-15
ADJUSTING THE VALVE CLEARANCE ................................................ 3-15
SYNCHRONIZING THE THROTTLE BODIES........................................ 3-21
CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE .............. 3-23
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-25
CHECKING THE EXHAUST GAS AT IDLE ............................................3-27
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-28
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-30
CHECKING THE SPARK PLUGS ........................................................... 3-32
CHECKING THE IGNITION TIMING.......................................................3-33
MEASURING THE COMPRESSION PRESSURE..................................3-35
CHECKING THE ENGINE OIL LEVEL....................................................3-37
CHANGING THE ENGINE OIL ...............................................................3-39
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-41
ADJUSTING THE CLUTCH LEVER........................................................ 3-43
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-43
BLEEDING THE HYDRAULIC CLUTCH SYSTEM .................................3-44
CLEANING THE AIR FILTER ELEMENT................................................ 3-46
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-47
CHECKING THE FUEL AND VACUUM HOSES .................................... 3-48
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-48
CHECKING THE EXHAUST SYSTEM....................................................3-49
CHECKING THE COOLANT LEVEL.......................................................3-50
CHECKING THE COOLING SYSTEM ....................................................3-51
CHANGING THE COOLANT................................................................... 3-52
CHK
ADJ
CHASSIS ....................................................................................................... 3-55
ADJUSTING THE FRONT BRAKE ......................................................... 3-55
ADJUSTING THE REAR BRAKE............................................................ 3-56
CHECKING THE BRAKE FLUID LEVEL................................................. 3-57
CHECKING THE BRAKE PADS ............................................................. 3-58
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-58
CHECKING THE BRAKE HOSES........................................................... 3-59
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-60
ADJUSTING THE SHIFT PEDAL............................................................ 3-61
CHECKING THE FINAL DRIVE OIL LEVEL ...........................................3-62
CHANGING THE FINAL DRIVE OIL .......................................................3-62
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-63
CHECKING THE FRONT FORK ............................................................. 3-65
ADJUSTING THE FRONT FORK LEGS ................................................. 3-66
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-68
CHECKING THE TIRES..........................................................................3-69
CHECKING THE WHEELS ..................................................................... 3-71
CHECKING AND LUBRICATING THE CABLES .................................... 3-72
LUBRICATING THE LEVERS AND PEDALS .........................................3-72
LUBRICATING THE SIDESTAND........................................................... 3-72
LUBRICATING THE CENTERSTAND ....................................................3-73
LUBRICATING THE REAR SUSPENSION............................................. 3-73
ELECTRICAL SYSTEM................................................................................. 3-74
CHECKING AND CHARGING THE BATTERY....................................... 3-74
CHECKING THE FUSES ........................................................................3-79
REPLACING THE HEADLIGHT BULBS ................................................. 3-81
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-82
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No.
1 *
Fuel line
(See page 3-48)
2
Spark plugs
(See page 3-32)
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
• Check fuel hoses for cracks or damage.
√
√
√
√
√
• Check condition.
• Clean and regap.
√
ITEM
CHECK OR MAINTENANCE JOB
1
√
√
• Replace.
√
3 *
Valves
(See page 3-15)
• Check valve clearance.
• Adjust.
4
Air filter element
(See page 3-46)
• Clean.
5 *
Clutch
(See page 3-43)
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
√
√
√
√
√
6 *
Front brake
(See page 3-55)
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
√
√
√
√
√
7 *
Rear brake
(See page 3-56)
8 *
Brake hoses
(See page 3-59)
9 *
Wheels
(See page 3-71)
Tires
10 *
(See page 3-69)
11 *
Wheel bearings
(See page 4-3)
12 *
Swingarm
(See page 4-89)
13 *
Steering bearings
(See page 3-63)
Every 40,000 km
√
√
√
• Replace.
• Replace brake pads.
√
√
Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
√
• Replace brake pads.
√
√
√
√
√
Whenever worn to the limit
√
• Check for cracks or damage.
• Replace. (See NOTE on page 3-2.)
√
√
√
Every 4 years
• Check runout and for damage.
√
√
√
√
•
•
•
•
√
√
√
√
• Check bearing for looseness or damage.
√
√
√
√
• Check operation and for excessive play.
√
√
√
√
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
• Lubricate with lithium-soap-based grease.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
3-1
Every 50,000 km
√
√
√
√
Every 20,000 km
√
√
PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
CHK
ADJ
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
√
√
Sidestand/
centerstand
(See page 3-72)
• Check operation.
• Lubricate.
√
√
√
√
√
16 *
Sidestand switch
(See page 8-4)
• Check operation.
√
√
√
√
√
17 *
Front fork
(See page 3-65)
• Check operation and for oil leakage.
√
√
√
√
• Check operation and shock absorber for oil leakage.
√
√
√
√
√
√
√
√
No.
ITEM
14 *
Chassis fasteners
(See page 2-23)
15
Shock absorber
18 * assembly
(See page 4-85)
CHECK OR MAINTENANCE JOB
1
√
• Check operation.
Rear suspension
relay arm and con19 * necting arm pivot• Lubricate with lithium-soap-based grease.
ing points
(See page 3-73)
Electronic fuel
20 * injection system
(See page 3-21)
√
• Adjust engine idling speed and synchronization.
√
√
√
√
√
√
√
√
√
√
√
21
Engine oil
(See page 3-39)
• Change.
√
22
Engine oil filter
cartridge
(See page 3-39)
• Replace.
√
23 *
Cooling system
(See page 3-50)
24
Final gear oil
(See page 3-62)
Front and rear
25 * brake switches
(See page 3-58)
26
Moving parts and
cables
(See page 3-72)
Muffler and
27 * exhaust pipe
(See page 3-49)
√
• Check coolant level and vehicle for coolant leakage.
√
√
• Change.
√
√
√
√
√
Every 3 years
• Check oil level and vehicle for oil leakage.
• Change.
√
√
√
√
√
• Check operation.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Lubricate.
• Check the screw clamp for looseness.
Lights, signals and
• Check operation.
28 * switches
• Adjust headlight beam.
(See page 3-82)
√
√
NOTE:
• The air filter needs more frequent service if you are 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.
3-2
SEATS AND FUEL TANK
CHK
ADJ
EAS00039
SEATS AND FUEL TANK
SEATS
Order
1
2
Job/Part
Removing the seats
Rider seat
Passenger seat
Q’ty
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
SEATS AND FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the fuel tank
Rider seat
Fuel
Fuel tank side panel (left and right)
Bolt
Nut
Fuel sender coupler
Fuel pump coupler
Fuel tank overflow hose
Fuel tank breather hose
Fuel hose holder
Fuel hose
Fuel return hose
Bolt
Fuel tank
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1/1
2
1
1
1
1
1
2
1
1
1
1
3-4
Refer to “REMOVING THE FUEL TANK”
and “INSTALLING THE FUEL HOSE”.
Refer to “REMOVING THE FUEL TANK”.
For installation, reverse the removal
procedure.
SEATS AND FUEL TANK
CHK
ADJ
T-BAR
Order
1
2
3
4
Job/Part
Removing the T-bar
Rider seat/fuel tank
Left rubber cover
Right rubber cover
T-bar
Rubber sheet
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK”.
1
1
1
1
For installation, reverse the removal
procedure.
3-5
SEATS AND FUEL TANK
CHK
ADJ
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• fuel return hose
• fuel hose
CAUTION:
Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hoses, since there may be fuel remaining in it.
NOTE:
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:
• fuel tank
NOTE:
Do not set the fuel tank down so that the installation surface of the fuel pump is directly under
the tank. Be sure to lean the fuel tank in an
upright position.
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
3-6
CHK
ADJ
SEATS AND FUEL TANK
T.
INSTALLING THE FUEL PUMP
1. Install:
4 Nm (0.4 m · kg)
• fuel pump
R.
NOTE:
• Do not damage the installation surfaces of
the fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump as shown in the illustration.
• Tighten the fuel pump bolts in stages in a
crisscross pattern and to the specified
torque.
FWD
INSTALLING THE FUEL HOSE
1. Install:
• fuel hose
• fuel hose holders
CAUTION:
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holders are in the correct position, otherwise the fuel hose will not be
properly installed.
T.
INSTALLING THE T-BAR
1. Install:
78 Nm (7.8 m · kg)
• T-bar
R.
CAUTION:
Always tighten the T-bar mounting bolts to
the specified torque.
3-7
AIR FILTER CASE
CHK
ADJ
EAS00043
AIR FILTER CASE
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the air filter case
Seats/fuel tank
Side covers (left and right)
Air shroud
Air filter case cover
Air filter element
Lean angle cut-off switch
Tray
Fuel tank bracket
Plastic locking tie
Intake air temperature sensor coupler
Crankcase breather hose
Q’ty
1
1
1
1
1
1
1
1
1
3-8
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK”.
Refer to “COWLINGS AND COVERS”.
Disconnect.
AIR FILTER CASE
Order
10
11
12
13
Job/Part
Air induction system hose 5
Clamp screw
Air filter case
Air filter case breather hose
CHK
ADJ
Q’ty
Remarks
1
Disconnect.
4
Loosen.
1
1
For installation, reverse the removal
procedure.
3-9
COWLINGS AND COVERS
CHK
ADJ
EAS00041
COWLINGS AND COVERS
COWLINGS
8
9
11
10
6
12
13
7
5
T.
R.
10 Nm (1.0 m • kg)
4
2
3
1
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Removing the cowlings
Rider seat/fuel tank
Left side cowling
Right side cowling
Front bottom cowling
Front turn signal connector (left)
Front turn signal connector (right)
Left inner panel (front cowling)
Fuse box
Hazard switch
Right inner panel (front cowling)
Front-right inner panel (front cowling)
Front-left inner panel (front cowling)
Sub wire harness coupler
Front cowling assembly
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK”.
1
1
1
2
2
1
1
1
1
1
1
3
1
For installation, reverse the removal
procedure.
3 - 10
COWLINGS AND COVERS
CHK
ADJ
(7)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Remarks
Disassembling the front cowling
Remove the parts in the order listed.
assembly
Windshield outer bracket
1
Windshield
1
Grommet
7
Windshield inner bracket
1
Rear view mirror (left and right)
2
Panel
1
Front cowling
1
Auxiliary light coupler
2
Headlight coupler
2
For assembly, reverse the disassembly
procedure.
3 - 11
COWLINGS AND COVERS
CHK
ADJ
1
Order
1
Job/Part
Removing the headlight assembly
Headlight assembly
Q’ty
Remarks
Remove the parts in the order listed.
1
For installation, reverse the removal
procedure.
3 - 12
COWLINGS AND COVERS
CHK
ADJ
9
8
4
7
6
5
3
2
1
(4)
Order
1
2
3
4
5
6
7
8
9
(4)
Job/Part
Q’ty
Remarks
Removing the windshield drive unit,
Remove the parts in the order listed.
meter assembly and relays
Windshield drive unit
1
Windshield drive unit coupler
2
Meter assembly
1
Meter assembly coupler
1
Headlight relay 1
1
Headlight relay 2
1
Fuel injection system relay
1
Turn signal relay
1
Radiator fan motor relay
1
For installation, reverse the removal
procedure.
3 - 13
COWLINGS AND COVERS
CHK
ADJ
COVERS
Order
1
2
3
4
Job/Part
Removing the covers
Seats
Left side cover
Right side cover
Rear carrier
Rear cover
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK”.
1
1
1
1
For installation, reverse the removal
procedure.
3 - 14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
@
1.
•
•
•
•
•
•
•
•
•
2.
•
•
•
3 - 15
Remove:
rider seat
fuel tank
T-bar
rubber sheet
Refer to “SEATS AND FUEL TANK”.
side cowlings
front cowling assembly
Refer to “COWLINGS AND COVERS”.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
thermostat assembly
Refer to “THERMOSTAT” in chapter 6.
air cut-off valve assembly
air induction system hoses
Remove:
spark plugs
cylinder head cover 1
cylinder head cover gasket
ADJUSTING THE VALVE CLEARANCE
3.
•
•
•
CHK
ADJ
Remove:
hose holder 1
lead holder 2
pickup coil rotor cover 3
4. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.15 ~ 0.22 mm
Exhaust valve
0.18 ~ 0.25 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
IN
EX
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the
pickup coil rotor with the crankcase mating
surface b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
@
c. Measure the valve clearance with a thickness gauge 1.
NOTE:
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
@
Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
È Front
d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
TDC, turn the crankshaft counterclockwise
as specified in the following table.
3 - 16
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
É Degrees that the crankshaft is turned counterclockwise
Ê Cylinder
Ë Combustion cycle
Cylinder #2
180°
Cylinder #4
360°
Cylinder #3
540°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.
•
•
•
Remove:
rubber plug 1
timing chain tensioner cap bolt 2
gasket
6. Turn the timing chain tensioner rod fully
clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
7.
•
•
•
Remove:
intake camshaft caps
exhaust camshaft caps
timing chain
(from the camshaft sprockets)
• intake camshaft
• exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in chapter 5.
• When removing the timing chain and camshafts, fasten the timing chain with a wire to
retrieve it if it falls into the crankcase.
@
8. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter 1 and the valve pad
2 with a valve lapper 3.
Valve lapper
90890-04101
3 - 17
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve
lifter 1 and valve pad 2 so that they can be
installed in the correct place.
@
b. Select the proper valve pad from the following table.
Valve pad thickness
Available valve pads
range
Nos.
1.20 ~
25 thicknesses in
120 ~ 240 2.40 mm 0.05 mm increments
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters on the
side that touches the valve lifter.
• Since valve pads of various sizes are originally installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
@
c. Round off the original valve pad number
according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 148 (thickness
=1.48 mm)
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance in the valve pad selection table. The
point where the column and row intersect is
the new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be
repeated if the measurement is still incorrect.
@
3 - 18
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
e. Install the new valve pad 1 and the valve
lifter 2.
NOTE:
• Lubricate the valve pad with molybdenum
disulfide grease.
• Lubricate the valve lifter with molybdenum
disulfide oil.
• The valve lifter must turn smoothly when
rotated by hand.
• Install the valve lifter and the valve pad in the
correct place.
@
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
T.
Camshaft cap bolt
10 Nm (1.0 m · kg)
R.
NOTE:
• Refer to “INSTALLING THE CAMSHAFTS —
CAMSHAFTS” in chapter 5.
• Lubricate the camshafts, camshaft lobes and
camshaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the camshaft
cap marks.
• Turn the crankshaft clockwise several full
turns to seat the parts.
@
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 19
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
INTAKE
MEASURED
CLEARANCE
0.00 ~ 0.02
0.03 ~ 0.08
0.09 ~ 0.14
0.15 ~ 0.22
0.23 ~ 0.28
0.29 ~ 0.34
0.35 ~ 0.40
0.41 ~ 0.46
0.47 ~ 0.52
0.53 ~ 0.58
0.59 ~ 0.64
0.65 ~ 0.70
0.71 ~ 0.76
0.77 ~ 0.82
0.83 ~ 0.88
0.89 ~ 0.94
0.95 ~ 1.00
1.01 ~ 1.06
1.07 ~ 1.12
1.13 ~ 1.18
1.19 ~ 1.24
1.25 ~ 1.30
1.31 ~ 1.36
1.37 ~ 1.42
1.43 ~ 1.48
1.49 ~ 1.54
1.55 ~ 1.60
1.61 ~ 1.66
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER
165 170 175 180 185 190 195 200 205 210 215 220 225
150 155 160 165 170 175 180 185 190 195 200 205 210
155 160 165 170 175 180 185 190 195 200 205 210 215
160 165 170 175 180 185 190 195 200 205 210 215 220
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215 220 225 230
170 175 180 185 190 195 200 205 210 215 220 225 230 235
175 180 185 190 195 200 205 210 215 220 225 230 235 240
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
VALVE CLEARANCE (cold):
235 240
0.15 ~ 0.22 mm
240
160
145
150
155
230
215
220
225
235
220
225
230
240
225
230
235
235 240
240
Example: Installed is pad 150
Measured clearance is 0.30 mm
Replace pad 150 with pad 160
Pad number: (example)
Pad No. 150 = 1.50 mm
Pad No. 160 = 1.60 mm
Always install pad with number down.
EXHAUST
MEASURED
CLEARANCE
0.00 ~ 0.05
0.06 ~ 0.11
0.12 ~ 0.17
0.18 ~ 0.25
0.26 ~ 0.31
0.32 ~ 0.37
0.38 ~ 0.43
0.44 ~ 0.49
0.50 ~ 0.55
0.56 ~ 0.61
0.62 ~ 0.67
0.68 ~ 0.73
0.74 ~ 0.79
0.80 ~ 0.85
0.86 ~ 0.91
0.92 ~ 0.97
0.98 ~ 1.03
1.04 ~ 1.09
1.10 ~ 1.15
1.16 ~ 1.21
1.22 ~ 1.27
1.28 ~ 1.33
1.34 ~ 1.39
1.40 ~ 1.45
1.46 ~ 1.51
1.52 ~ 1.57
1.58 ~ 1.63
1.64 ~ 1.69
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER
165 170 175 180 185 190 195 200 205 210 215 220 225
150 155 160 165 170 175 180 185 190 195 200 205 210
155 160 165 170 175 180 185 190 195 200 205 210 215
160 165 170 175 180 185 190 195 200 205 210 215 220
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215 220 225 230
170 175 180 185 190 195 200 205 210 215 220 225 230 235
175 180 185 190 195 200 205 210 215 220 225 230 235 240
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
VALVE CLEARANCE (cold):
235 240
0.18 ~ 0.25 mm
240
160
145
150
155
230
215
220
225
235
220
225
230
235 240
240
Example: Installed is pad 175
Measured clearance is 0.32 mm
Replace pad 175 with pad 185
Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
Always install pad with number down.
3 - 20
240
225
230
235
ADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
9. Install:
• all removed parts
NOTE:
For installation, reverse the removal procedure.
@
EAS00050
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 motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
@
2.
•
•
•
Remove:
rider seat
fuel tank
T-bar
Refer to “SEATS AND FUEL TANK”.
3. Remove:
• caps 1
4. Install:
• vacuum gauge
(onto the pipes)
• engine tachometer
(onto the spark plug lead of cylinder #1)
Vacuum gauge
90890-03094
Engine tachometer
90890-06760
5. Install:
• fuel tank
Refer to “SEATS AND FUEL TANK”.
6. Start the engine and let it warm up for several minutes.
3 - 21
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
7. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE
IDLING SPEED”.
ENGINE
Engine idling speed
1,000 ~ 1,100 r/min
8. Adjust:
• throttle body synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screw 1.
NOTE:
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If the air screw is removed, turn the screw 3/4
turn in and be sure to synchronize the throttle
body.
@
CAUTION:
Do not use the throttle valve adjusting screws
to adjust the throttle body synchronization.
Carburetor angle driver
90890-03158
Vacuum pressure at engine idling
speed
28.9 ~ 36.8 kPa
(220 ~ 280 mm Hg)
NOTE:
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mm Hg).
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Measure:
• engine idling speed
Out of specification → Adjust.
Make sure that the vacuum pressure is
within specification.
10.Stop the engine and remove the measuring
equipment.
3 - 22
SYNCHRONIZING THE THROTTLE BODIES/CHECKING
AND ADJUSTING THE EXHAUST GAS AT IDLE
CHK
ADJ
11.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
12.Remove:
• engine tachometer
• vacuum gauge
13.Remove:
• fuel tank
14.Install:
• T-bar
15.Install:
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
Note: On North American models the ECU jumper must be relocated prior to performing the
following proceedure. Please refer to http://www.micapeak.com/bike/FJR1300/howto/jumper.html
CHECKING AND ADJUSTING THE
EXHAUST GAS AT IDLE
(Measuring the exhaust gas at idle [when the
air induction system does not operate])
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
2.
•
•
•
Remove:
rider seat
fuel tank
T-bar
Refer to “SEATS AND FUEL TANK”.
• side cowlings
Refer to “COWLINGS AND COVERS”.
• exhaust pipe bolts 1
3 - 23
CHECKING AND ADJUSTING THE EXHAUST GAS AT
IDLE
CHK
ADJ
3. Install:
• pocket tester 1
(onto the engine oil drain bolt)
• engine tachometer
(onto the spark plug lead of cylinder #1)
• exhaust attachment 2
(onto the exhaust pipe)
Pocket tester
90890-03132
Engine tachometer
90890-06760
Exhaust attachment
90890-03134
4. Install:
• fuel tank
Refer to “SEATS AND FUEL TANK”.
5. Start the engine and warm it up until the
specified oil temperature is reached.
Oil temperature
80 ~ 90 °C
6. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE
IDLING SPEED”.
ENGINE
Engine idling speed
1,000 ~ 1,100 r/min
Note: Not all bikes are equipped with the exhaust ports on the headers. Refer to
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html for directions on how to add
them.
7. Install:
• CO/HC tester 1
(onto the exhaust attachment)
3 - 24
CHECKING AND ADJUSTING THE EXHAUST GAS AT
IDLE/ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
8. Measure:
• carbon monoxide density
Out of specification → Adjust.
Within specification → Measure the exhaust
gas when induction system is operating.
Carbon monoxide density (when
air induction system is not operating)
3.0 ~ 4.0%
Hydrocarbon density (when air
induction system is not operating)
ADJUSTING THE EXHAUST GAS VOLUME
NOTE:
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Setting steps
NOTE:
If the battery is not fully charged errors one to
four will be indicated on the display.
a. “CO” and “DIAG” modes
Push the “SELECT” button and the
“RESET” button together, and then set the
main switch to “ON”.
NOTE:
Be sure to push the buttons for more than
eight seconds after setting the main switch to
“ON”.
• All segments, except the clock and “TRIP”,
will start flashing.
• “DIAG” will be indicated on the display.
3 - 25
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
b. To switch to the “CO” adjusting mode
1) Push the “SELECT” button to switch the
display between the “CO” adjusting
mode and the “DIAG” mode.
2) Push the “SELECT” button and “RESET”
button together for more than two seconds to set the desired mode.
c. To select the cylinder to be adjusted
• Push the “SELECT” button or the “RESET”
button to select the cylinder.
NOTE:
The number of the cylinder to be adjusted will
be indicated on the display.
• Push the “RESET” button to scroll down the
cylinder numbers.
• Push the “SELECT” button to scroll up the
cylinder numbers.
• Push the “SELECT” button and the
“RESET” button together for more than two
seconds to set the cylinder.
d. To adjust the carbon monoxide exhaust gas
volume
• After selecting the cylinder, adjust the
exhaust gas volume by pushing the
“SELECT” button or the “RESET” button.
NOTE:
The exhaust gas volume will be indicated on
the display.
• Push the “RESET” button to increase the
volume.
• Push the “SELECT” button to decrease the
volume.
• Release the button to set the volume.
• Push the “SELECT” button and the
“RESET” button together to return to the
selected cylinder.
e. To deactivate the mode set the main switch
“OFF”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 26
CHECKING THE EXHAUST GAS AT IDLE
CHK
ADJ
CHECKING THE EXHAUST GAS AT IDLE
(Measuring the exhaust gas at idle [when air
induction system is operating])
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
2.
•
•
•
Remove:
rider seat
fuel tank
T-bar
Refer to “SEATS AND FUEL TANK”.
3. Install:
• pocket tester 1
(onto the engine oil drain bolt)
• engine tachometer
(onto the spark plug lead of cylinder #1)
Pocket tester
90890-03132
Engine tachometer
90890-06760
4. Install:
• fuel tank
Refer to “SEATS AND FUEL TANK”.
5. Start the engine and warm it up until the
specified oil temperature is reached.
Oil temperature
80 ~ 90 °C
6. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE
IDLING SPEED”.
Engine idling speed
1,000 ~ 1,100 r/min
3 - 27
ENGINE
CHECKING THE EXHAUST GAS AT IDLE/
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
7. Install:
• carbon monoxide and hydrocarbon tester
1
• sampling probe 2
NOTE:
• Since it is necessary to insert the sampling
probe 600 mm into the exhaust pipe, be sure
to use a heat-resistant rubber tube as shown
in the illustration.
• Be sure to set the heat-resistant rubber tube
so that exhaust gas does not leak out.
• Before using the carbon monoxide and
hydrocarbon tester, be sure to read the
user’s manual.
8. Measure:
• carbon monoxide density
• hydrocarbon density
Carbon monoxide density (when
air induction system is operating)
Below 1%
(Reference value)
Out of specification → Check air induction
system.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
EAS00052
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
throttle bodies synchronization should be
adjusted properly, the air filter element should
be clean, and the engine should have adequate compression.
@
3 - 28
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
1. Start the engine and let it warm up for several minutes.
2. Remove:
• fuel tank side panels (left and right)
• fuel tank front mounting bolts
3. Lift up the front of the fuel tank.
4. Attach:
• engine tachometer
(onto the spark plug lead of cylinder #1)
Engine tachometer
90890-06760
5. Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
1,000 ~ 1,100 r/min
6. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the throttle stop screw 1 in direction
a or b until the specified engine idling
speed is obtained.
Direction a
Engine idling speed is
increased.
Direction b
Engine idling speed is
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 29
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
7. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
8. Install:
• fuel tank front mounting bolts
• fuel tank side panels (left and right)
Refer to “SEATS AND FUEL TANK”.
EAS00055
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed and carburetor synchronization should be adjusted properly.
@
1. Check:
• throttle cable free play a
Out of specification → Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
2. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND FUEL TANK”.
3 - 30
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
3. Adjust:
• throttle cable free play
NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Throttle body side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or
b to take up any slack on the decelerator
cable.
c. Loosen the locknut 4 on the accelerator
cable.
d. Turn the adjusting nut 5 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot
be obtained on the throttle body side of the
cable, use the adjusting nut on the handlebar
side.
@
Handlebar side
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.
Direction c
Throttle cable free play
is increased.
Direction d
Throttle cable free play
is decreased.
c. Tighten the locknut.
3 - 31
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
CHK
ADJ
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
• rider seat
• fuel tank
• T-bar
Refer to “SEATS AND FUEL TANK”.
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
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.
4. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
CR8E (NGK)
U24ESR-N (DENSO)
3 - 32
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
CHK
ADJ
5. Check:
• electrodes 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
(with a wire gauge)
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm
T.
R.
8. Install:
• spark plug
13 Nm (1.3 m · kg)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
@
9. Connect:
• spark plug cap
10.Install:
• T-bar
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
EAS00061
CHECKING THE 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.
@
3 - 33
CHECKING THE IGNITION TIMING
CHK
ADJ
1.
•
•
•
Remove:
rider seat
fuel tank
T-bar
Refer to “SEATS AND FUEL TANK”.
• right side cowling
Refer to “COWLINGS AND COVERS”.
• timing mark accessing screw 1
2. Attach:
• timing light 1
• engine tachometer
(onto the spark plug lead of cylinder #1)
Timing light
90890-03141
Engine tachometer
90890-06760
3. Install:
• fuel tank
Refer to “SEATS AND FUEL TANK”.
4. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several minutes, and then let it run at the specified
engine idling speed.
Engine idling speed
1,000 ~ 1,100 r/min
b. Check that the mark a is within the
required firing range b on the timing plate.
Incorrect firing range → Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 34
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
5.
•
•
•
6.
•
•
Remove:
fuel tank
engine tachometer
timing light
Install:
timing mark accessing screw
right side cowling
Refer to “COWLINGS AND COVERS”.
• T-bar
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
@
1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
• rider seat
• fuel tank
• T-bar
Refer to “SEATS AND FUEL TANK”.
4. Disconnect:
• spark plug cap
5. Remove:
• spark plug
CAUTION:
@
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
3 - 35
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
6. Install:
• compression gauge adapter 1
• compression gauge 2
Compression gauge
90890-03081
Compression gauge adapter
90890-04136
7.
•
8.
•
Install:
fuel tank
Measure:
compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
1,390 kPa (13.9 kg/cm2, 13.9 bar)
Standard
1,600 kPa (16.0 kg/cm2, 16.0 bar)
Maximum
1,790 kPa (17.9 kg/cm2, 17.9 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
@
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure
between cylinders should not exceed 100 kPa
(1 kg/cm2, 1 bar).
@
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
3 - 36
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than without oil
Piston wear or
damage → Repair.
Same as without oil
Piston ring(s),
valves, cylinder
head gasket or piston possibly defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Remove:
• fuel tank
T.
R.
10.Install:
• spark plug
11.Connect:
• Spark plug cap
12.Install:
• T-bar
• fuel tank
• rider seat
13 Nm (1.3 m · kg)
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
2. Start the engine, warm it up for several minutes, and then turn it off.
3 - 37
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
3. Check:
• engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
Recommended oil
Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
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 or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CONSERVING II” d or higher.
• Do not allow foreign materials to enter the
crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
@
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
@
3 - 38
CHANGING THE ENGINE OIL
CHK
ADJ
EAS00073
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the gasket)
4. Drain:
• engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be
replaced, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the left side cowling.
Refer to “COWLINGS AND COVERS”.
b. Remove the oil filter cartridge 1 with an oil
filter wrench 2.
Oil filter wrench
90890-01426
c. Lubricate the O-ring 3 of the new oil filter
cartridge with a thin coat of engine oil.
CAUTION:
@
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
d. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
Oil filter cartridge
17 Nm (1.7 m · kg)
R.
e. Install the left side cowling.
Refer to “COWLINGS AND COVERS”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 39
CHK
ADJ
CHANGING THE ENGINE OIL
T.
6. Check:
• engine oil drain bolt gasket
Damage → Replace.
7. Install:
43 Nm (4.3 m · kg)
• engine oil drain bolt
R.
8. Fill:
• crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
4.9 L
Without oil filter cartridge
replacement
3.8 L
With oil filter cartridge replacement
4.0 L
9. Install:
• engine oil filler cap
10.Start the engine, warm it up for several minutes, and then turn it off.
11.Check:
• engine
(for engine oil leaks)
12.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
3 - 40
CHANGING THE ENGINE OIL/
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
13.Check:
• engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt 1.
b. Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “OIL PAN AND OIL
PUMP” in chapter 5.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
T.
Oil gallery bolt
20 Nm (2.0 m · kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
• engine oil level
Below the minimum level mark → Add the
recommended engine oil to the proper level.
2. Remove:
• side cowlings
3. Start the engine, warm it up for several minutes, and then turn it off.
CAUTION:
@
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3 - 41
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
4. Remove:
• main gallery bolt
WARNING
@
The engine, muffler and engine oil are
extremely hot.
5. Install:
• pressure gauge 1
• oil pressure adapter B 2
Pressure gauge
90890-03153
Oil pressure adapter B
90890-03124
6. Measure:
• engine oil pressure
(at the following conditions)
Engine oil pressure
65 kPa
(0.65 kg/cm2, 0.65 bar)
Engine speed
Approx. 1,000 ~ 1,100 r/min
Engine oil temperature
73 °C
Out of specification → Adjust.
Engine oil pressure
Possible causes
Below specification
• Faulty oil pump
• Clogged oil filter
• Leaking oil passage
• Broken or damaged oil seal
Above specification
• Leaking oil passage
• Faulty oil filter
• Oil viscosity too
high
7. Install:
• main gallery bolt
T.
R.
3 - 42
Main gallery bolt
12 Nm (1.2 m · kg)
ADJUSTING THE CLUTCH LEVER/
CHECKING THE CLUTCH FLUID LEVEL
CHK
ADJ
EAS00082
ADJUSTING THE CLUTCH LEVER
1. Adjust:
• clutch lever position
(distance a from the handlebar grip to the
clutch lever)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While pushing the clutch lever forward, turn
the adjusting dial 1 until the clutch lever is
in the desired position.
NOTE:
Be sure to align the setting on the adjusting
dial with the arrow mark 2 on the clutch lever
holder.
@
Position #1
Distance a is the largest.
Position #5
Distance a is the smallest.
WARNING
@
After adjusting the clutch lever position,
make sure the pin on the clutch lever
holder is firmly inserted in the hole in the
adjusting dial.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00083
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle 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
3 - 43
CHECKING THE CLUTCH FLUID LEVEL/
BLEEDING THE HYDRAULIC CLUTCH SYSTEM
CHK
ADJ
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.
• 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.
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.
@
EAS00084
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
WARNING
@
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.
3 - 44
BLEEDING THE HYDRAULIC CLUTCH SYSTEM
CHK
ADJ
NOTE:
• 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.
@
1. Bleed:
• hydraulic clutch system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
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.
T.
R.
3 - 45
Bleed screw
6 Nm (0.6 m · kg)
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
k. Add the recommended clutch fluid to the
proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL”.
WARNING
@
After bleeding the hydraulic clutch system,
check the clutch operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• seats
Refer to “SEATS AND FUEL TANK”.
• left side cover
Refer to “COWLINGS AND COVERS”.
2. Remove:
• air shroud 1
3. Remove:
• air filter case cover 1
• air filter element
4. Clean:
• air filter element
Apply compressed air to the outer surface
of the air filter element.
5. Check:
• air filter element
Damage → Replace.
3 - 46
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINTS
CHK
ADJ
6. Install:
• air filter element
• air filter case cover
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 tuning, leading to poor
engine performance and possible overheating.
NOTE:
When installing the air filter element into the air
filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.
@
7.
•
8.
•
Install:
air shroud
Install:
left side cover
Refer to “COWLINGS AND COVERS”.
• seats
Refer to “SEATS AND FUEL TANK”.
EAS00095
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the
throttle body joints.
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND FUEL TANK”.
2. Check:
• throttle body joint 1
Cracks/damage → Replace.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
3. Install:
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
3 - 47
CHECKING THE FUEL AND VACUUM HOSES/
CHECKING THE CRANKCASE BREATHER HOSE
CHK
ADJ
EAS00096
CHECKING THE FUEL AND VACUUM
HOSES
The following procedure applies to all of the
fuel and vacuum hoses.
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND FUEL TANK”.
2. Check:
• vacuum hose
• fuel hose
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND FUEL TANK”.
• air filter case
Refer to “AIR FILTER CASE”.
2. Check:
• crankcase breather hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
@
Make sure the crankcase breather hose is
routed correctly.
3. Install:
• air filter case
Refer to “AIR FILTER CASE”.
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
3 - 48
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes and gaskets.
1. Remove:
• side cowlings
Refer to “COWLINGS AND COVERS”.
2. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
• gasket 3
Exhaust gas leaks → Replace.
3. Check:
• tightening torque
T.
R.
Exhaust pipe assembly and
bracket bolt 4
17 Nm (1.7 m · kg)
Exhaust pipe nut 5
20 Nm (2.0 m · kg)
Muffler and passenger footrest
bracket bolt 6
25 Nm (2.5 m · kg)
Exhaust pipe and muffler bolt 7
20 Nm (2.0 m · kg)
4. Install:
• side cowlings
Refer to “COWLINGS AND COVERS”.
3 - 49
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
2. Remove:
• right side cowling
Refer to “COWLINGS AND COVERS”.
3. Check:
• coolant level
The coolant level should be between the
maximum level mark a and minimum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
CAUTION:
@
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available soft water may
be used.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
@
6. Install:
• side cowling (right)
Refer to “COWLINGS AND COVERS”.
3 - 50
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND FUEL TANK”.
• side cowlings
• front cowling assembly
Refer to “COWLINGS AND COVERS”.
2. Check:
• radiator 1
• radiator inlet hose 2
• radiator outlet hose 3
• oil cooler inlet hose 4
• oil cooler outlet hose 5
• water jacket joint 6
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
• front cowling assembly
• side cowlings
Refer to “COWLINGS AND COVERS”.
• fuel tank
• rider seat
Refer to “SEATS AND FUEL TANK”.
3 - 51
CHANGING THE COOLANT
CHK
ADJ
EAS00105
CHANGING THE COOLANT
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
2. Remove:
• side cowlings
• front cowling assembly
Refer to “COWLINGS AND COVERS”.
3. Disconnect:
• coolant reservoir hose 1
4. Drain:
• coolant
(from the coolant reservoir)
5. Remove:
• radiator cap 1
WARNING
@
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant
(from the engine and radiator)
3 - 52
CHK
ADJ
CHANGING THE COOLANT
T.
8. Check:
• copper washer 1 (coolant drain bolt 2)
Damage → Replace.
9. Install:
10 Nm (1.0 m · kg)
• coolant drain bolt
10.Connect:
• coolant reservoir hose
R.
11.Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1 : 1 (antifreeze : water)
Quantity
Total amount
3.2 L
Coolant reservoir capacity
0.485 L
From minimum to maximum
level mark
0.15 L
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
@
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
3 - 53
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
@
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water
may be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
12.Install:
• radiator cap
13.Remove:
• coolant reservoir cap cover 1
• coolant reservoir cap
14.Fill:
• coolant reservoir
(with the recommended coolant to the maximum level mark a)
15.Install:
• coolant reservoir cap
• coolant reservoir cap cover
16.Start the engine, warm it up for several minutes, and then stop it.
17.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
@
18.Install:
• front cowling assembly
• side cowlings
Refer to “COWLINGS AND COVERS”.
3 - 54
ADJUSTING THE FRONT BRAKE
CHK
ADJ
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• brake lever position
(distance a from the throttle grip to the
brake lever)
NOTE:
• While pushing the brake lever forward, turn
the adjusting dial 1 until the brake lever is in
the desired position.
• Be sure to align the setting on the adjusting
dial with the arrow mark 2 on the brake
lever holder.
@
Position #1
Distance a is the largest.
Position #5
Distance a is the smallest.
WARNING
@
• After adjusting the brake lever position,
make sure the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.
• A soft or spongy feeling in the brake system lever can indicate the presence of air
in the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an accident.
Therefore, check and if necessary, bleed
the brake system.
CAUTION:
@
After adjusting the brake lever position,
make sure there is no brake drag.
3 - 55
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00110
ADJUSTING THE REAR 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.
Brake pedal position (below the
top of the rider footrest)
42 mm
2. Adjust:
• brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction a or
b until the specified brake pedal position is
obtained.
Direction a
Brake pedal is raised.
Direction b
Brake pedal is lowered.
WARNING
@
After adjusting the brake pedal position,
check that the end of the adjusting bolt c
is visible through the hole d.
c. Tighten the locknut 1 to specification.
T.
Locknut
16 Nm (1.6 m · kg)
R.
WARNING
@
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
@
After adjusting the brake pedal position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 56
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
È
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
É
2. Remove: (rear brake only)
• seats
Refer to “SEATS AND FUEL TANK”.
• right side cover
Refer to “COWLINGS AND COVERS”.
3. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
È Front brake
É Rear brake
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.
3 - 57
CHECKING THE BRAKE FLUID LEVEL/
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
@
È
É
EAS00118
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• front brake pad
Wear indicator 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
• rear brake pad
Wear indicator 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
È Front brake
É Rear brake
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts.
@
3 - 58
ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE BRAKE HOSES
CHK
ADJ
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the right footrest bracket bolts 1.
b. Hold the main body 2 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 3 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.
c. Install the right footrest bracket bolts.
T.
Right footrest bracket bolt
28 Nm (2.8 m · kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00131
CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
• brake hose
Activate the brake several times.
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
3 - 59
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00134
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
@
Bleed the hydraulic brake system whenever: the system is disassembled, a brake
hose is loosened, disconnected or
replaced, the brake fluid level is very low,
brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
@
È
1. Remove:
• right side cover
Refer to “COWLINGS AND COVERS”.
2. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
È Front
É Rear
É
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in position.
3 - 60
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SHIFT PEDAL
CHK
ADJ
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
@
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T.
Bleed screw
6 Nm (0.6 m · kg)
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
@
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Check:
• shift pedal position
The end 1 of the shift pedal with the left
middle gear cover bolt.
Incorrect → Adjust.
2. Adjust:
• shift pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 2.
b. Turn the shift rod 3 in direction a or b to
obtain the correct shift pedal position.
3 - 61
Direction a
Shift pedal is raised.
Direction b
Shift pedal is lowered.
ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL
DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL
CHK
ADJ
NOTE:
Make sure that the mark on the shift pedal is
between the marks on the frame.
c. Tighten both locknuts.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00144
CHECKING THE FINAL DRIVE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
2. Remove:
• final drive housing oil filler bolt 1
3. Check:
• final drive oil level
The final drive oil level should be to the bottom brim 1 of the filler hole.
Below the bottom brim → Add the recommended final drive oil to the proper level.
Recommended oil
Drive shaft gear oil
4. Install:
• final drive housing oil filler bolt
T.
R.
23 Nm (2.3 m · kg)
EAS00145
CHANGING THE FINAL DRIVE OIL
1. Place a container under the final drive
housing.
2. Remove:
• final drive housing oil filler bolt 1
• final drive housing oil drain bolt 2
Completely drain the final drive housing of
its oil.
3 - 62
CHANGING THE FINAL DRIVE OIL/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
3. Check:
• final drive housing oil drain bolt gasket
Damage → Replace.
4. Install:
• final drive housing oil drain bolt
T.
R.
23 Nm (2.3 m · kg)
5. Fill:
• final drive housing
(with the specified amount of the recommended final drive oil)
Quantity
0.2 L
Refer to “CHECKING THE FINAL DRIVE
OIL LEVEL”.
EAS00147
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Loosen:
• upper bracket pinch bolts 1
3 - 63
CHECKING AND ADJUSTING THE STEERING HEAD
4.
•
•
•
CHK
ADJ
Remove:
steering stem nut 1
washer
upper bracket 2
(with the handlebars)
5. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer 1, the upper ring
nut 2, and the rubber washer 3.
b. Tighten the lower ring nut 4 with a steering
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
@
Steering nut wrench
90890-01403
T.
R.
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m · kg)
c. Loosen the lower ring nut one turn and then
tighten it to specification with a steering nut
wrench.
WARNING
@
Do not overtighten the lower ring nut.
T.
R.
Lower ring nut (final tightening
torque)
18 Nm (1.8 m · kg)
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “HANDLEBARS” and “STEERING
HEAD” in chapter 4.
e. Install the rubber washer.
f. Install the upper ring nut.
3 - 64
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
g. Finger tighten the upper ring nut, 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.
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
6. Install:
• upper bracket
(with the handlebars)
• washer
115 Nm (11.5 m · kg)
• steering stem nut
7. Tighten:
• upper bracket pinch bolts
R.
T.
R.
34 Nm (3.4 m · kg)
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.
3 - 65
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
@
• Always adjust both front fork legs evenly.
Uneven adjustment can result in poor
handling and loss of stability.
• Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
@
• Grooves are provided to indicate the
adjustment position.
• Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt 1 in direction a or
b.
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 1
Standard: 3
Maximum: 6
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping
CAUTION:
@
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• rebound damping
3 - 66
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 17 clicks out*
Standard: 12 clicks out*
Maximum: 1 click out*
*: from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
CAUTION:
@
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 21 clicks out*
Standard: 12 clicks out*
Maximum: 1 click out*
* from the fully turned-in position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 67
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY
CHK
ADJ
EAS00157
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Move the adjusting lever 1 in direction a or
b.
b. Adjust the adjusting lever to HARD or
SOFT.
Position a
Spring preload is
increased (suspension is
harder).
Position b
Spring preload is
decreased (suspension is
softer).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping
CAUTION:
@
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension is
softer).
3 - 68
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY/CHECKING THE TIRES
CHK
ADJ
Adjusting positions
Minimum: 20 clicks out*
Standard: 10 clicks out*
Maximum: 3 clicks out*
* from the fully turned-in position a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00162
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:
• tire pressure
Out of specification → Regulate.
WARNING
@
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil and
268 kg
a full fuel
tank)
Maximum
208 kg
load*
Cold tire
Front
pressure
250 kPa
Up to 90 kg
(2.5 kgf/cm2,
load*
2.5 bar)
250 kPa
90 kg ~ maxi(2.5 kgf/cm2,
mum load*
2.5 bar)
250 kPa
High-speed
(2.5 kgf/cm2,
riding
2.5 bar)
Rear
250 kPa
(2.5 kgf/cm2,
2.5 bar)
290 kPa
(2.9 kgf/cm2,
2.9 bar)
290 kPa
(2.9 kgf/cm2,
2.9 bar)
* total of cargo, rider, passenger and accessories
3 - 69
CHECKING THE TIRES
CHK
ADJ
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.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Sidewall
3 Wear indicator
WARNING
@
È
É
• 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.
È Tire
É Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning handling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
3 - 70
CHECKING THE TIRES/
CHECKING THE WHEELS
CHK
ADJ
Front tire
Manufacturer
Model
Size
METZELER
MEZ4B
FRONT
120/70ZR17
(58W)
BRIDGESTONE
BT020F
N
120/70ZR17
(58W)
Manufacturer
Model
Size
METZELER
MEZ4J
180/55ZR17
(73W)
BRIDGESTONE
BT020R
N
180/55ZR17
(73W)
Rear tire
WARNING
@
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 4:
• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 5 with the valve installation
point.
@
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• wheel
Damage/out-of-round → Replace.
WARNING
@
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or
replaced, always balance the wheel.
@
3 - 71
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE SIDESTAND
CHK
ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
cable sheaths and cables.
WARNING
@
Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement.
Replace
damaged
cable
sheaths and cables as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
@
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium soap base grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium soap base grease
3 - 72
LUBRICATING THE CENTERSTAND/
LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium soap base grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Lithium soap base grease
3 - 73
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
@
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
@
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
3 - 74
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
@
1. Remove:
• right inner panel (front cowling)
Refer to “COWLINGS AND COVERS”.
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
@
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3.
•
4.
•
Remove:
battery
Measure:
battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Open-circuit voltage (V)
a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
Relationship between the open-circuit voltage and the
charging time at 20 °C
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
@
Charging time (hours)
These values vary with the temperature, the condition of the battery
plates, and the electrolyte level.
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 75
CHECKING AND CHARGING THE BATTERY
Ambient temperature
20 °C
Open-circuit voltage (V)
Charging
CHK
ADJ
5. Charge:
• battery
(refer to the appropriate charging method
illustration)
WARNING
@
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
@
Open-circuit voltage (V)
Ambient
temperature
20 °C
Charging condition of the battery (%)
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charging has to be done with the battery
mounted on the motorcycle, disconnect
the negative battery lead from the battery
terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
3 - 76
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable voltage charger
Charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Ammeter
NOTE:
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
Set the charging voltage to
16 ~ 17 V. (If the charging
voltage is lower, charging will
be insufficient, if it is higher,
the battery will be overcharged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
Monitor the amperage for 3 ~ 5
minutes. Is the standard charging amperage exceeded?
YES
NO
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the
charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3 - 77
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variable
voltage- charger is recommended.
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Voltmeter
CAUTION:
Constant amperage chargers are
not suitable for charging MF batteries.
3 - 78
Ammeter
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
6.
•
7.
•
CHK
ADJ
Install:
battery
Connect:
battery leads
(to the battery terminals)
CAUTION:
@
First, connect the positive battery lead 1,
and then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• right inner panel (front cowling)
Refer to “COWLINGS AND COVERS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
@
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1.
•
•
•
Remove:
right inner panel (front cowling)
left inner panel (front cowling)
front-right inner panel (front cowling)
Refer to “COWLINGS AND COVERS”.
2. Check:
• continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
3 - 79
CHECKING THE FUSES
CHK
ADJ
NOTE:
Set the pocket tester selector to “Ω × 1”.
@
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Items
Amperage
rating
Q’ty
Main fuse
50 A
1
Headlight fuse
25 A
1
Radiator fan motor
fuse
15 A
1
Signaling system
fuse
15 A
1
Fuel injection
system fuse
15 A
1
Ignition fuse
10 A
1
Parking lighting fuse
10 A
1
Windshield motor
fuse
2A
1
Hazard lighting fuse
7.5 A
1
Backup fuse
10 A
1
Reserve fuse
50 A
1
Reserve fuse
25 A
1
Reserve fuse
15 A
2
Reserve fuse
10 A
1
Reserve fuse
7.5 A
1
Reserve fuse
2A
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 80
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
@
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
4.
•
•
•
Install:
front-right inner panel (front cowling)
right inner panel (front cowling)
left inner panel (front cowling)
Refer to “COWLINGS AND COVERS”.
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:
• headlight coupler 1
2. Remove:
• headlight bulb cover 2
3.
•
4.
•
Detach:
headlight bulb holder 1
Remove:
headlight bulb 2
WARNING
@
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
3 - 81
REPLACING THE HEADLIGHT BULBS/
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
5. Install:
• headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
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.
6.
•
7.
•
8.
•
Attach:
headlight bulb holder
Install:
headlight bulb cover
Connect:
headlight coupler
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 82
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
2. Adjust:
• headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Left headlight
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beam moves
to the left.
Right headlight
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beam moves
to the left.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 83
CHAS
4
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS ............................................................ 4-1
REMOVING THE FRONT WHEEL............................................................ 4-3
CHECKING THE FRONT WHEEL ............................................................ 4-3
CHECKING THE BRAKE DISCS .............................................................. 4-5
INSTALLING THE FRONT WHEEL .......................................................... 4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-7
REAR WHEEL AND BRAKE DISC.................................................................4-9
REMOVING THE REAR WHEEL ............................................................ 4-11
CHECKING THE REAR WHEEL............................................................. 4-11
INSTALLING THE REAR WHEEL........................................................... 4-12
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-12
FRONT AND REAR BRAKES....................................................................... 4-13
FRONT BRAKE PADS ............................................................................4-13
REAR BRAKE PADS............................................................................... 4-14
REPLACING THE FRONT BRAKE PADS .............................................. 4-15
REPLACING THE REAR BRAKE PADS................................................. 4-17
FRONT BRAKE MASTER CYLINDER....................................................4-20
REAR BRAKE MASTER CYLINDER ......................................................4-23
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 4-26
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-26
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS..4-27
ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER...........................................4-28
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-30
FRONT BRAKE CALIPERS .................................................................... 4-33
REAR BRAKE CALIPER .........................................................................4-35
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-37
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-38
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................4-39
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS ..... 4-40
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER..........4-42
HYDRAULIC CLUTCH .................................................................................. 4-46
CLUTCH MASTER CYLINDER...............................................................4-46
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 4-49
CHECKING THE CLUTCH MASTER CYLINDER................................... 4-50
ASSEMBLING AND INSTALLING THE CLUTCH
MASTER CYLINDER ............................................................................. 4-51
CLUTCH RELEASE CYLINDER ............................................................. 4-54
DISASSEMBLING THE CLUTCH RELEASE CYLINDER.......................4-56
CHECKING THE CLUTCH RELEASE CYLINDER .................................4-57
ASSEMBLING AND INSTALLING THE CLUTCH
RELEASE CYLINDER ............................................................................4-57
CHAS
FRONT FORK................................................................................................4-60
REMOVING THE FRONT FORK LEGS.................................................. 4-63
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-63
CHECKING THE FRONT FORK LEGS .................................................. 4-65
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-66
INSTALLING THE FRONT FORK LEGS ................................................ 4-70
HANDLEBARS ..............................................................................................4-71
LEFT HANDLEBAR................................................................................. 4-71
RIGHT HANDLEBAR .............................................................................. 4-72
REMOVING THE HANDLEBARS ........................................................... 4-73
CHECKING THE HANDLEBARS ............................................................ 4-73
INSTALLING THE HANDLEBARS .......................................................... 4-74
STEERING HEAD.......................................................................................... 4-77
REMOVING THE LOWER BRACKET.....................................................4-79
CHECKING THE STEERING HEAD .......................................................4-79
INSTALLING THE STEERING HEAD .....................................................4-80
REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM .....................4-82
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-84
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-84
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-84
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-85
CHECKING THE CONNECTING ARM AND RELAY ARM.....................4-85
INSTALLING THE RELAY ARM..............................................................4-86
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-86
SWINGARM................................................................................................... 4-87
REMOVING THE SWINGARM................................................................4-89
CHECKING THE SWINGARM ................................................................4-89
INSTALLING THE SWINGARM ..............................................................4-90
SHAFT DRIVE ...............................................................................................4-92
TROUBLESHOOTING ............................................................................4-92
CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION
AND CHECKING THE SHAFT DRIVE FOR LEAKS ..............................4-95
MEASURING THE RING GEAR BACKLASH .........................................4-96
ADJUSTING THE RING GEAR BACKLASH...........................................4-97
MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE ... 4-98
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE .... 4-98
REMOVING THE LEFT FOOTREST BRACKET .................................. 4-104
DISASSEMBLING THE FINAL DRIVE ASSEMBLY .............................4-104
REMOVING AND INSTALLING THE RING GEAR BEARINGS ........... 4-105
ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR........4-107
CHECKING THE DRIVE SHAFT........................................................... 4-112
INSTALLING THE UNIVERSAL JOINT AND
FINAL DRIVE ASSEMBLY ................................................................... 4-112
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the front wheel and brake
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
@
1
2
3
4
5
6
7
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collar (left)
Collar (right)
Brake disc (left and right)
2
1
1
1
1
1
2
Loosen.
Refer to “REMOVING/
INSTALLING THE
FRONT WHEEL”.
For installation, reverse the removal
procedure.
4-1
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00518
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal
Wheel bearing
Spacer
Q’ty
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
2. Remove:
• left brake caliper
• right brake caliper
NOTE:
Do not squeeze the brake lever when removing the brake calipers.
@
3. Elevate:
• front wheel
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
@
Do not attempt to straighten a bent wheel
axle.
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
4-3
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Radial wheel runout limit
1.0 mm
Lateral wheel runout limit
0.5 mm
4. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
5. Replace:
• wheel bearings New
• oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
@
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
@
Do not contact the wheel bearing inner race
4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-4
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maximum)
Front: 0.10 mm
Rear: 0.15 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm below the
edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
Front: 4.5 mm
Rear: 5.5 mm
4-5
CHAS
FRONT WHEEL AND BRAKE DISCS
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
@
T.
R.
Brake disc bolt
18 Nm (1.8 m · kg)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium soap base grease
T.
2. Tighten:
72 Nm (7.2 m · kg)
• wheel axle 1
• wheel axle pinch bolt 2
R.
T.
R.
23 Nm (2.3 m · kg)
CAUTION:
@
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds
smoothly.
4-6
CHAS
FRONT WHEEL AND BRAKE DISCS
T.
R.
3. Install:
• brake caliper
40 Nm (4.0 m · kg)
WARNING
@
Make sure the brake hose is routed properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
• Adjust the front wheel static balance with the
brake discs installed.
@
1.
•
2.
•
Remove:
balancing weight(s)
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 “X” mark
at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X” mark at
the bottom of the wheel.
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”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-7
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
@
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
REAR WHEEL AND BRAKE DISC
CHAS
EAS00551
REAR WHEEL AND BRAKE DISC
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the rear wheel and brake
disc
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
@
1
2
3
4
5
6
7
8
Brake torque rod nut/bolt
Wheel axle nut
Wheel axle pinch bolt
Rear wheel axle
Rear brake caliper
Rear wheel
Collar
Brake disc
1/1
1
1
1
1
1
1
1
Loosen.
Refer to “INSTALLING
THE REAR WHEEL”.
For installation, reverse the removal
procedure.
4-9
REAR WHEEL AND BRAKE DISC
CHAS
AS00560
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the rear wheel
Dust cover
Rear wheel drive hub
Dust seal
Wheel bearing
Rear wheel drive hub damper
Oil seal
Circlip
Wheel bearing
Spacer
Collar
Oil seal
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
2
6
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 10
REAR WHEEL AND BRAKE DISC
CHAS
EEAS00562
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
2. Remove:
• brake caliper bracket
NOTE:
Do not depress the brake pedal when removing the brake caliper bracket with brake caliper.
@
3. Remove:
• rear wheel
NOTE:
Move the rear wheel to the right to separate it
from the final drive housing.
EAS00565
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
2. Check:
• tire
• rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
4 - 11
CHAS
REAR WHEEL AND BRAKE DISC
3. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
EEAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
Recommended lubricant
Lithium soap base grease
2. Tighten:
• brake torque rod nut
T.
R.
T.
R.
• wheel axle nut
• wheel axle pinch bolt
30 Nm (3.0 m · kg)
125 Nm (12.5 m · kg)
T.
R.
16 Nm (1.6 m · kg)
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub
installed.
@
1. Adjust:
• rear wheel static balance
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
4 - 12
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the front brake pads
Brake hose holder bolt
Brake caliper bolt
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
1
2
2
1
1
2
2
1
For installation, reverse the removal
procedure.
4 - 13
FRONT AND REAR BRAKES
CHAS
EAS00578
REAR BRAKE PADS
Order
1
2
3
4
Job/Part
Removing the rear brake pads
Retaining bolt
Brake pad
Brake pad shim
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
2
2
2
1
For installation, reverse the removal
procedure.
4 - 14
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
@
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.
EAS00582
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
@
1. Remove:
• brake hose holder bolt 1
• brake caliper 2
4 - 15
FRONT AND REAR BRAKES
2.
•
•
•
•
CHAS
Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
brake pads
(along with the brake pad shims)
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
Bleed screw
6 Nm (0.6 m · kg)
R.
d. Install a new brake pad shim onto the new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 16
CHAS
FRONT AND REAR BRAKES
R.
T.
R.
Install:
brake pad pins
brake pad clips
brake caliper
brake hose holder
T.
5.
•
•
•
•
40 Nm (4.0 m · kg)
7 Nm (0.7 m · kg)
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
@
1. Remove:
• retaining bolts 1
• brake caliper 2
2. Remove:
• brake pads 1
(along with the brake pad shims)
• brake pad springs 2
4 - 17
CHAS
FRONT AND REAR BRAKES
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm
4. Install:
• brake pad springs
• brake pad shims
(onto the brake pads)
• brake pads
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper piston into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
Bleed screw
6 Nm (0.6 m · kg)
R.
d. Install new brake pad springs 3.
e. Install a new brake pad shim 4 onto each
new brake pad 5.
f. Install new brake pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
4 - 18
T.
5. Install:
• retaining bolts
26 Nm (2.6 m · kg)
FRONT AND REAR BRAKES
CHAS
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 19
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
Order
1
2
3
4
5
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the front brake master
cylinder
Brake fluid
Drain.
Brake master cylinder reservoir cap
1
Brake master cylinder reservoir dia1
phragm holder
Brake master cylinder reservoir dia1
phragm
Brake lever
1
Front brake light switch connector
2
Disconnect.
4 - 20
FRONT AND REAR BRAKES
Order
6
7
8
9
10
11
Job/Part
Union bolt
Copper washer
Brake hose
Brake master cylinder holder
Brake master cylinder
Front brake light switch
Q’ty
1
2
1
Disconnect.
1
1
CHAS
Remarks
Refer to
“DISASSEMBLING/
ASSEMBLING AND
INSTALLING THE
FRONT BRAKE MASTER
CYLINDER”.
1
For installation, reverse the removal
procedure.
4 - 21
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the front brake master cylinder
Dust boot
1
Circlip
1
Brake master cylinder kit
1
Brake master cylinder
1
For assembly, reverse the disassembly
procedure.
4 - 22
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the rear brake master cylinder
Side cover (right)
Refer to “COWLINGS AND COVERS” in
chapter 3.
Brake fluid
Drain.
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Hose joint
1
Rear brake light switch coupler
1
Disconnect.
Right footrest bracket bolt
2
4 - 23
FRONT AND REAR BRAKES
Order
9
10
11
12
13
14
Job/Part
Union bolt
Copper washer
Brake hose
Cotter pin
Pin
Brake master cylinder
Q’ty
1
2
1
Disconnect.
CHAS
Remarks
Refer to
“DISASSEMBLING/
ASSEMBLING THE
REAR BRAKE MASTER
CYLINDER”.
1
1
1
For installation, reverse the removal
procedure.
4 - 24
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
1
2
3
4
5
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the rear brake master cylinder
Dust boot
1
Circlip
1
Push rod
1
Brake master cylinder kit
1
Brake master cylinder
1
For assembly, reverse the disassembly
procedure.
4 - 25
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
@
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
@
4 - 26
FRONT AND REAR BRAKES
CHAS
EAS00592
È
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
É
È Front
É Rear
È
É
2. Check:
• brake master cylinder kit 1
Damage/scratches/wear → Replace.
È Front
É Rear
3. Check:
• rear brake fluid reservoir 1
Cracks/damage → Replace.
• rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
4. Check:
• front brake master cylinder reservoir 1
Cracks/damage → Replace.
• front brake master cylinder reservoir diaphragm 2
Damage/wear → Replace.
4 - 27
CHAS
FRONT AND REAR BRAKES
5. Check:
• brake hoses
Cracks/damage/wear → Replace.
EAS00606
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
1. Install:
• brake master cylinder 1
T.
R.
10 Nm (1.0 m · kg)
NOTE:
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a in the right
handlebar.
• First, tighten the upper bolt, then the lower
bolt.
@
New
R.
Install:
copper washers 1
brake hose 2
union bolt 3
T.
2.
•
•
•
30 Nm (3.0 m · kg)
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
4 - 28
FRONT AND REAR BRAKES
CHAS
CAUTION:
@
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
NOTE:
Turn the handlebars to the left and to the right
to make sure the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
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.
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” in chapter 3.
4 - 29
CHAS
FRONT AND REAR BRAKES
5. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
T.
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• copper washers 1 New
• brake hose 2
30 Nm (3.0 m · kg)
• union bolt 3
R.
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
@
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
2. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
4 - 30
FRONT AND REAR BRAKES
CHAS
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Adjust:
• brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position (below the
top of the rider footrest)
42 mm
4 - 31
FRONT AND REAR BRAKES
CHAS
6. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4 - 32
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPERS
Order
1
2
3
4
5
6
Job/Part
Removing the front brake calipers
Brake fluid
Brake hose holder bolt
Union bolt
Copper washer
Brake hose
Brake caliper bolt
Brake caliper
Q’ty
1
1
2
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Drain.
Disconnect.
Refer to
“DISASSEMBLING/
ASSEMBLING AND
INSTALLING THE
FRONT BRAKE
CALIPERS”.
For installation, reverse the removal
procedure.
4 - 33
FRONT AND REAR BRAKES
CHAS
EAS00615
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the front brake calipers
The following procedure applies to both
of the front brake calipers.
Brake pad clip
2
Brake pad pin
1
Brake pad spring
1
Brake pad/brake pad shim
2/2
Brake caliper piston
4
Refer to “DISASSEMBLING THE
FRONT BRAKE CALIPERS”.
Brake caliper piston seal
8
Bleed screw
1
For assembly, reverse the disassembly
procedure.
4 - 34
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Retaining bolt
Brake torque rod
Wheel axle nut
Wheel axle pinch bolt
Rear wheel axle
Brake caliper
Q’ty
1
2
1
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
Loosen.
Loosen.
Refer to
“DISASSEMBLING/
ASSEMBLING AND
INSTALLING THE REAR
BRAKE CALIPER”.
For installation, reverse the removal
procedure.
4 - 35
FRONT AND REAR BRAKES
CHAS
EAS00617
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the rear brake caliper
Retaining bolt
2
Brake pad/brake pad shim
2/2
Brake pad spring
2
Rear brake caliper bracket
1
Brake caliper piston
1
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER”.
Brake caliper piston seal
2
Bleed screw
1
For assembly, reverse the disassembly
procedure.
4 - 36
FRONT AND REAR BRAKES
CHAS
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the entire brake system.
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
@
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper pistons
with a piece of wood a.
b. Blow compressed air into the brake hose
joint opening b to force out the left side pistons from the brake caliper.
WARNING
@
• Never try to pry out the brake caliper pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 37
FRONT AND REAR BRAKES
CHAS
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
@
2. Remove:
• brake caliper piston 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening a to force out the piston from
the brake caliper.
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.
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 38
FRONT AND REAR BRAKES
CHAS
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every two years
Brake fluid
Every two years
and whenever the
brake is disassembled
È
É
1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper.
• brake caliper cylinders 2
Scratches/wear → Replace the brake caliper.
• brake calipers
Cracks/damage → Replace.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
@
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
È Front
É Rear
2. Check:
• rear brake caliper bracket 1
• brake torque rod 2
Cracks/damage → Replace.
4 - 39
CHAS
FRONT AND REAR BRAKES
EAS00638
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
T.
1. Install:
• brake caliper 1
(temporarily)
• copper washers New
• brake hose 2
30 Nm (3.0 m · kg)
• union bolt 3
R.
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
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.
2. Remove:
• brake caliper
4 - 40
CHAS
FRONT AND REAR BRAKES
Install:
brake pads
brake pad spring
40 Nm (4.0 m · kg)
brake caliper
7 Nm (0.7 m · kg)
brake hose holder
Refer to “REPLACING THE FRONT
BRAKE PADS”.
T.
R.
T.
R.
3.
•
•
•
•
4. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
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.
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” in chapter 3.
4 - 41
FRONT AND REAR BRAKES
CHAS
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00642
ASSEMBLING AND INSTALLING THE
REAR BRAKE CALIPER
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1. Lubricate:
• wheel axle
Recommended lubricant
Lithium soap base grease
4 - 42
CHAS
FRONT AND REAR BRAKES
R.
T.
R.
Tighten:
brake torque rod
wheel axle nut
wheel axle pinch bolt
T.
2.
•
•
•
T.
R.
125 Nm (12.5 m · kg)
16 Nm (1.6 m · kg)
New
T.
R.
3. Install:
• brake caliper
(temporarily)
• copper washers 1
• brake hose 2
• union bolt 3
30 Nm (3.0 m · kg)
30 Nm (3.0 m · kg)
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
@
When installing the brake hose onto the
brake caliper, make sure the brake pipe a
touches the projection b on the brake caliper.
4. Remove:
• brake caliper
R.
4 - 43
Install:
brake pad springs
brake pads
brake caliper
26 Nm (2.6 m · kg)
retaining bolts
Refer to “REPLACING THE REAR BRAKE
PADS”.
T.
5.
•
•
•
•
FRONT AND REAR BRAKES
CHAS
6. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
7. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
8. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4 - 44
FRONT AND REAR BRAKES
CHAS
9. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 45
HYDRAULIC CLUTCH
CHAS
EAS00305
HYDRAULIC CLUTCH
CLUTCH MASTER CYLINDER
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the clutch master cylinder
Clutch fluid
Drain.
Clutch master reservoir cap
1
Clutch master reservoir diaphram
1
holder
Clutch master reservoir diaphram
1
Clutch lever
1
Bushing
1
Clutch switch coupler
1
Disconnect.
4 - 46
HYDRAULIC CLUTCH
Order
7
8
9
10
Job/Part
Union bolt
Copper washer
Clutch hose
Clutch master cylinder holder
CHAS
Q’ty
1
2
1
Disconnect.
1
11
Clutch master cylinder
1
12
Clutch switch
1
Remarks
Refer to
“DISASSEMBLING/
ASSEMBLING AND
INSTALLING THE
CLUTCH MASTER
CYLINDER”.
Refer to “ASSEMBLING AND
INSTALLING THE CLUTCH MASTER
CYLINDER”.
For installation, reverse the removal
procedure.
4 - 47
HYDRAULIC CLUTCH
CHAS
EAS00306
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the clutch master
cylinder
Clutch master cylinder push rod
1
Dust seal
1
Circlip
1
Washer
1
Clutch master cylinder kit
1
Clutch master cylinder
1
For assembly, reverse the disassembly
procedure.
4 - 48
HYDRAULIC CLUTCH
CHAS
EAS00307
CAUTION:
@
Clutch components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble clutch components
unless absolutely necessary.
• If any connection on the hydraulic clutch
system is disconnected, the entire clutch
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal clutch
components.
• Use only clean or new clutch fluid for
cleaning clutch components.
• Clutch fluid may damage painted surfaces and plastic parts. Therefore, always
clean up any spilt fluid immediately.
• Avoid clutch fluid coming into contact
with the eyes as it can cause serious
injury.
• First aid for clutch fluid entering the eyes:
• Flush with water for 15 minutes and get
immediate medical attention.
DISASSEMBLING THE CLUTCH MASTER
CYLINDER
NOTE:
Before disassembling the clutch master cylinder, drain the clutch fluid from the entire clutch
system.
1.
•
•
•
Remove:
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.
4 - 49
HYDRAULIC CLUTCH
CHAS
EAS00308
CHECKING THE CLUTCH MASTER
CYLINDER
Recommended clutch component
replacement schedule
Piston seals
Every two years
Clutch hose
Every two years
Clutch fluid
Every two years
and whenever the
clutch is disassembled
1. Check:
• clutch master cylinder body 1
Cracks/damage → Replace the clutch master cylinder.
• clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
• clutch master cylinder 1
• clutch master cylinder kit 2
Rust/scratches/wear → Replace the clutch
master cylinder and clutch master cylinder
kit as a set.
3. Check:
• clutch master cylinder reservoir 1
Cranks/damage → Replace.
• clutch master cylinder reservoir diaphragm 2
Damage/wear → Replace.
4. Check:
• clutch hose
Cracks/damage/wear → Replace.
4 - 50
CHAS
HYDRAULIC CLUTCH
EAS00309
EAS00310
ASSEMBLING AND INSTALLING THE
CLUTCH MASTER CYLINDER
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
seals to swell and distort.
Recommended clutch fluid
Brake fluid DOT 4
1. Install:
• clutch master cylinder 1
T.
R.
10 Nm (1.0 m · kg)
NOTE:
• Install the clutch master cylinder holder with
the “UP” mark facing up.
• Align the end of the clutch master cylinder
holder with the punch mark a in the left handlebar.
• First, tighten the upper bolt, then the lower
bolt.
@
Install:
copper washers 1 New
clutch hose 2
30 Nm (3.0 m · kg)
union bolt 3
T.
R.
2.
•
•
•
WARNING
@
Proper clutch hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
4 - 51
HYDRAULIC CLUTCH
CHAS
CAUTION:
@
When installing the clutch hose onto the
clutch master cylinder, make sure the
clutch pipe touches the projection a as
shown.
NOTE:
Turn the handlebars to the left and to the right
to make sure the clutch hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
• clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
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.
• 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.
CAUTION:
@
Clutch fluid may damage painted surfaces
or plastic parts. Therefore, always clean up
any spilt clutch fluid immediately.
4 - 52
HYDRAULIC CLUTCH
CHAS
4. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
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” in chapter 3.
6. Check:
• clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4 - 53
HYDRAULIC CLUTCH
CHAS
EAS00311
CLUTCH RELEASE CYLINDER
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the clutch release cylinder
Clutch fluid
Drain.
Union bolt
1
Refer to
“DISASSEMBLING/
Copper washer
2
Clutch hose
1
Disconnect. ASSEMBLING AND
INSTALLING THE
CLUTCH MASTER
CYLINDER”.
Clutch release cylinder
1
Dowel pin
2
Plate
1
For installation, reverse the removal
procedure.
4 - 54
HYDRAULIC CLUTCH
Order
1
2
3
4
CHAS
Job/Part
Q’ty
Remarks
Disassembling the clutch release
Remove the parts in the order listed.
cylinder
Clutch release cylinder piston
1
Refer to “DISASSEMBLING THE
Clutch release cylinder spring
1
CLUTCH RELEASE CYLINDER”.
Clutch release cylinder piston seal
1
Bleed screw
1
For assembly, reverse the disassembly
procedure.
4 - 55
HYDRAULIC CLUTCH
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
NOTE:
Before disassembling the clutch release cylinder, drain the clutch fluid from the entire clutch
system.
1.
•
•
•
Remove:
union bolt 1
copper washers 2
clutch hose 3
NOTE:
Put the end of the clutch hose into a container
and pump out the clutch fluid carefully.
2.
•
•
•
Remove:
clutch release cylinder piston 1
clutch release cylinder spring 2
clutch release cylinder piston seal 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the clutch hose
joint opening a to force out the piston from
the clutch release cylinder.
WARNING
@
• Cover the clutch release cylinder with a
rag. Be careful not to get injured when the
piston is expelled from the clutch release
cylinder.
• Never try to pry out the clutch release cylinder piston.
b. Remove the clutch release cylinder spring
and piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 56
CHAS
HYDRAULIC CLUTCH
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
Recommended clutch component
replacement schedule
Piston seal
Every two years
Clutch hose
Every two years
Clutch fluid
Every two years
and whenever the
clutch is disassembled
1. Check:
• clutch release cylinder body 1
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.
EAS00315
T.
ASSEMBLING AND INSTALLING THE
CLUTCH RELEASE CYLINDER
1. Install:
• copper washers 1 New
• clutch hose 2
30 Nm (3.0 m · kg)
• union bolt 3
R.
WARNING
@
Proper clutch hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
@
When installing the clutch hose onto the
clutch release cylinder, make sure the
clutch pipe a touches the projection b on
the clutch release cylinder.
4 - 57
HYDRAULIC CLUTCH
CHAS
2. Fill:
• clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
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.
• 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.
CAUTION:
@
Clutch fluid may damage painted surfaces
or plastic parts. Therefore, always clean up
any spilt clutch fluid immediately.
3. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
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” in chapter 3.
4 - 58
HYDRAULIC CLUTCH
CHAS
5. Check:
• clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4 - 59
FRONT FORK
CHAS
EAS00647
FRONT FORK
Order
Job/Part
Removing the front fork legs
Q’ty
Front cowling assembly
Front wheel
1
2
3
4
5
Front fender
Upper bracket pinch bolt
Cap bolt
Lower bracket pinch bolt
Front fork leg
1
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “COWLINGS” AND “COVERS”
in chapter 3.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Loosen.
Loosen.
Loosen.
Refer to “REMOVING/
INSTALLING THE
FRONT FORK LEGS”.
For installation, reverse the removal
procedure.
4 - 60
FRONT FORK
CHAS
EAS00648
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the front fork legs
Q’ty
Cap bolt/O-ring
Damper adjusting rod
Nut
Spacer
Washer
Fork spring
Spring seat
Dust seal
Oil seal clip
Damper rod assembly bolt
Copper washer
1/1
1
1
1
1
1
1
1
1
1
1
4 - 61
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
FRONT FORK
Order
B
C
D
E
F
G
H
I
Job/Part
Damper rod assembly
Inner tube
Oil seal
Seal spacer
Outer tube bushing
Inner tube bushing
Oil flow stopper
Outer tube
Q’ty
1
1
1
1
1
1
1
1
CHAS
Remarks
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
Refer to “ASSEMBLING THE FRONT
FORK LEGS”.
For assembly, reverse the disassembly
procedure.
4 - 62
FRONT FORK
CHAS
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
2.
•
•
•
Loosen:
upper bracket pinch bolt 1
cap bolt 2
lower bracket pinch bolts 3
WARNING
@
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
3. Remove:
• front fork leg
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Loosen:
• nut 1
• cap bolt 2
2. Remove:
• cap bolt
• nut
3. Drain:
• fork oil
NOTE:
Stroke the inner tube several times while
draining the fork oil.
@
4 - 63
FRONT FORK
CHAS
4. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
@
Do not scratch the inner tube.
NOTE:
• Do not remove the fork leg protector from the
outer tube.
• If the front fork leg protector must be
removed, always install a new one.
@
5.
•
•
•
Remove:
washer
damper rod assembly bolt 1
copper washer
NOTE:
• If the washer is difficult to remove, use an
impact wrench to loosen the damper rod
assembly bolt.
• While holding the damper rod with the
damper rod holder 2, loosen the damper rod
assembly bolt.
@
Damper rod holder
90890-01447
6. 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CAUTION:
@
4-
• 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,
64 as the oil flow stopper will be damaged.
FRONT FORK
CHAS
EAS00657
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
@
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• spring free length a
Out of specification → Replace.
Spring free length
261 mm
3. Check:
• damper rod 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• oil flow stopper 2
Damage → Replace.
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 - 65
FRONT FORK
CHAS
4. Check:
• cap bolt O-ring
Damage/wear → Replace.
EAS00661
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
@
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
• 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.
@
1. Install:
• damper rod assembly 1
CAUTION:
@
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil 01 or
equivalent
4 - 66
CHAS
FRONT FORK
3. Tighten:
• damper rod assembly bolt 1
T.
R.
35 Nm (3.5 m · kg)
NOTE:
• If the washer has not been removed during
disassembly, strike the washer lightly, and
then remove it.
• While holding the damper rod assembly with
the damper rod holder 2, tighten the damper
rod assembly bolt.
@
Damper rod holder
90890-01447
4. Install:
• outer tube bushing 1 New
(with the fork seal driver 2)
Fork seal driver
90890-01442
5. Install:
• seal spacer
• oil seal 1 New
(with the fork seal driver)
CAUTION:
@
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium soap base grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 2 to protect the oil seal during installation.
@
4 - 67
FRONT FORK
CHAS
6. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
groove of the outer tube.
@
7. Install:
• dust seal 1 New
(with the fork seal driver)
8. Fully compress the front fork leg.
9. Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.7 L
Recommended oil
Suspension oil “01” or equivalent
CAUTION:
@
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
10.After filling the front fork leg, slowly stroke
the damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly
because the fork oil may spurt out.
@
4 - 68
FRONT FORK
CHAS
11.Slowly stroke the inner tube 1 up and
down.
12.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual air.
@
13.Measure:
• front fork leg oil level a
Out of specification → Correct.
Front fork leg oil level (from the
top of the inner tube, with the
inner tube fully compressed, and
without the spring)
79 mm
14.Install:
• nut 1
• damper adjusting rod 2
• cap bolt 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the nut 1 and finger tighten it.
b. Install the damper adjusting rod 2.
c. Install the cap bolt 3 and finger tighten it.
WARNING
@
Always use a new cap bolt O-ring.
d. Hold the cap bolt and tighten the nut 1 to
specification.
T.
Nut
25 Nm (2.5 m · kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
15.Install:
• cap bolt
(to the outer tube)
NOTE:
• Before installing the cap bolt, lubricate its Oring with grease.
• Temporarily tighten the cap bolt.
@
4 - 69
CHAS
FRONT FORK
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
NOTE:
• Make sure that the inner tube end is flush
with the top of the upper bracket.
• Temporarily tighten the upper and lower
bracket pinch bolts.
WARNING
@
Make sure the brake hoses are routed properly.
2. Tighten:
• lower bracket pinch bolts 1
T.
R.
23 Nm (2.3 m · kg)
T.
25 Nm (2.5 m · kg)
• cap bolt 2
• upper bracket pinch bolt 3
R.
T.
R.
3.
•
•
•
4 - 70
34 Nm (3.4 m · kg)
Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
HANDLEBARS
CHAS
EAS00665
HANDLEBARS
LEFT HANDLEBAR
Order
1
2
3
4
5
6
7
Job/Part
Removing the left handlebar
Clutch switch coupler
Clutch master cylinder holder
Clutch master cylinder
Left handlebar switch
Grip end
Handlebar grip
Left handlebar
Q’ty
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
Refer to “REMOVING/INSTALLING THE
HANDLEBARS”.
For installation, reverse the removal
procedure.
4 - 71
HANDLEBARS
CHAS
RIGHT HANDLEBAR
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the right handlebar
Front brake light switch connector
Brake master cylinder holder
Brake master cylinder
Grip end
Throttle cable housing
Throttle cable
Throttle grip
Right handlebar switch
Right handlebar
Q’ty
2
1
1
1
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Refer to “REMOVING/
INSTALLING THE
HANDLEBARS”.
For installation, reverse the removal
procedure.
4 - 72
HANDLEBARS
CHAS
EAS00667
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the left handlebar and the handlebar grip, and gradually push
the grip off the handlebar.
@
3. Remove:
• throttle cable housing 1
• throttle grip 2
NOTE:
While removing the throttle cable housing, pull
back the rubber cover 3.
@
EAS00669
CHECKING THE HANDLEBARS
1. Check:
• left handlebar 1
• right handlebar 2
Bends/cracks/damage → Replace.
WARNING
@
Do not attempt to straighten bent handlebars as this may dangerously weaken
them.
4 - 73
CHAS
HANDLEBARS
EAS00674
INSTALLING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
2. Install:
• right handlebar switch 1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the right handlebar.
@
Install:
throttle grip 1
throttle cable housing 2
throttle cables
4 Nm (0.4 m · kg)
grip end
T.
R.
3.
•
•
•
•
NOTE:
• Lubricate the inside of the throttle grip with a
thin coat of lithium soap base grease and
install it onto the handlebar.
• Align the projection a on the throttle cable
housing with the hole b in the right handlebar.
• There should be 1 ~ 3 mm of clearance c
between the throttle grip and the grip end.
@
WARNING
@
Make sure
smoothly.
4 - 74
the
throttle
grip
operates
CHAS
HANDLEBARS
4. Install:
• brake master cylinder
• brake master cylinder holder 1
T.
10 Nm (1.0 m · kg)
R.
NOTE:
• Install the brake master cylinder holder with
the “UP” mark facing up.
• First, tighten the upper bolt, and then the
lower bolt.
• Align the mating surfaces of the brake master cylinder holder with the punch mark a in
the right handlebar.
@
T.
R.
5. Install:
• handlebar grip
• grip end
4 Nm (0.4 m · kg)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the left handlebar.
b. Slide the handlebar grip over the left end of
the left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
@
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
NOTE:
There should be 1 ~ 3 mm of clearance a
between the throttle grip and the grip end.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b in the left handlebar.
@
4 - 75
CHAS
HANDLEBARS
7. Install:
• clutch master cylinder
• clutch master cylinder holder 1
T.
R.
10 Nm (1.0 m · kg)
NOTE:
Align the slit in the clutch master cylinder
holder with the punch mark a in the left handlebar.
@
8. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
4 - 76
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
Order
1
2
3
4
5
6
Job/Part
Removing the lower bracket
Front wheel
Front fork legs
Handlebars
Lead guide
Main switch coupler
Steering stem nut
Upper bracket
Lower bracket panel
Brake hose holding bolt
Q’ty
2
2
1
1
1
2
4 - 77
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT FORK”.
Refer to “HANDLEBARS”.
Disconnect.
Refer to “INSTALLING
THE STEERING HEAD”.
STEERING HEAD
Order
7
8
9
10
11
12
13
14
15
16
17
Job/Part
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Bearing outer race
Dust seal
Q’ty
1
1
1
1
1
1
2
1
1
2
1
CHAS
Remarks
Refer to “REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
For installation, reverse the removal
procedure.
4 - 78
STEERING HEAD
CHAS
EAS00677
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• lower ring nut 1
(with the special tool 2)
Steering nut wrench
90890-01403
WARNING
@
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• bearings 1
• bearing races 2
Damage/pitting → Replace.
3. Replace:
• bearings
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
4 - 79
STEERING HEAD
CHAS
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
@
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
• Always replace the bearings and bearing
races as a set.
• Whenever the steering head is disassembled, replace the rubber seal.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium soap base grease
2.
•
•
•
•
4 - 80
Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
CHAS
STEERING HEAD
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
@
4. Install:
• front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the lower and upper
bracket pinch bolts.
@
R.
4 - 81
T.
5. Tighten:
• steering stem nut
115 Nm (11.5 m · kg)
REAR SHOCK ABSORBER ASSEMBLY AND RELAY
ARM
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM
T.
R.
64 Nm (6.4 m • kg)
5
5
(3)
1
8
LS
T.
R.
40 Nm (4.0 m • kg)
14
13 10
8
3
13
13
6
4
LS
3
3
3
4
13
11
15
15
9 13
2
14
13 12
2
T.
R.
T.
R.
T.
R.
55 Nm (5.5 m • kg)
40 Nm (4.0 m • kg)
48 Nm (4.8 m • kg)
7
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the rear shock absorber
assembly and relay arm
Rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
Mufflers/exhaust pipe
Refer to “ENGINE” in chapter 5.
Nut
3
Nut/washer/bolt
1/1/1 Bolt = 54 mm
Refer to
“REMOVING/
Nut/washer/bolt
2/2/2 Bolt = 117 mm
INSTALLING THE
Connecting arm
2
REAR SHOCK
Nut/bolt/spacer
1/1/1 Bolt = 105 mm
ABSORBER
Rear shock absorber assembly
1
ASSEMBLY”.
Centerstand
1
Nut/bolt/spacer
1/1/1 Bolt = 76 mm
Relay arm
1
Collar
1
4 - 82
REAR SHOCK ABSORBER ASSEMBLY AND RELAY
ARM
T.
R.
64 Nm (6.4 m • kg)
5
CHAS
5
(3)
1
8
LS
T.
R.
40 Nm (4.0 m • kg)
14
13 10
8
3
13
13
6
4
LS
3
3
3
4
13
11
15
15
9 13
2
14
13 12
2
T.
R.
T.
R.
T.
R.
55 Nm (5.5 m • kg)
40 Nm (4.0 m • kg)
48 Nm (4.8 m • kg)
7
Order
11
12
13
14
15
Job/Part
Collar
Collar
Oil seal
Bearing
Bearing
Q’ty
1
1
6
2
2
4 - 83
Remarks
Refer to “INSTALLING THE RELAY
ARM”.
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY AND RELAY
ARM
CHAS
EAS00686
HANDLING THE REAR SHOCK ABSORBER
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.
EAS00688
DISPOSING OF A REAR SHOCK
ABSORBER
Gas pressure must be released before disposing of a rear shock absorber. To release the
gas pressure, drill a 2 ~ 3-mm hole through the
rear shock absorber at a point 15 ~ 20 mm
from its end as shown.
WARNING
@
Wear eye protection to prevent eye damage
from released gas or metal chips.
EAS00694
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
4 - 84
REAR SHOCK ABSORBER ASSEMBLY AND RELAY
ARM
CHAS
2. Remove:
• rear shock absorber assembly lower bolt 1
• connecting arms
NOTE:
While removing the connecting arm bolt, hold
the swingarm so that it does not drop down.
@
3. Remove:
• rear shock absorber assembly upper bolt 1
• rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
@
EAS00695
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.
• bolts
Bends/damage/wear → Replace.
CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• connecting arms 1
• relay arm 2
Damage/wear → Replace.
4 - 85
REAR SHOCK ABSORBER ASSEMBLY AND RELAY
ARM
CHAS
2. Check:
• bearings
• oil seals
Damage/pitting → Replace.
3. Check:
• spacers
Damage/scratches → Replace.
INSTALLING THE RELAY ARM
1. Lubricate:
• spacers
• bearings
Recommended lubricant
Lithium soap base grease
2. Install:
• bearing 1, 2
(to the relay arm)
Installed depth a
4.0 mm
Installed depth b
4.5 mm
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
• spacers
• bearings
Recommended lubricant
Lithium soap base grease
2. Install:
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
@
4 - 86
SWINGARM
CHAS
EAS00701
SWINGARM
Order
Job/Part
Removing the swingarm
Mufflers
Rear wheel
Q’ty
Final drive assembly/universal joint
Rear shock absorber assembly
1
2
3
4
5
6
7
8
Right footrest bracket bolt
Cover
Cover
Pivot shaft nut
Locknut
Pivot shaft
Swingarm
Spacer
2
1
1
1
1
1
1
1
4 - 87
Remarks
Remove the parts in the order listed.
Refer to “ENGINE” in chapter 5.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “SHAFT DRIVE”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY AND RELAY ARM”.
Refer to “REMOVING THE
SWINGARM”.
SWINGARM
Order
9
10
Oil seal
Bearing
Job/Part
11
12
13
14
15
16
17
18
Spacer
Oil seal
Bushing
Oil seal
Circlip
Bearing
Spacer
Bearing
CHAS
Q’ty
Remarks
2
2
Refer to “INSTALLING THE
SWINGARM”.
1
1
1
1
1
1
1
1
Refer to “INSTALLING THE
SWINGARM”.
For installation, reverse the removal
procedure.
4 - 88
SWINGARM
CHAS
EAS00702
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
2. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the swingarm pivot shaft, pivot shaft nut and locknut.
T.
R.
Pivot shaft nut
125 Nm (12.5 m · kg)
Locknut
115 Nm (11.5 m · kg)
Pivot shaft
7 Nm (0.7 m · kg)
b. Measure the swingarm side play È by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bushing and bearings.
Swingarm side play (at the end of
the swingarm)
0 mm
d. Check the swingarm vertical movement É
by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bushing and bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00707
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
4 - 89
SWINGARM
CHAS
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
@
Do not attempt to straighten a bent pivot
shaft.
3.
•
•
•
•
Wash:
pivot shaft
spacers
bushing
bearings
Recommended cleaning solvent
Kerosene
4.
•
•
•
Check:
spacers
bushing
oil seals
Damage/wear → Replace.
• bearings
Damage/pitting → Replace.
EAS00712
INSTALLING THE SWINGARM
1. Lubricate:
• bearings
• spacers
• oil seals
• pivot shaft
Recommended lubricant
Lithium soap base grease
2. Install:
• bearing 1
(to the swingarm)
Installed depth a
7.0 mm
4 - 90
SWINGARM
CHAS
3. Install:
• bearing 1
(to the swingarm)
Installed depth a
4.0 mm
4 - 91
SHAFT DRIVE
CHAS
EAS00715
SHAFT DRIVE
TROUBLESHOOTING
A
Symptom
B
1. A pronounced hesitation or jerky movement
during acceleration, deceleration or sustained
speeds. (not to be confused with engine surging or transmission-related movements.)
2. A rolling “rumble” noticeable at low speeds, a
high-pitched whine or a “clunk” from a shaft
drive component, or from the vicinity of the
shaft drive.
3. The shaft drive is locked up or no power is
transmitted from the engine to the rear wheel.
Possible cause
A. Bearing damage
B. Improper gear backlash
C. Damaged gear teeth
D. Broken drive shaft
E. Broken gear teeth
F. Seizure due to lack of lubrication
G. Small foreign objects lodged between moving
parts
NOTE:
Causes A, B, and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual.
@
@
4 - 92
SHAFT DRIVE
CHAS
Inspection notes
1. Investigate any unusual noises.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following noises may indicate a
mechanical defect:
a. A rolling “rumble” during coasting, acceleration or deceleration (increases with the rear
wheel speed, but does not increase with
higher engine or transmission speeds).
Diagnosis: Possible wheel bearing damage
b. A whining noise that varies with acceleration and deceleration.
Diagnosis: Possible incorrect reassembly or
too little gear backlash
WARNING
@
Insufficient gear backlash is extremely
destructive to the gear teeth. If a test ride,
following reassembly, indicates these
symptoms, stop riding immediately to minimize gear damage.
@
c. A slight “clunk” evident at low speed operation (not to be confused with normal motorcycle operation).
Diagnosis: Possible broken gear teeth
WARNING
@
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing a loss of control and possible
injury to the rider.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 93
SHAFT DRIVE
CHAS
EAS00716
Troubleshooting chart
When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section
exist, check the following points.
Place the motorcycle on a suitable stand so YES Replace the wheel bearing.
Refer to “FRONT WHEEL AND BRAKE
that the front wheel is elevated and then
DISCS”.
spin the front wheel. Is the wheel bearing
damaged?
NO
Place the motorcycle on a suitable stand so
that the rear wheel is elevated and then spin
the rear wheel. Is the wheel bearing damaged?
NO
Rear wheel bearings and shaft drive bearings are probably not damaged. Repeat the
test or remove and check the components.
YES
Remove the rear wheel. Is the wheel bear- YES Replace the rear wheel bearing.
ing damaged?
Refer to “REAR WHEEL AND BRAKE
DISC”.
NO
Remove and check the drive shaft components.
4 - 94
SHAFT DRIVE
CHAS
EAS00717
CHECKING THE FINAL DRIVE OIL FOR
CONTAMINATION AND CHECKING THE
SHAFT DRIVE FOR LEAKS
1. Drain:
• final drive oil
(from the final drive housing)
Refer to “CHANGING THE FINAL DRIVE
OIL” in chapter 3.
2. Check:
• final drive oil
Large amount of metal particles → Check
for bearing seizure.
NOTE:
A small amount of metal particles in the final
drive oil is normal.
@
@
3. Check:
• shaft drive housing
(for oil leaks)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Thoroughly clean the entire motorcycle and
then completely dry it.
b. Apply a leak-locating compound or dry powder spray to the shaft drive.
c. Test ride the motorcycle long enough to
locate a leak.
Oil leak → Repair or replace the faulty
part(s).
1 Oil seal
2 O-ring
3 Forward
NOTE:
• What may appear to be an oil leak on a new
or fairly new motorcycle, may result from the
application of a rust preventive coating or
excessive seal lubrication.
• Always clean the motorcycle and recheck the
area where the leak is thought to originate
from.
@
@ STPEL
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 95
SHAFT DRIVE
CHAS
EAS00719
MEASURING THE RING GEAR BACKLASH
1. Secure the final drive assembly in a vise.
2. Remove:
• final drive oil drain bolt
3. Drain:
• final drive oil
(from the final drive assembly)
4. Measure:
• ring gear backlash
Out of specification → Adjust.
Ring gear backlash
0.25 ~ 0.45 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a bolt 1 of the specified size, into the
final drive oil filler hole.
b. Finger tighten the bolt until it stops the ring
gear from moving.
NOTE:
Do not overtighten the bolt.
@
@
c. Install the final gear backlash band 2 and
dial gauge 3.
Final gear backlash band
90890-01230
a Dial-gauge-plunger contact point 60 mm
d. Gently rotate the gear coupling from
engagement to engagement.
e. Record the reading on the dial gauge.
f. Remove the dial gauge, final gear backlash
band, and bolt.
g. Rotate the final drive pinion gear 90°.
h. Reinstall the bolt, special tool, and dial
gauge.
i. Repeat steps (d) to (h) three more times (for
a total of four measurements).
j. If any of the readings are over specification,
adjust the ring gear backlash.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 96
CHAS
SHAFT DRIVE
EAS00720
ADJUSTING THE RING GEAR BACKLASH
1. Remove:
• ring gear bearing housing nuts
• ring gear bearing housing bolts
NOTE:
Working in a crisscross pattern, loosen each
nut 1/4 of a turn. After all of the nuts are fully
loosened, remove them and the bolts.
@
@
2.
•
•
•
•
•
3.
•
Remove:
ring gear bearing housing 1
dust cover 2
ring gear 3
ring gear shim(s) 4
thrust washer 5
Adjust:
ring gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shim(s) and thrust
washer with the following chart.
Thinner shim
Ring gear backlash is
increased.
Thicker shim
Ring gear backlash is
decreased.
b. If it is necessary to increase the ring gear
backlash by more than 0.2 mm, reduce the
thrust washer thickness by 0.2 mm for every
0.2 mm increase of ring gear shim thickness.
c. If it is necessary to reduce the ring gear
backlash by more than 0.2 mm, increase
the thrust washer thickness by 0.2 mm for
every 0.2 mm decrease of ring gear shim
thickness.
Ring gear shims
Thickness (mm)
0.25 0.30 0.40 0.50
Thrust washers
Thickness (mm)
1.2 1.4 1.6 1.8 2.0
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 97
SHAFT DRIVE
CHAS
EAS00721
MEASURING THE RING-GEAR-TOSTOPPER-BOLT CLEARANCE
1. Remove:
• ring gear bearing housing
(along with the ring gear)
Refer to “ADJUSTING THE RING GEAR
BACKLASH”.
2. Measure:
• ring-gear-to-stopper-bolt clearance a
Out of specification → Adjust.
Ring-gear-to-stopper-bolt clearance
0.30 ~ 0.60 mm
1 Stopper bolt
2 Ring gear
3. Install:
• ring gear bearing housing
(along with the ring gear)
EAS00722
ADJUSTING THE RING-GEAR-TOSTOPPER-BOLT CLEARANCE
1. Remove:
• ring gear 1
• stopper bolt 2
• stopper bolt shim(s) 3
• ring gear bearing housing
2. Select:
• stopper bolt shim(s)
Stopper bolt shims
Thickness (mm)
4 - 98
0.10 0.15 0.20 0,30
0,40 0,50
CHAS
SHAFT DRIVE
Install:
stopper bolt shim(s) 1
9 Nm (0.9 m · kg)
stopper bolt 2
ring gear 3
ring gear bearing housing
T.
R.
3.
•
•
•
•
CAUTION:
@
• The stopper bolt has left-hand threads. To
tighten the stopper bolt, turn it counterclockwise.
• Apply LOCTITE® onto the stopper bolt.
@
4. Measure:
• ring-gear-to-stopper-bolt clearance
NOTE:
If the ring-gear-to-stopper-bolt clearance is out
of specification, repeat the above procedure.
@
@
4 - 99
SHAFT DRIVE
CHAS
EAS00718
Order
1
Job/Part
Removing the final drive assembly
Final gear oil
Rear wheel
Final drive assembly
Q’ty
1
4 - 100
Remarks
Remove the parts in the order listed.
Drain.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “INSTALLING THE UNIVERSAL
JOINT AND FINAL DRIVE ASSEMBLY”.
For installation, reverse the removal
procedure.
SHAFT DRIVE
Order
1
Job/Part
Removing the universal joint
Final drive assembly
Shift arm
Q’ty
2
Left footrest bracket
1
3
4
5
Dust cover
Dust seal
Universal joint
1
1
1
1
CHAS
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE UNIVERSAL
JOINT AND FINAL DRIVE ASSEMBLY”.
Refer to “REMOVING THE LEFT
FOOTREST BRACKET”.
For installation, reverse the removal
procedure.
4 - 101
SHAFT DRIVE
CHAS
EAS00723
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the final drive
assembly
Circlip
Oil seal
Drive shaft
Spring
Ring gear bearing housing/oil seal
Dust cover
Ring gear/bearing
Ring gear shim(s)
Thrust washer
Stopper bolt
Stopper bolt shim(s)
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
1
1/1
1
1/1
1
1
4 - 102
Left-hand threads.
Refer to “ALIGNING
THE FINAL DRIVE
PINION GEAR AND
RING GEAR”.
SHAFT DRIVE
Order
B
C
D
E
F
G
H
I
J
K
Job/Part
Nut
Gear coupling
Bearing retainer/oil seal
Final drive pinion gear/bearing
Final drive pinion gear shim(s)
Bearing
Bearing
Oil seal
Collar
Final drive housing
CHAS
Q’ty
Remarks
1
Left-hand threads.
Refer to
1
“DISASSEMBLING
1/1 Left-hand threads.
THE FINAL DRIVE
1/1
ASSEMBLY” and
“ALIGNING THE
FINAL DRIVE
1
PINION GEAR AND
1
RING GEAR”.
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 103
SHAFT DRIVE
CHAS
REMOVING THE LEFT FOOTREST
BRACKET
1. Remove:
• left footrest bracket bolt 1
(with the T50 torx wrench)
EAS00724
DISASSEMBLING THE FINAL DRIVE
ASSEMBLY
1. Remove:
• ring gear bearing housing nuts
• ring gear bearing housing bolts
NOTE:
Working in a crisscross pattern, loosen each
nut 1/4 of a turn. After all of the nuts are fully
loosened, remove them and the bolts.
@
@
2. Straighten:
• punched portion of the nut
3. Remove:
• nut
• gear coupling 1
(with the coupling gear/middle shaft tool 2)
Coupling gear/middle shaft tool
90890-01229
4 - 104
SHAFT DRIVE
CHAS
4. Remove:
• bearing retainer
(with the bearing retainer wrench 1)
Bearing retainer wrench
90890-04050
CAUTION:
@
The bearing retainer has left-hand threads.
To loosen the bearing retainer, turn it
clockwise.
@
5. Remove:
• final drive pinion gear
WARNING
@
Always use new bearings.
@
CAUTION:
@
The final drive pinion gear should only be
removed if ring gear replacement is necessary.
@
NOTE:
Lightly tap on the end of the final drive pinion
gear with a soft hammer.
@
@
EAS00725
REMOVING AND INSTALLING THE RING
GEAR BEARINGS
1. Remove:
• collar 1
• oil seal 2
• bearing 3
(with an suitable press tool 4 and an
appropriate support for the final drive housing)
2. Check:
• bearing
Damage → Replace.
4 - 105
SHAFT DRIVE
CHAS
3. Remove:
• bearing 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the final drive housing to approximately 150 °C.
b. Remove the bearing outer races with an
appropriately shaped punch 2.
c. Remove the inner race from the final drive
pinion gear.
NOTE:
The removal of the final drive pinion gear bearing is a difficult procedure and is rarely necessary.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• bearing New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the final gear case to approximately
150 °C.
b. Install the bearing outer races with a socket
or appropriate tool that matches the diameter of the races.
c. Install the inner race onto the final drive pinion gear.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.
•
•
•
Install:
collar 1
oil seal 2 New
bearing 3
(with a suitable press tool 4 and an appropriate support for the final drive housing)
NOTE:
The bearing can be reused, but Yamaha recommends installing a new one.
@
@
4 - 106
SHAFT DRIVE
CHAS
EAS00726
ALIGNING THE FINAL DRIVE PINION GEAR
AND RING GEAR
NOTE:
Aligning the final drive pinion gear and ring
gear is necessary when any of the following
parts are replaced:
• Final drive housing
• Ring gear bearing housing
• Any bearing
@
@
1. Select:
• final drive pinion gear shim(s) 1
• ring gear shim(s) 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the final drive pinion gear and the
ring gear with shims 1 and 2. Calculate
the respective thicknesses from information
marked on the final drive housing and the
drive pinion gear.
1 Final drive pinion gear shim
2 Ring gear shim
3 Thrust washer
b. To find final drive pinion gear shim thickness
“A”, use the following formula:
Final drive pinion gear shim thickness
A = (84 + a/100) – (83 + b/100)
Where:
a = a numeral (positive or negative) on the
final drive pinion gear, to be divided by 100
and added to “84”. If there is not a numeral
available on the final drive pinion gear, a
equals zero.
b = a numeral on the final drive housing, to be
divided by 100 and added to “83”.
Example:
If the final drive pinion gear is marked “+01”
and the final drive housing is marked “50”:
A = (84 + 1/100) – (83 + 50/100)
= (84 + 0.01) – (83 + 0.50)
= 84.01 – 83.50
= 0.51
4 - 107
SHAFT DRIVE
CHAS
Therefore, the calculated final drive pinion
gear shim thickness is 0.51 mm. Shim sizes
are supplied in the following thicknesses.
Final drive pinion gear shims
Thickness (mm)
0.30 0.40 0.50
Since the final drive pinion gear shims are only
available in 0.10 mm increments, round off to
the hundredths digit.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
In the example above, the calculated final
drive pinion gear shim thickness is 0.51 mm.
The chart instructs you to round off the 1 to 0.
Thus, you should use a 0.50 mm final drive
pinion gear shim.
c. To find ring gear shim thickness “B”, use the
following formula:
Ring gear shim thickness
B = (45 + c/100) + (3 + d/100) –
[(35.40 – e/100) + f]
Where:
c = a numeral on the final drive housing, to be
divided by 100 and added to “45”.
d = a numeral usually on the outside of the
ring gear bearing housing, to be divided by 100
and added to “3”.
e = a numeral (positive or negative) on the
inside of the ring gear, to be divided by 100
and added to “35.40”.
f = the ring gear bearing thickness constant.
Ring gear bearing thickness “f”
13.00 mm
4 - 108
SHAFT DRIVE
CHAS
Example:
If the final drive housing is marked “51”, the
ring gear bearing housing is marked “35”, the
ring gear is marked “– 05”, and “f” is 13.00:
B = (45 + 51/100) + (3 + 35/100) –
[(35.40 – 5/100) + 13]
= (45 + 0.51) + (3 + 0.35) –
[(35.40 – 0.05) + 13]
= 45.51 + 3.35 – [(35.40 – 0.05) + 13]
= 48.86 – [35.35 + 13]
= 48.86 – 48.35
= 0.51
Therefore, the calculated ring gear shim thickness is 0.51 mm.
Shim sizes are supplied in the following thicknesses.
Ring gear shims
Thickness (mm)
0.25 0.30 0.40 0.50
Since the ring gear shims are only available in
0.10 mm increments, round off the hundredths
digit.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
In the example above, the calculated ring gear
shim thickness is 0.51 mm. The chart instructs
you to round off the 1 to 0. Thus, you should
use a 0.50 mm ring gear shim.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 109
CHAS
SHAFT DRIVE
Install:
shims (as calculated)
final drive pinion gear
110 Nm (11.0 m · kg)
bearing retainer
(with the bearing retainer wrench 1)
T.
R.
2.
•
•
•
CAUTION:
@
The bearing retainer has left-hand threads.
To tighten the bearing retainer, turn it
counterclockwise.
@
Bearing retainer wrench
90890-04050
T.
3. Install:
• gear coupling 1
110 Nm (11.0 m · kg)
• nut 2
(with the coupling gear/middle shaft tool 3)
R.
Coupling gear/middle shaft tool
90890-01229
CAUTION:
@
Apply LOCTITE® to the nut.
@
4. Lock the threads with a drift punch.
5. Install:
• ring gear bearing housing
(along with the ring gear, but without the
thrust washer)
6. Adjust:
• ring gear backlash
Refer to “MEASURING THE RING GEAR
BACKLASH” and “ADJUSTING THE RING
GEAR BACKLASH”.
4 - 110
CHAS
SHAFT DRIVE
7. Measure:
• ring-gear-to-thrust-washer clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the ring gear bearing housing
(along with the ring gear).
b. Place four pieces of Plastigauge® between
the original thrust washer and the ring gear.
c. Install the ring gear bearing housing and
tighten the bolts and nuts to specification.
T.
R.
Ring gear bearing housing bolt
40 Nm (4.0 m · kg)
Ring gear bearing housing nut
23 Nm (2.3 m · kg)
NOTE:
Do not turn the final drive pinion gear and ring
gear while measuring the ring-gear-to-thrustwasher clearance with Plastigauge®.
@
@
d. Remove the ring gear bearing housing.
e. Measure the width of the flattened Plastigauge® 1.
Ring-gear-to-thrust-washer clearance
0.10 ~ 0.20 mm
f. If the ring-gear-to-thrust-washer clearance
is within specification, install the ring gear
bearing housing (along with the ring gear).
g. If the ring-gear-to-thrust-washer clearance
is out of specification, select the correct
thrust washer as follows.
h. Select the suitable thrust washer from the
following chart.
Thrust washers
Thickness (mm)
1.2 1.4 1.6 1.8 2.0
i. Repeat the measurement steps until the
ring-gear-to-thrust-washer clearance is
within the specified limits.
Ring-gear-to-thrust-washer clearance
0.10 ~ 0.20 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 111
CHAS
SHAFT DRIVE
EAS00727
CHECKING THE DRIVE SHAFT
1. Check:
• drive shaft splines
Damage/wear → Replace the drive shaft.
EAS00728
INSTALLING THE UNIVERSAL JOINT AND
FINAL DRIVE ASSEMBLY
1. Lubricate:
• universal joint splines
• drive shaft splines
Recommended lubricant
Lithium soap base grease
2. Install:
• universal joint
• final drive assembly
NOTE:
Align the drive shaft splines with the driven
yoke of the universal joint.
3. Tighten:
• final drive assembly nuts
T.
R.
T.
R.
4. Install:
• shift arm 1
42 Nm (4.2 m · kg)
10 Nm (1.0 m · kg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
5. Install:
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
6. Fill:
• final drive assembly
Refer to “CHECKING THE FINAL DRIVE
OIL LEVEL” in chapter 3.
7. Check:
• shift pedal position
Refer to “ADJUSTING THE SHIFT PEDAL”
in chapter 3.
4 - 112
ENG
5
ENG
CHAPTER 5
ENGINE
ENGINE ...........................................................................................................5-1
MUFFLERS AND EXHAUST PIPE ASSEMBLY ....................................... 5-1
LEADS AND HOSES................................................................................. 5-2
ENGINE..................................................................................................... 5-4
INSTALLING THE ENGINE....................................................................... 5-6
CAMSHAFTS...................................................................................................5-8
CYLINDER HEAD COVER........................................................................ 5-8
CAMSHAFTS ............................................................................................ 5-9
REMOVING THE CAMSHAFTS..............................................................5-11
CHECKING THE CAMSHAFTS ..............................................................5-12
CHECKING THE CAMSHAFT SPROCKETS .........................................5-13
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-14
INSTALLING THE CAMSHAFTS ............................................................ 5-14
CYLINDER HEAD.......................................................................................... 5-19
REMOVING THE CYLINDER HEAD.......................................................5-20
CHECKING THE CYLINDER HEAD .......................................................5-20
INSTALLING THE CYLINDER HEAD .....................................................5-21
VALVES AND VALVE SPRINGS.................................................................. 5-24
REMOVING THE VALVES...................................................................... 5-25
CHECKING THE VALVES AND VALVE GUIDES ..................................5-26
CHECKING THE VALVE SEATS ............................................................ 5-28
CHECKING THE VALVE SPRINGS........................................................ 5-30
CHECKING THE VALVE LIFTERS ......................................................... 5-31
INSTALLING THE VALVES .................................................................... 5-32
GENERATOR AND STARTER CLUTCH......................................................5-34
GENERATOR ROTOR AND STARTER CLUTCH..................................5-34
STATOR ASSEMBLY.............................................................................. 5-36
REMOVING THE GENERATOR ............................................................. 5-37
REMOVING THE STARTER CLUTCH ...................................................5-38
CHECKING THE STARTER CLUTCH ....................................................5-38
INSTALLING THE STARTER CLUTCH .................................................. 5-39
INSTALLING THE GENERATOR............................................................ 5-39
PICKUP COIL ROTOR .................................................................................. 5-41
REMOVING THE PICKUP COIL ROTOR ............................................... 5-43
INSTALLING THE PICKUP COIL ROTOR.............................................. 5-43
ENG
CLUTCH ........................................................................................................5-45
CLUTCH COVER ....................................................................................5-45
CLUTCH .................................................................................................. 5-46
REMOVING THE CLUTCH ..................................................................... 5-48
CHECKING THE FRICTION PLATES.....................................................5-49
CHECKING THE CLUTCH PLATES .......................................................5-50
CHECKING THE CLUTCH SPRING PLATE...........................................5-50
CHECKING THE CLUTCH HOUSING ....................................................5-50
CHECKING THE CLUTCH BOSS........................................................... 5-51
CHECKING THE PRESSURE PLATE ....................................................5-51
CHECKING THE CLUTCH PUSH RODS ............................................... 5-51
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-51
INSTALLING THE CLUTCH.................................................................... 5-52
SHIFT SHAFT................................................................................................5-55
CHECKING THE SHIFT SHAFT ............................................................. 5-57
CHECKING THE STOPPER LEVER ......................................................5-57
INSTALLING THE SHIFT SHAFT ........................................................... 5-57
OIL PAN AND OIL PUMP ............................................................................. 5-59
OIL PUMP ...............................................................................................5-61
REMOVING THE OIL PAN...................................................................... 5-62
CHECKING THE OIL PUMP ................................................................... 5-62
CHECKING THE RELIEF VALVE ........................................................... 5-63
CHECKING THE OIL DELIVERY PIPES ................................................ 5-63
CHECKING THE OIL STRAINER ........................................................... 5-63
ASSEMBLING THE OIL PUMP...............................................................5-63
INSTALLING THE OIL PUMP .................................................................5-64
INSTALLING THE OIL STRAINER ......................................................... 5-64
INSTALLING THE OIL PAN .................................................................... 5-64
MIDDLE GEAR ..............................................................................................5-66
REMOVING THE MIDDLE GEAR ........................................................... 5-70
DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ............... 5-71
DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY............. 5-71
CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY.......................... 5-71
CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY .......................5-72
ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY .....................5-72
ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY................... 5-72
INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY........................ 5-73
INSTALLING THE MIDDLE DRIVEN SHAFT ASSEMBLY .....................5-74
MEASURING THE MIDDLE GEAR BACKLASH..................................... 5-75
ADJUSTING THE MIDDLE GEAR BACKLASH ...................................... 5-76
ALIGNING THE MIDDLE GEAR ............................................................. 5-79
CRANKCASE ................................................................................................5-82
DISASSEMBLING THE CRANKCASE....................................................5-86
CHECKING THE CRANKCASE ..............................................................5-87
CHECKING THE BEARINGS AND OIL SEALS...................................... 5-87
CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN.........5-88
ASSEMBLING THE CRANKCASE.......................................................... 5-88
ENG
CONNECTING RODS AND PISTONS .......................................................... 5-92
REMOVING THE CONNECTING RODS AND PISTONS.......................5-93
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-94
CHECKING THE PISTON RINGS........................................................... 5-95
CHECKING THE PISTON PINS..............................................................5-96
CHECKING THE CONNECTING RODS................................................. 5-98
INSTALLING THE CONNECTING RODS AND PISTONS ...................5-100
CRANKSHAFT ............................................................................................5-104
REMOVING THE CRANKSHAFT ......................................................... 5-105
CHECKING THE CRANKSHAFT .......................................................... 5-105
INSTALLING THE CRANKSHAFT ........................................................ 5-108
TRANSMISSION.......................................................................................... 5-109
REMOVING THE TRANSMISSION ...................................................... 5-115
CHECKING THE SHIFT FORKS........................................................... 5-115
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-116
CHECKING THE TRANSMISSION ....................................................... 5-116
INSTALLING THE TRANSMISSION .....................................................5-118
BALANCERS...............................................................................................5-119
FRONT BALANCER.............................................................................. 5-119
REAR BALANCER ................................................................................ 5-120
CHECKING THE BALANCER ...............................................................5-121
INSTALLING THE FRONT BALANCER................................................ 5-121
INSTALLING THE REAR BALANCER ..................................................5-123
ENG
ENGINE
ENG
EAS00188
ENGINE
ENGINE
MUFFLERS AND EXHAUST PIPE ASSEMBLY
Order
1
2
3
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the mufflers and exhaust
pipe assembly
Seats/fuel tank/T-bar/rubber seat
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Side cowlings/front cowling assembly
Refer to “COWLINGS” in chapter 3.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Radiator
Refer to “RADIATOR” in chapter 6.
O2 sensor coupler
1
Disconnect.
Muffler (left and right)
2
Exhaust pipe assembly
1
For installation, reverse the removal
procedure.
5-1
ENGINE
ENG
LEADS AND HOSES
Order
Job/Part
Removing the leads and hoses
Air filter case
Q’ty
Throttle bodies
Air cut-off valve assembly/hoses/reed
valves
Thermostat assembly
Engine oil/oil filter cartridge
Oil cooler
Water pump
5-2
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “THERMOSTAT” in chapter 6.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “WATER PUMP” in chapter 6.
ENGINE
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Left footrest bracket/dust cover
Clutch release cylinder
Dowel pin
Sidestand switch coupler
Crankcase breather hose
Starter motor lead
Stator assembly coupler
Oil level sensor connector
Crankshaft position sensor coupler
Neutral switch connector
Speed sensor coupler
Ground lead
Q’ty
1
2
1
1
1
1
1
1
1
1
1
ENG
Remarks
Refer to “SHAFT DRIVE” in chapter 4.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
5-3
ENG
ENGINE
EAS00191
ENGINE
T.
R.
45 Nm (4.5 m • kg)
T.
R.
11
55 Nm (5.5 m • kg)
9
T.
R.
45 Nm (4.5 m • kg)
14
T.
55 Nm (5.5 m • kg)
R.
9
T.
R.
7
55 Nm (5.5 m • kg)
T.
R.
10
24 Nm (2.4 m • kg)
7
13
8
T.
R.
18 Nm (1.8 m • kg)
5
T.
R.
6
10
36 Nm (3.6 m • kg)
T.
5
R.
12
4
4
T.
R.
15
T.
6
55 Nm (5.5 m • kg)
24 Nm (2.4 m • kg)
R.
36 Nm (3.6 m • kg)
3
2
T.
R.
16
T.
R.
Order
Job/Part
Removing the engine
32 Nm (3.2 m • kg)
1
Q’ty
16 Nm (1.6 m • kg)
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
@
1
2
3
4
5
6
7
8
9
10
Bolt (engine bracket 1 and engine)
Bolt (engine bracket 1 and frame)
Engine bracket 1
Bolt (engine bracket 2 and frame)
Bolt (engine bracket 2 and engine)
Engine bracket 2
Pinch bolt
Pinch bolt
Front mounting bolt (right)
Front mounting bolt (left)
2
1
1
4
2
2
2
2
2
2
5-4
Refer to “INSTALLING THE ENGINE”.
ENG
ENGINE
T.
R.
45 Nm (4.5 m • kg)
T.
R.
11
55 Nm (5.5 m • kg)
9
T.
R.
45 Nm (4.5 m • kg)
14
T.
55 Nm (5.5 m • kg)
R.
9
T.
R.
7
55 Nm (5.5 m • kg)
T.
R.
10
24 Nm (2.4 m • kg)
7
13
8
T.
R.
18 Nm (1.8 m • kg)
5
T.
R.
6
10
36 Nm (3.6 m • kg)
T.
5
R.
12
4
4
T.
R.
15
T.
6
55 Nm (5.5 m • kg)
24 Nm (2.4 m • kg)
R.
36 Nm (3.6 m • kg)
3
2
T.
R.
16
T.
R.
Order
11
12
13
14
15
16
Job/Part
Nut
Spacer bolt
Rear upper mounting bolt
Rear lower mounting bolt
Spacer
Engine
32 Nm (3.2 m • kg)
1
16 Nm (1.6 m • kg)
Q’ty
Remarks
1
1
Loosen.
1
Refer to “INSTALLING
THE ENGINE”.
1
1
1
For installation, reverse the removal
procedure.
5-5
ENG
ENGINE
EAS00192
INSTALLING THE ENGINE
1. Install:
• spacer 1
• spacer bolt 2
• rear lower mounting bolt 3
• rear upper mounting bolt 4
• front mounting bolts 5, 6
• engine bracket 2 7
• engine bracket 1 8
NOTE:
Do not fully tighten the bolts.
@
2. Tighten the bolts in the following order.
• front mounting bolts (left) 5
T.
R.
55 Nm (5.5 m · kg)
• rear lower mounting bolt 3
T.
R.
45 Nm (4.5 m · kg)
T.
18 Nm (1.8 m · kg)
• spacer bolt 2
45 Nm (4.5 m · kg)
• nut 9
• front mounting bolts (left) 5
R.
T.
R.
T.
R.
55 Nm (5.5 m · kg)
• front mounting bolts (right) 6
T.
R.
T.
R.
T.
R.
• pinch bolts 0
• pinch bolt A
55 Nm (5.5 m · kg)
24 Nm (2.4 m · kg)
24 Nm (2.4 m · kg)
NOTE:
• Tighten the spacer bolt 2 to specification
with a pivot shaft wrench B.
• When tightened, the spacer bolt 2 should be
flat against the engine surface.
Pivot shaft wrench
90890-01471
3. Temporarily tighten the bolts (engine
bracket 2 and engine) 1 and bolts (engine
bracket 2 and frame) 2.
NOTE:
When temporarily tightened, the bolts 1, 2
should be flat against the engine and frame
surface.
5-6
ENG
ENGINE
4. Tighten the bolts in the following order.
• bolts (engine bracket 2 and engine) 1
T.
R.
36 Nm (3.6 m · kg)
• bolts (engine bracket 2 and frame) 2
T.
R.
16 Nm (1.6 m · kg)
5. Temporarily tighten the bolt (engine bracket
1 and frame) 1 and bolts (engine bracket 1
and engine) 2.
NOTE:
When temporarily tightened, the bolts 1, 2
should be flat against the engine and frame
surface.
6. Tighten the bolts in the following order.
• bolt (engine bracket 1 and engine) 1
T.
R.
32 Nm (3.2 m · kg)
• bolts (engine bracket 1 and fame) 2
T.
R.
5-7
16 Nm (1.6 m · kg)
ENG
CAMSHAFTS
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
1
T.
R.
T.
R.
13 Nm (1.3 m • kg)
10 Nm (1.0 m • kg)
LT
2
LS
T.
R.
10 Nm (1.0 m • kg)
(8)
3
6
5
4 New
Order
Job/Part
Removing the cylinder head cover
Reed valves
Q’ty
Engine oil
1
2
3
4
5
6
Spark plug
Cylinder identification sensor
Cylinder head cover
Cylinder head cover gasket
Dowel pin
Timing chain guide (top side)
4
1
1
1
4
1
Remarks
Remove the parts in the order listed.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “INSTALLING THE CAMSHAFTS”.
For installation, reverse the removal
procedure.
5-8
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the camshafts
Throttle bodies
Pickup coil rotor cover
Timing chain tensioner
Timing chain tensioner gasket
Intake camshaft cap
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Intake camshaft sprocket
Exhaust camshaft sprocket
Q’ty
1
1
4
4
16
1
1
1
1
5-9
Remarks
Remove the parts in the order listed.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
Refer to “PICKUP COIL ROTOR”.
Refer to “REMOVING/INSTALLING THE
CAMSHAFTS”.
Refer to “INSTALLING THE CAMSHAFTS”.
CAMSHAFTS
Order
10
11
12
Job/Part
Timing chain guide (exhaust side)
Pin
Timing chain guide (intake side)
Q’ty
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
5 - 10
CAMSHAFTS
ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Align:
• “T” mark on the pickup coil rotor
(with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the
pickup coil rotor with the crankcase mating
surface b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2.
•
3.
•
•
Loosen:
cap bolt 1
Remove:
timing chain tensioner 2
gasket
4. Remove:
• camshaft caps
• dowel pins
CAUTION:
@
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
5 - 11
CAMSHAFTS
ENG
5. Remove:
• intake camshaft 1
• exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3.
@
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Minimum cam lobe dimensions
Intake camshaft
a 32.05 mm
b 23.997 mm
Exhaust camshaft
a 32.95 mm
b 24.897 mm
3. Measure:
• camshaft runout
Out of specification → Replace.
Maximum camshaft runout
0.03 mm
4. Measure:
• camshaft-journal-to-camshaft-cap
clearance
Out of specification → Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.028 ~ 0.062 mm
5 - 12
CAMSHAFTS
ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of Plastigauge® 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the
inner caps out.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap clearance with the Plastigauge®.
@
T.
Camshaft cap bolt
10 Nm (1.0 m · kg)
R.
d. Remove the camshaft caps and then measure the width of the Plastigauge® 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• camshaft journal diameter a
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
24.472 ~ 24.459 mm
CHECKING THE CAMSHAFT SPROCKETS
1. Check:
• camshaft sprocket
Wear/damage → Replace the camshaft
sprockets and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Timing chain
2 Camshaft sprocket
5 - 13
ENG
CAMSHAFTS
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00217
INSTALLING THE CAMSHAFTS
1. Install:
• exhaust camshaft sprocket 1
T.
R.
24 Nm (2.4 m · kg)
• intake camshaft sprocket 2
T.
R.
24 Nm (2.4 m · kg)
(with the special tool 3)
Rotor holding tool
90890-01235
E
E
E
E
NOTE:
Make sure that the holes a in the cylinder #4
cam and marks b and c on the camshaft
sprockets are in the position shown in the illustration.
b : Intake side “—”
c : Exhaust side “→”
d : Cylinder #1 - cam
5 - 14
CAMSHAFTS
ENG
2. Install:
• exhaust camshaft 1
• intake camshaft 2
(with the camshaft sprockets)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the
pickup coil rotor with the crankcase mating
surface b.
c. Install the timing chain onto both camshaft
sprockets, and then install the camshafts.
NOTE:
• Install the camshafts with the hole c in the
cylinder #4 - cam facing up.
• When installing the timing chain, start with
the exhaust camshaft and be sure to keep
the timing chain as tight as possible on the
exhaust side.
• Make sure the marks e on the timing chain
sprockets are parallel with the edge of the
cylinder head.
d : Intake side “—”
e : Exhaust side “→”
f : Cylinder #1 - cam
@
E
E
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3.
•
•
•
Install:
dowel pins
intake camshaft caps
exhaust camshaft caps
NOTE:
• The “I” mark refers to the intake camshaft
caps and the “E” mark refers to the exhaust
camshaft cap.
• Install the camshaft caps with the arrow mark
a pointing towards the right side of the
engine.
• Make sure the punch marks b in the camshaft are aligned with the arrow mark a on
the camshaft caps.
@
5 - 15
ENG
CAMSHAFTS
T.
R.
4. Install:
• camshaft cap bolts
10 Nm (1.0 m · kg)
NOTE:
Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the inner
caps out.
@
CAUTION:
@
• Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or
improper valve timing.
5. Install:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
@
b. With the timing chain tensioner rod turned
all the way into the timing chain tensioner
housing (with the thin screwdriver still
installed), install the gasket and the timing
chain tensioner 2 onto the cylinder block.
WARNING
@
Always use a new gasket.
c. Tighten the timing chain tensioner bolts 3
to the specified torque.
T.
R.
5 - 16
Timing chain tensioner bolt
10 Nm (1.0 m · kg)
CAMSHAFTS
ENG
d. Remove the screwdriver, make sure the timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.
T.
Cap bolt
10 Nm (1.0 m · kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Turn:
• crankshaft
(several turns clockwise)
7. Check:
• “T” mark a
Make sure the “T” mark a on the pickup
coil rotor is aligned with the crankcase mating surface b.
• camshaft holes c
Make sure the holes c in the cylinder #4 cam are aligned with the arrow marks d on
the camshaft caps.
Out of alignment → Adjust.
Refer to the installation steps above.
8. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE
CLEARANCE” in chapter 3.
5 - 17
VALVE
ENG
CAMSHAFTS
9. Install:
• cylinder head cover gasket New
• cylinder head cover
T.
R.
10 Nm (1.0 m · kg)
NOTE:
• Apply bond T1541 1 onto the mating surfaces of the cylinder head cover and cylinder
head cover gasket.
• Apply bond YGK8624-C1 2 onto the mating
surfaces of the cylinder head cover gasket
and cylinder head.
• Tighten the cylinder head cover bolts stages
and in a crisscross pattern.
Out of specification → Adjust.
5 - 18
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
(10)
New
E
T.
R.
12 Nm (1.2 m • kg)
1
New
T.
R.
20 Nm (2.0 m • kg)
2 New
3
3
Order
1
2
3
Job/Part
Removing the cylinder head
Radiator
Exhaust pipe assembly
Camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
1
1
2
Remarks
Remove the parts in the order listed.
Refer to “RADIATOR” in chapter 6.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
Refer to “INSTALLING THE CYLINDER
HEAD”.
For installation, reverse the removal
procedure.
5 - 19
CYLINDER HEAD
ENG
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head bolts
NOTE:
Loosen each bolt 1/2 of a turn at a time. After
all of the bolt are fully loosened, remove them.
@
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
@
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
5 - 20
CYLINDER HEAD
ENG
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00232
INSTALLING THE CYLINDER HEAD
1. Install:
• dowel pins 1
• gasket 2 New
2. Install:
• cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
@
3. Tighten:
• cylinder head bolts (M10) 1 New
NOTE:
• Do not reuse the cylinder head bolts.
• The tightening procedure of the cylinder
head bolts is angle controlled, therefore
tighten the bolts using the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lubricate the cylinder head bolts and washers with engine oil.
b. Install the washers and cylinder head bolts.
c. Tighten the cylinder head bolts in the proper
tightening sequence as shown.
T.
R.
5 - 21
Cylinder head bolt (M10)
1st
25 Nm (2.5 m · kg)
CYLINDER HEAD
ENG
d. Loosen and retighten the cylinder head
bolts in the proper tightening sequence as
shown.
T.
R.
Cylinder head bolt (M10)
2nd
25 Nm (2.5 m · kg)
e. Tighten the cylinder head bolts further to
reach the specified angle 180° in the proper
tightening sequence as shown.
T.
R.
Cylinder head bolt (M10)
Final
Specified angle 180°
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform the procedure again.
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.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60°.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 22
ENG
CYLINDER HEAD
4. Tighten:
• cylinder head bolts (M6) 1
T.
R.
5 - 23
12 Nm (1.2 m · kg)
ENG
VALVES AND VALVE SPRINGS
EAS00236
VALVES AND VALVE SPRINGS
1
2
3
3
M
4
5
New 6
1
7
2
M
M
3
3
4
5
New
6
M
7
10
8
10
9
M
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the valves and valve
springs
Cylinder head
Valve lifter
Valve pad
Valve cotter
Upper spring seat
Valve spring
Oil seal
Lower spring seat
Intake valve
Exhaust valve
Valve guide
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
16
16
32
16
16
16
16
4
4
16
Refer to “REMOVING/INSTALLING THE
VALVES”.
For installation, reverse the removal
procedure.
5 - 24
VALVES AND VALVE SPRINGS
ENG
EAS00237
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. Remove:
• valve lifter 1
• valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
@
2. Check:
• valve
(for leakage)
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 25
VALVES AND VALVE SPRINGS
ENG
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3.
@
Valve spring compressor
90890-04019
Attachment
90890-04108
4.
•
•
•
•
•
Remove:
upper spring seat 1
valve spring 2
oil seal 3
lower spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
@
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
5 - 26
VALVES AND VALVE SPRINGS
ENG
1. Measure:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clearance
Intake
0.010 ~ 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 ~ 0.052 mm
<Limit>: 0.1 mm
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C in an oven.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valveguide clearance.
NOTE:
After replacing the valve guide, reface the
valve seat.
@
Valve guide remover (5 mm)
90890-04097
Valve guide installer (5 mm)
90890-04098
Valve guide reamer (5 mm)
90890-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 27
VALVES AND VALVE SPRINGS
ENG
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness
Intake : 0.8 ~ 1.2 mm
Exhaust : 0.5 ~ 0.9 mm
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
@
Valve stem runout
0.01 mm
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder head.
5 - 28
VALVES AND VALVE SPRINGS
ENG
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width
Intake: 0.9 ~ 1.1 mm
<Limit>: 1.6 mm
Exhaust: 0.9 ~ 1.1 mm
<Limit>: 1.6 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
@
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.
5 - 29
VALVES AND VALVE SPRINGS
ENG
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.
@
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.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• valve spring free length a
Out of specification → Replace the valve
spring.
Valve spring free length (intake
and exhaust)
39.7 mm
<Limit> : 37.7 mm
5 - 30
VALVES AND VALVE SPRINGS
ENG
2. Measure:
• compressed valve spring force a
Out of specification → Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
13.9 ~ 16.1 kg at 33 mm
3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
Maximum valve spring tilt
1.7 mm
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
• valve lifter
Damage/scratches → Replace the valve lifters and cylinder head.
5 - 31
VALVES AND VALVE SPRINGS
ENG
EAS00249
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3.
•
•
•
•
•
Install:
valve 1
lower spring seat 2
oil seal 3
valve spring 4
upper spring seat 5
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its original place.
• Install the valve spring with the larger pitch
a facing up.
@
b Smaller pitch
5 - 32
VALVES AND VALVE SPRINGS
ENG
4. Install:
• valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3.
@
Valve spring compressor
90890-04019
Attachment
90890-04108
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
@
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
• valve pad
• valve lifter
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
• valve pad
• valve lifter
NOTE:
• The valve lifter must move smoothly when
rotated with a finger.
• Each valve lifter and valve pad must be reinstalled in its original position.
@
5 - 33
GENERATOR AND STARTER CLUTCH
ENG
EAS00343
GENERATOR AND STARTER CLUTCH
GENERATOR ROTOR AND STARTER CLUTCH
Order
Job/Part
Removing the generator rotor and
starter clutch
Fuel tank/seats/T-bar/rubber seat
Q’ty
Side covers/front cowling assembly
Engine oil
1
2
Stator assembly coupler
Generator cover
1
1
3
4
Generator cover gasket
Dowel pin
1
2
5 - 34
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
Refer to “REMOVING THE GENERATOR”.
GENERATOR AND STARTER CLUTCH
Order
5
6
7
8
9
10
Job/Part
Starter clutch idle gear shaft
starter clutch idle gear
Generator rotor
Woodruff key
Starter clutch gear
Starter clutch
Q’ty
1
1
1
1
1
1
5 - 35
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
GENERATOR”.
Refer to “REMOVING/INSTALLING THE
STARTER CLUTCH”.
For installation, reverse the removal
procedure.
GENERATOR AND STARTER CLUTCH
ENG
STATOR ASSEMBLY
Order
1
2
Job/Part
Removing the stator assembly
Lead holder
Stator assembly
Q’ty
1
1
5 - 36
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE GENERATOR”.
For installation, reverse the removal
procedure.
GENERATOR AND STARTER CLUTCH
ENG
EAS00346
REMOVING THE GENERATOR
1. Remove:
• generator cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
@
2. Remove:
• generator rotor bolt 1
• washer
NOTE:
While holding the generator rotor 2 with the
sheave holder 3, loosen the generator rotor
bolt.
@
Sheave holder
90890-01701
3. Remove:
• generator rotor 1
(with the flywheel puller 2)
• woodruff key
Flywheel puller
90890-01362
5 - 37
GENERATOR AND STARTER CLUTCH
ENG
REMOVING THE STARTER CLUTCH
1. Remove:
• starter clutch bolts 1
• starter clutch
NOTE:
While holding the generator rotor with the
sheave holder, remove the starter clutch bolts.
@
Sheave holder
90890-01701
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
Damage/wear → Replace.
2. Check:
• starter clutch idle gear 1
• starter clutch gear 2
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• starter clutch gear’s contacting surfaces a
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto the
starter clutch 2 and hold the starter clutch.
5 - 38
ENG
GENERATOR AND STARTER CLUTCH
b. When turning the starter clutch drive gear
clockwise È, the starter clutch and the
starter clutch drive gear should engage,
otherwise the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch drive gear
counterclockwise É, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• starter clutch
• starter clutch bolts 1
LT
T.
R.
32 Nm (3.2 m · kg)
NOTE:
While holding the generator rotor with the
sheave holder, tighten the starter clutch bolt.
@
Sheave holder
90890-01701
EAS00354
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator assembly lead grommet)
Yamaha bond No. 1215
90890-85505
5 - 39
ENG
GENERATOR AND STARTER CLUTCH
2. Install:
• stator assembly 1
LT
T.
R.
R.
3.
•
•
•
•
T.
• lead holder 2
10 Nm (1.0 m · kg)
6 Nm (0.6 m · kg)
Install:
woodruff key
generator rotor
washer
generator rotor bolt
NOTE:
• Clean the tapered portion of the crankshaft
and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
• Lubricate the generator rotor bolt and washer
with engine oil.
@
4. Tighten:
• generator rotor bolt 1
T.
R.
130 Nm (13.0 m · kg)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3, tighten the generator rotor
bolt.
@
Sheave holder
90890-01701
5 - 40
PICKUP COIL ROTOR
ENG
PICKUP COIL ROTOR
Order
Job/Part
Removing the pickup coil rotor
Fuel tank/seats/T-bar/rubber seat
Q’ty
Air filter case
Side covers/front cowling assembly
Engine oil
Generator cover
1
Pickup coil rotor cover
1
2
Pickup coil rotor cover gasket
1
5 - 41
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “GENERATOR ROTOR AND
STARTER CLUTCH”.
Refer to “REMOVING/INSTALLING THE
PICKUP COIL ROTOR”.
PICKUP COIL ROTOR
Order
3
4
5
6
Job/Part
Dowel pin
Crankshaft position sensor coupler
Crankshaft position sensor
Pickup coil rotor
ENG
Q’ty
Remarks
2
1
Disconnect.
1
Refer to “INSTALLING THE PICKUP
COIL ROTOR”.
1
Refer to “REMOVING/INSTALLING THE
PICKUP COIL ROTOR”.
For installation, reverse the removal
procedure.
5 - 42
PICKUP COIL ROTOR
ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• pickup coil rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
@
2.
•
•
•
Remove:
pickup coil rotor bolt 1
washer
pickup coil rotor 2
NOTE:
While holding the generator rotor 3 with the
sheave holder 4, remove the pickup coil rotor
bolt.
@
Sheave holder
90890-01701
INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
Align the projection a into the pickup coil rotor
with the groove b into the crankshaft.
@
5 - 43
ENG
PICKUP COIL ROTOR
2. Tighten:
• pickup coil rotor bolt 1
T.
R.
45 Nm (4.5 m · kg)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3, tighten the pickup coil rotor
bolt.
@
Sheave holder
90890-01701
3. Apply:
• sealant
• (onto the crankshaft position sensor lead
grommet)
Yamaha bond No. 1215
90890-85505
4. Install:
• pickup coil rotor cover 1
T.
R.
12 Nm (1.2 m · kg)
NOTE:
Align the hole a into the pickup coil rotor
cover with the pin b.
@
5 - 44
CLUTCH
ENG
EAS00273
CLUTCH
CLUTCH COVER
T.
R.
12 Nm (1.2 m • kg)
LT
(5)
3
(10)
3
4
5
New 2
1
T.
R.
Order
Job/Part
Removing the clutch cover
Q’ty
Right side cowling
Clutch cover
Clutch cover gasket
Dowel pin
Damper cover
Damper
Remarks
Remove the parts in the order listed.
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Engine oil
1
2
3
4
5
12 Nm (1.2 m • kg)
1
1
2
1
1
For installation, reverse the removal
procedure.
5 - 45
CLUTCH
ENG
EAS00274
CLUTCH
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the clutch
Clutch release cylinder
Rear balancer
Oil guide plate
Clutch spring plate retainer
Clutch spring plate
Clutch spring plate seat
Pressure plate
Short clutch push rod
Ball
Long clutch push rod
Friction plate 1
Clutch plate
Friction plate 2
Q’ty
1
1
1
1
1
1
1
1
1
7
7
5 - 46
Remarks
Remove the parts in the order listed.
Refer to “HYDRAULIC CLUTCH” in chapter 4.
Refer to “BALANCERS”.
Refer to “REMOVING/INSTALLING THE
CLUTCH”.
CLUTCH
Order
12
13
14
15
16
17
18
19
20
21
Job/Part
Lock washer
Clutch boss
Wire circlip
Clutch plate 2
Friction plate 3
Clutch damper spring
Clutch damper spring seat
Thrust washer
Spacer
Clutch housing
Q’ty
1
1
1
1
1
1
1
1
1
1
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
CLUTCH”.
For installation, reverse the removal
procedure.
5 - 47
CLUTCH
ENG
EAS00275
EAS00277
REMOVING THE CLUTCH
1. Remove:
• rear balancer weight
Refer to “BALANCERS”.
2. Remove:
• clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
@
3. Straighten the lock washer tab.
4. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss
nut.
@
Universal clutch holder
90890-04086
5.
•
•
•
Remove:
clutch boss nut 1
lock washer 2
clutch boss assembly 3
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip 4 and disassemble the
built-in damper unless there is serious clutch
chattering.
@
5 - 48
CLUTCH
ENG
6. Remove:
• spacer 1
NOTE:
• Insert a cross-headed screwdriver into one of
the holes of the clutch housing and primary
driven gear, and then rotate the inner primary driven gear until both primary driver
gears are aligned. The teeth of both primary
driven gears must be aligned for installation.
• Insert two 5-mm bolts 2 into the spacer and
then remove the spacer by pulling on the
bolts.
@
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
1. Check:
• friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
@
Friction plate thickness
2.9 ~ 3.1 mm
<Limit>: 2.8 mm
5 - 49
CLUTCH
ENG
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.
Maximum
Maximum clutch plate warpage
0.1 mm
EAS00283
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate 1
Damage → Replace.
2. Check:
• clutch spring plate seat 2
Damage → Replace.
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.
@
2. Check:
• bearing
Damage/wear → Replace the bearing and
clutch housing.
5 - 50
CLUTCH
ENG
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
@
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.
EAS00288
CHECKING THE CLUTCH PUSH RODS
1. Check:
• O-ring 1
• short clutch push rod 2
• long clutch push rod 3
• ball 4
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• long clutch push rod bending
Out of specification → Replace the long
clutch push rod.
Long clutch push rod bending
limit
0.37 mm
EAS00292
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• primary driven gear 1
Damage/wear → Replace the clutch housing and crankshaft as a set.
Excessive noise during operation →
Replace the clutch housing and crankshaft
as a set.
5 - 51
CLUTCH
ENG
EAS00294
INSTALLING THE CLUTCH
1. Install:
• clutch housing 1
NOTE:
• Make sure that the slots a into the clutch
housing align with the tabs b onto the oil
pump drive sprocket.
• Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
• Insert a cross-headed screwdriver into one of
the holes of the clutch housing and primary
driven gear, and then rotate the inner primary driven gear until both primary driver
gears are aligned. The teeth of both primary
driven gears must be aligned for installation.
@
2. Install:
• spacer
NOTE:
Install the spacer with the two screw holes facing towards the clutch boss.
@
3. Install:
• clutch boss assembly 1
NOTE:
• If the wire circlip 2 has been removed, carefully install a new one as shown.
• Install the clutch spring plate 3 with the
“OUTSIDE” mark facing out.
@
5 - 52
ENG
CLUTCH
R.
Install:
thrust washer
clutch boss 1
lock washer New
clutch boss nut 2
T.
4.
•
•
•
•
90 Nm (9.0 m · kg)
NOTE:
While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss
nut.
@
Universal clutch holder
90890-04086
5. Bend the lock washer tab along a flat side of
the nut.
6.
•
•
•
Lubricate:
long clutch push rod 1
ball 2
short clutch push rod 3
(with the recommended lubricant)
Recommended lubricant
Lithium soap base grease
7.
•
•
•
Install:
long clutch push rod
ball
short clutch push rod
(along with a new O-ring)
8. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 53
ENG
CLUTCH
9. Install:
• friction plates
• clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
@
10.Install:
• pressure plate 1
• clutch spring plate seat 2
• clutch spring plate 3
• clutch spring plate retainer 4
T.
R.
8 Nm (0.8 m · kg)
NOTE:
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
@
11.Install:
• rear balancer weight
Refer to “BALANCERS”.
9
7
@
3,13
5
12 Nm (1.2 m · kg)
NOTE:
Tighten the clutch cover bolts in the proper
tightening sequence as show.
2,12
6
R.
1,11
T.
12.Install:
• clutch cover 1
10
8
4
5 - 54
SHIFT SHAFT
ENG
EAS00326
SHIFT SHAFT
Order
Job/Part
Removing the shift shaft
Engine oil
Q’ty
1
2
3
4
Clutch housing
Oil baffle plate
Shift arm
Circlip
Shift shaft
1
1
1
1
5
Shift shaft spring
1
5 - 55
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “CLUTCH”.
Refer to
SHAFT”.
“INSTALLING
THE
SHIFT
SHIFT SHAFT
Order
6
7
8
9
10
Job/Part
Stopper lever spring
Stopper lever
Circlip
Collar
Shift shaft spring stopper
Q’ty
1
1
1
1
1
ENG
Remarks
Refer to “INSTALLING THE SHIFT
SHAFT”.
For installation, reverse the removal
procedure.
5 - 56
SHIFT SHAFT
ENG
EAS00329
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
• shift shaft pawl 2
Bends/damage/wear → Replace.
• shift shaft spring 3
Damage/wear → Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
• Roller turns roughly → Replace the stopper
lever.
• stopper lever spring 2
Damage/wear → Replace.
EAS00331
INSTALLING THE SHIFT SHAFT
1. Install:
• stopper lever 1
• stopper lever spring 2
NOTE:
• Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss 3.
• Mesh the stopper lever with the shift drum
segment assembly.
@
2. Install:
• shift shaft 1
NOTE:
• Lubricate the oil seal lips with lithium soap
base grease.
• Hook the end of the shift shaft spring onto
the shift shaft spring stopper 2.
@
5 - 57
ENG
SHIFT SHAFT
T.
R.
3. Install:
• shift arm 1
10 Nm (1.0 m · kg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
@
5 - 58
OIL PAN AND OIL PUMP
ENG
EAS00356
OIL PAN AND OIL PUMP
Order
Job/Part
Removing the oil pan and oil pump
Exhaust pipe assembly
Air filter case
Q’ty
Engine oil
1
2
3
4
5
6
7
8
Sidestand
Oil level switch connector
Oil level switch
Oil pan
Oil pan gasket
Dowel pin
Oil delivery pipe
Oil pipe
1
1
1
1
1
2
1
1
5 - 59
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “AIR FILTER CASE” in chapter
3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
Refer to “REMOVING/INSTALLING THE
OIL PAN”.
OIL PAN AND OIL PUMP
Order
9
10
11
12
Job/Part
Oil strainer
Dowel pin
Oil pump
Relief valve assembly
ENG
Q’ty
Remarks
1
Refer to “INSTALLING THE OIL
STRAINER”.
2
1
Refer to “INSTALLING THE OIL PUMP”.
1
For installation, reverse the removal
procedure.
5 - 60
OIL PAN AND OIL PUMP
ENG
EAS00360
OIL PUMP
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the oil pump
Oil pump housing cover
Pin
Oil pump inner rotor
Oil pump outer rotor
Pin
Washer
Oil pump shaft
Oil pump housing
Q’ty
Remarks
Remove the parts in the order listed.
1
2
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 61
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• gasket
• dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
@
EAS00363
CHECKING THE OIL PUMP
1. Check:
• oil pump shaft 1
• oil pump housing 2
• oil pump housing cover 3
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.09 ~ 0.15 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 ~ 0.08 mm
5 - 62
OIL PAN AND OIL PUMP
ENG
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear → Replace the defective
part(s).
EAS00367
CHECKING THE OIL DELIVERY PIPES
The following procedure applies to all of the oil
delivery pipes.
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 63
ENG
OIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
12 Nm (1.2 m · kg)
• oil pump 1
LT
T.
R.
WARNING
Align the projection a on the oil pump with
the slit b on the impeller shaft.
CAUTION:
@
After tightening the bolts, make sure the oil
pump turns smoothly.
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
10 Nm (1.0 m · kg)
• oil strainer 1
LT
T.
R.
NOTE:
The arrow a on the oil strainer cover must
point towards the front of the engine.
@
EAS00380
T.
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• gasket New
12 Nm (1.2 m · kg)
• oil pan 1
10 Nm (1.0 m · kg)
• oil level switch 2
43
Nm (4.3 m · kg)
• engine oil drain bolt
R.
T.
R.
T.
R.
5 - 64
OIL PAN AND OIL PUMP
ENG
WARNING
@
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and in a
crisscross pattern.
• Lubricate the oil level switch O-ring with
engine oil.
@
5 - 65
MIDDLE GEAR
ENG
EAS00431
MIDDLE GEAR
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the middle gear
Engine
Oil pan/oil pump
Left middle gear cover
Left middle gear cover gasket
Dowel pin
Right middle gear cover
Bearing
Middle driven shaft end cover
Oil seal
Middle driven pinion gear nut
Middle driven shaft assembly
Middle driven shaft shim
Q’ty
1
1
2
1
1
1
1
1
1
2
5 - 66
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “OIL PAN AND OIL PUMP”.
Loosen.
Refer to “REMOVING THE MIDDLE
GEAR” and “INSTALLING THE MIDDLE
DRIVEN SHAFT ASSEMBLY”.
MIDDLE GEAR
Order
11
12
13
14
15
16
17
18
19
20
Job/Part
Middle drive pinion gear nut
Lock washer
Middle drive pinion gear
Middle drive shaft assembly
Spacer
Middle driven gear
Bearing retainer
Bearing
Middle drive shaft shim
Bearing
ENG
Q’ty
Remarks
1
Refer to “REMOVING THE MIDDLE
1
GEAR” and “INSTALLING THE MIDDLE
DRIVE SHAFT ASSEMBLY”.
1
1
1
1
1
Refer to “REMOVING THE MIDDLE
GEAR” and “INSTALLING THE MIDDLE
DRIVE SHAFT ASSEMBLY”.
1
1
1
For installation, reverse the removal
procedure.
5 - 67
MIDDLE GEAR
Order
1
Job/Part
Disassembling the middle drive
shaft assembly
Spring retainer
2
3
4
5
6
Spring seat
Damper spring
Damper driven cam
Damper drive cam
Middle drive shaft
Q’ty
2
ENG
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING/ASSEMBLING THE MIDDLE DRIVE SHAFT
ASSEMBLY”.
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 68
MIDDLE GEAR
Order
Q’ty
1
2
3
4
Job/Part
Disassembling the middle driven
shaft assembly
Middle driven pinion gear nut
Middle driven shaft
Middle driven pinion gear
Bearing retainer
5
6
Bearing
Middle driven shaft bearing housing
1
1
1
1
1
1
ENG
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING/ASSEMBLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
5 - 69
MIDDLE GEAR
ENG
EAS00432
REMOVING THE MIDDLE GEAR
1. Straighten the punched point of the middle
driven shaft nut.
2. Loosen:
• middle driven shaft nut 1
NOTE:
While holding the middle drive shaft 2.
3. Straighten the lock washer tab.
4. Loosen:
• middle drive shaft nut 1
NOTE:
While holding the middle drive shaft 2.
5. Straighten the punched point of the middle
drive shaft bearing retainer.
6. Loosen:
• bearing retainer 1
(with the bearing retainer wrench 2)
Bearing retainer wrench
90890-04057
5 - 70
MIDDLE GEAR
ENG
EAS00433
DISASSEMBLING THE MIDDLE DRIVE
SHAFT ASSEMBLY
1. Remove:
• spring retainers 1
NOTE:
While compressing the spring with the damper
spring compressor 2, remove the spring
retainers.
@
Damper spring compressor
90890-04090
DISASSEMBLING THE MIDDLE DRIVEN
SHAFT ASSEMBLY
1. Straighten the punched point of the bearing
retainer.
2. Loosen:
• bearing retainer 1
(with the bearing retainer wrench 2)
Bearing retainer wrench
90890-04140
EAS00438
CHECKING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Check:
• damper cam surface
Scratches/wear → Replace the damper
cam.
2. Check:
• spring
Cracks/damage → Replace.
5 - 71
ENG
MIDDLE GEAR
EAS00439
CHECKING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Check:
• middle driven gear
Galling/pitting/wear → Replace the middle
driven shaft assembly.
2. Check:
• bearings
Damage/pitting → Replace the middle drive
shaft bearing housing assembly.
3. Check:
• O-ring
• oil seal
Damage → Replace the defective part(s).
EAS00440
ASSEMBLING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Install:
• spring retainers 1
NOTE:
While compressing the spring with the damper
spring compressor 2, install the spring retainers.
@
Damper spring compressor
90890-04090
EAS00442
ASSEMBLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Tighten:
• bearing retainer 1
T.
R.
110 Nm (11.0 m · kg)
(with the bearing retainer wrench 2)
Bearing retainer wrench
90890-04140
5 - 72
ENG
MIDDLE GEAR
NOTE:
Lock the threads on the bearing retainer by
staking them with a center punch.
@
2. Install:
• middle driven shaft nut 1
NOTE:
Temporarily tighten the middle driven shaft
nut.
@
INSTALLING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Install:
• middle drive shaft shim
• bearing
• bearing retainer 1
T.
R.
110 Nm (11.0 m · kg)
(with the bearing retainer wrench 2
Bearing retainer wrench
90890-04057
NOTE:
Lock the threads on the bearing retainer by
staking them with a center punch.
@
2.
•
•
•
Install:
middle drive pinion gear
lock washer New
middle drive pinion gear nut 1
T.
R.
5 - 73
110 Nm (11.0 m · kg)
ENG
MIDDLE GEAR
NOTE:
While holding the middle drive shaft 2.
3. Bend the lock washer tab along a flat side of
the nut.
INSTALLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Install:
• middle driven shaft assembly 1
• middle driven shaft shims 2
• middle driven shaft bearing housing bolts
NOTE:
Finger tighten the middle driven shaft housing
bolts.
@
2. Tighten:
• middle driven shaft nut 1
T.
R.
110 Nm (11.0 m · kg)
NOTE:
• While holding the middle drive shaft 2.
• Lock the threads on the middle driven shaft
nut by staking them with a center punch.
5 - 74
ENG
MIDDLE GEAR
3. Tighten:
• middle driven shaft bearing housing bolts
T.
R.
25 Nm (2.5 m · kg)
NOTE:
Before tightening the bolts:
1. Adjust the middle gear backlash.
Refer to “ADJUSTING THE MIDDLE GEAR
BACKLASH”.
2. Check that the middle driven gear turns
smoothly.
@
EAS00449
MEASURING THE MIDDLE GEAR
BACKLASH
1. Measure:
• middle gear backlash
Out of specification → Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH”.
Middle gear backlash
0.10 ~ 0.20 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the gear lash measurement tool 1
as shown.
Gear lash measurement tool
90890-01467
b. Make sure the dial gauge plunger contacts
the measuring point a on the middle gear
backlash band as shown.
a: 38 mm
c. Hold the middle drive shaft 2.
5 - 75
MIDDLE GEAR
ENG
d. While gently turning the middle driven shaft
back and forth, measure the middle gear
backlash.
NOTE:
Measure the middle gear backlash at four
positions. Rotate the middle driven shaft 90°
each time and observe the reading on the dial
gauge.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00450
ADJUSTING THE MIDDLE GEAR
BACKLASH
1. Loosen:
• middle driven shaft bearing housing bolts
2. Remove:
• shim(s)
3. Tighten:
• middle driven shaft bearing housing bolts
CAUTION:
@
Do not overtighten the middle driven shaft
bearing housing bolts or you may obtain
too little middle gear backlash and damage
the middle gears. If the bolts are overtightened, loosen them until the crankcase-tomiddle-driven-shaft-bearing-housing clearance is within specification, as stated
below. Then, repeat all of the previous
steps.
5 - 76
MIDDLE GEAR
ENG
NOTE:
• Tighten the middle driven shaft bearing
housing bolts carefully, one thread turn at a
time only. Push in the middle driven shaft
bearing housing and then tighten the bolts to
specification.
• Clearance between the crankcase and the
middle driven shaft bearing housing should
be approximately 2 mm, when measured
with a thickness gauge 1.
@
4. Hold the middle drive shaft 1.
5. Turn:
• middle driven shaft
NOTE:
While carefully tightening the middle driven
shaft bearing housing bolts in stages and in a
crisscross pattern, turn the middle driven shaft
back and forth until the dial gauge reads 0.10 ~
0.20 mm.
@
6. Measure:
• crankcase-to-middle-driven-shaft-bearinghousing clearance
(with a thickness gauge)
5 - 77
ENG
MIDDLE GEAR
7. Select:
• shim(s) 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Shims can only be selected in 0.05 mm
increments, therefore round off to the hundredth’s digit of the calculated thickness
and select the appropriate shim with the following chart.
b. For example, the clearance between the
crankcase and the middle driven shaft bearing housing is 0.42 mm. Therefore, the
chart instructs you to round off the 2 to 0.
Thus, you should use one 0.40 mm shim.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle driven pinion gear shim
Thickness (mm)
0.10 0.15 0.30
0.40 0.50 0.60
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Loosen:
• middle driven shaft bearing housing bolts
9. Install:
• shim(s)
10.Tighten:
• middle driven shaft bearing housing bolts
T.
R.
25 Nm (2.5 m · kg)
11.Measure:
• middle gear backlash
Out of specification → Refer to “MEASURING THE MIDDLE GEAR BACKLASH”.
5 - 78
MIDDLE GEAR
ENG
EAS00452
ALIGNING THE MIDDLE GEAR
NOTE:
Aligning the middle gear is necessary when
any of the following parts are replaced:
• Crankcase
• Middle drive shaft
• Middle driven shaft bearing housing
@
1. Select:
• middle drive shaft shim(s) 1
• middle driven shaft shim(s) 2
NOTE:
Select the middle driven shaft shim(s) 2 by
calculating the middle drive shaft shim thickness and then measuring the middle gear
backlash.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the middle gear with the appropriate shim(s) 1 and 2 that has had its
respective thickness calculated from information marked on the crankcase and the
end of the middle drive gear.
1 Middle drive gear shim thickness “A”
2 Middle drive gear shim thickness “B”
b. To find middle drive shaft shim thickness
“A”, use the following formula.
Middle drive shaft shim thickness
“A” = c – a – b
a = “65.00”
b = bearing thickness constant
c = a numeral on the upper crankcase near
the main bearing selection numbers and which
is added to the nominal size “84”
Example:
a is 65.00
b is 18.94
If the upper crankcase is marked “45”
c is 84.45 (i.e., 84.00 + 0.45 = 84.45)
“A” = 84.45 – 65.00 – 18.94 = 0.51
Round off to the hundredths digit and select
the appropriate shim(s).
5 - 79
MIDDLE GEAR
ENG
NOTE:
In the above example, the calculated number
is 0.51. The chart instructs you to round off the
1 to 0. Thus, the shim thickness is 0.50 mm.
@
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle drive shaft shim
Thickness (mm)
0.10 0.15 0.30
0.40 0.50 0.60
c. To find middle driven shaft shim thickness
“B”, use the following formula.
Middle driven shaft shim thickness
“B” = d + e – f
d = a numeral on the middle driven pinion
gear which is added to the nominal size “34”
e = Measured value
f = a numeral on the upper crankcase near
the main bearing selection numbers and which
is added to the nominal size “88”
Example:
If the middle driven pinion gear is marked
“– 03”
d is 33.97 (i.e., 34.00 + (– 0.03) = 33.97)
e is 54.49
If the upper crankcase is marked “95”
f is 87.95 (i.e., 87.00 + 0.95 = 87.95)
“B” = 33.97 + 54.49 – 87.95 = 0.51
Round off to the hundredths digit and select
the appropriate shim(s).
NOTE:
In the above example, the calculated number
is 0.51. The chart instructs you to round off the
1 to 0. Thus, the shim thickness is 0.50 mm.
@
5 - 80
MIDDLE GEAR
ENG
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle drive shaft shim
Thickness (mm)
0.10 0.15 0.30
0.40 0.50 0.60
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 81
CRANKCASE
ENG
CRANKCASE
9
T.
R.
10 Nm (1.0 m • kg)
10
T.
R.
10 Nm (1.0 m • kg)
8
3
10
LT
7
UP
10
2
1
6
5
4
Order
1
2
3
4
Job/Part
Separating the crankcase
Engine
Cylinder head
Generator rotor
Pickup coil rotor
Stopper lever
Oil pump
Middle drive shaft
Timing chain
Oil pump drive chain guide
Oil pump drive chain
Oil pump drive sprocket
Q’ty
1
1
1
1
5 - 82
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “GENERATOR AND STARTER
CLUTCH”.
Refer to “PICKUP COIL ROTOR”.
Refer to “SHIFT SHAFT”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “MIDDLE GEAR”.
CRANKCASE
ENG
9
T.
R.
10
T.
R.
10 Nm (1.0 m • kg)
3
10 Nm (1.0 m • kg)
8
10
LT
7
UP
10
2
1
6
5
4
Order
5
6
7
8
9
10
Job/Part
Collar
Spacer
Neutral switch
Speed sensor
Lower crankcase
Dowel pin
Q’ty
Remarks
1
1
1
1
1
Refer to “DISASSEMBLING/ASSEMBLING THE CRANKCASE”.
3
For installation, reverse the removal
procedure.
5 - 83
CRANKCASE
ENG
10
T.
R.
11
70 Nm (7.0 m • kg)
9
T.
R.
10 Nm (1.0 m • kg)
T.
R.
LT
12 Nm (1.2 m • kg)
4
LT
LT
8
1
7
3
LT
6
LS
2
5
Order
1
2
3
4
5
Job/Part
Removing the oil baffle plates and
bearings
Connecting rod assemblies
Crankshaft/crankshaft journal bearings
Transmission
Oil baffle plate
Oil delivery pipe
Plate
Oil baffle plate
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CONNECTING RODS AND
PISTONS”.
Refer to “CRANKCASE”.
Refer to “TRANSMISSION”.
1
1
1
1
1
5 - 84
CRANKCASE
ENG
10
T.
R.
11
70 Nm (7.0 m • kg)
9
T.
R.
10 Nm (1.0 m • kg)
T.
R.
LT
12 Nm (1.2 m • kg)
4
LT
LT
8
1
7
3
LT
6
LS
2
5
Order
6
7
8
9
10
11
Job/Part
Oil seal
Bearing
Upper crankcase
Bearing
Oil filter bolt
Lower crankcase
Q’ty
1
1
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
5 - 85
CRANKCASE
ENG
EAS00384
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
@
2. Place the engine upside down.
3. Remove:
• lower crankcase
CAUTION:
@
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
M9 × 115 mm bolts: 1 ~ 0
M8 × 65 mm bolts: A
M8 × 50 mm bolts: B
M6 × 80 mm bolts: M, O
M6 × 65 mm bolts: C, D
M6 × 65 mm bolts: I, L, N, P
M6 × 55 mm bolts: E ~ H, J, K, Q ~ T
M6 × 45 mm bolts: U
4. Remove:
• dowel pins
5 - 86
CRANKCASE
ENG
EAS00399
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.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seals
Damage/wear → Replace.
5 - 87
CRANKCASE
ENG
EAS00208
CHECKING THE TIMING CHAIN AND OIL
PUMP DRIVE CHAIN
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
• timing chain 1
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
• oil pump drive chain 2
Damage/stiffness → Replace the oil pump
drive chain, oil pump drive sprocket and oil
pump shaft as a set.
2. Check:
• oil pump drive sprocket
Cracks/damage/wear → Replace the oil
pump drive sprocket and the oil pump drive
chain as a set.
EAS00413
ASSEMBLING THE CRANKCASE
1. Lubricate:
• crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 88
CRANKCASE
ENG
2. Apply:
• sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm
of the crankshaft journal bearings.
@
3. Install:
• dowel pins
4. Set the shift drum assembly and transmission gears in the neutral position.
5. Install:
• lower crankcase 1
(onto the upper crankcase 2)
CAUTION:
@
Before tightening the crankcase bolts,
make sure the transmission gears shift correctly when the shift drum assembly is
turned by hand.
5 - 89
CRANKCASE
ENG
6. Install:
• crankcase bolts
NOTE:
• Lubricate the bolt threads and washers with
engine oil.
• Finger tighten the crankcase bolts.
@
M9 × 115 mm bolts: 1 ~ 0 New
M8 × 65 mm bolts: A
M8 × 50 mm bolts: B
M6 × 80 mm bolts: M, O
M6 × 65 mm bolts: C, D
M6 × 65 mm bolts: I, L, N, P
M6 × 55 mm bolts: E ~ H, J, K, Q ~ T
M6 × 45 mm bolts: U
7. Tighten:
• crankcase bolts 1 ~ 0
NOTE:
• Do not reuse crankcase bolts 1 ~ 0.
• The tightening procedure of crankcase bolts
1 ~ 0 is angle controlled, therefore tighten
the bolts using the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the bolts in the tightening sequence
cast on the crankcase.
T.
R.
Crankcase bolt 1 ~ 0
1st
20 Nm (2.0 m · kg)
b. Loosen and retighten the crankcase bolts in
the proper tightening sequence as shown.
T.
R.
5 - 90
Crankcase bolt 1 ~ 0
2nd
20 Nm (2.0 m · kg)
CRANKCASE
ENG
c. Tighten the crankcase bolts further to reach
the specified angle 120° in the proper tightening sequence as shown.
T.
R.
Crankcase bolt 1 ~ 0
Final
Specified angle 120°
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform the procedure again.
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.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60°.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Tighten:
• crankcase bolts A ~ U
NOTE:
Tighten the bolts in the tightening sequence
cast on the crankcase.
@
T.
R.
5 - 91
Bolt A, B
24 Nm (2.4 m · kg)
Bolt C, D
12 Nm (1.2 m · kg)
Bolt E ~ U
10 Nm (1.0 m · kg)
CONNECTING RODS AND PISTONS
ENG
EAS00252
CONNECTING RODS AND PISTONS
New
1
M
2
E
E
7
M
6
New
5
New 3
4
M
New
3 New
E
10
E
9
8
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the connecting rods and
pistons
Crankcase
Connecting rod cap
Big end lower bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Big end upper bearing
Top ring
2nd ring
Oil ring
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
4
4
8
4
4
4
4
4
4
4
Refer to “REMOVING THE CONNECTING RODS AND PISTONS” and
“INSTALLING THE CONNECTING
RODS AND PISTONS”.
For installation, reverse the removal
procedure.
5 - 92
CONNECTING RODS AND PISTONS
ENG
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
• connecting rod cap 1
• big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
@
2.
•
•
•
•
Remove:
piston pin clips 1
piston pin 2
piston 3
connecting rod 4
CAUTION:
@
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put identification marks on the piston crown.
• Before removing the piston pin, deburr the
piston pin clip’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 5.
@
Piston pin puller
90890-01304
5 - 93
CONNECTING RODS AND PISTONS
3.
•
•
•
ENG
Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
@
EAS00258
CHECKING THE CYLINDERS AND
PISTONS
The following procedure applies to all of the
cylinders and pistons.
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
@
Cylinder bore “C”
79.00 ~ 79.01 mm
Taper limit “T”
0.05 mm
Out of round “R”
0.05 mm
“C” = maximum of D1 ~ D6
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1, D3 or D5 – minimum of D2, D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
5 - 94
CONNECTING RODS AND PISTONS
ENG
c. Measure piston skirt diameter “P” with the
micrometer.
a 5 mm from the bottom edge of the piston
Piston size “P”
Standard
78.965 ~ 78.980 mm
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.020 ~ 0.045 mm
<Limit>: 0.012 mm
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
@
Piston ring side clearance
Top ring
0.03 ~ 0.07 mm
<Limit>: 0.12 mm
2nd ring
0.02 ~ 0.06 mm
<Limit>: 0.12 mm
5 - 95
CONNECTING RODS AND PISTONS
ENG
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown.
@
a 5 mm
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
@
Piston ring end gap
Top ring
0.35 ~ 0.45 mm
<Limit>: 0.70 mm
2nd ring
0.75 ~ 0.85 mm
<Limit>: 1.20 mm
Oil ring
0.2 ~ 0.6 mm
EAS00266
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.
5 - 96
CONNECTING RODS AND PISTONS
ENG
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
Piston pin outside diameter
11.9 ~ 12.1 mm
<Limit>: 11.88 mm
3. Measure:
• piston pin bore diameter (in the piston) b
Out of specification → Replace the piston.
Piston pin bore diameter (in the
piston)
19.004 ~ 19.015 mm
<Limit>: 19.045 mm
4. Calculate:
• piston-pin-to-piston clearance
Out of specification → Replace the piston
pin.
Piston-pin-to-piston clearance =
Piston pin bore diameter (in the piston)
b–
Piston pin outside diameter a
Piston-pin-to-piston clearance
6.904 ~ 7.115 mm
<Limit>: 7.165 mm
5 - 97
CONNECTING RODS AND PISTONS
ENG
EAS00396
CHECKING THE CONNECTING RODS
1. Measure:
• crankshaft-pin-to-big-end-bearing
clearance
Out of specification → Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing clearance
0.031 ~ 0.048 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to all of the
connecting rods.
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.
@
c. Put a piece of Plastigauge® 1 on the crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or crankshaft until the clearance measurement has
been completed.
• Lubricate the bolts threads and nut seats
with molybdenum disulfide grease.
• Make sure the “Y” mark 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.
@
5 - 98
CONNECTING RODS AND PISTONS
ENG
e. Tighten the connecting rod nuts.
Refer to “INSTALLING THE CONNECTING
RODS AND PISTONS”.
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS AND PISTONS”.
g. Measure the compressed Plastigauge®
width e on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• big end bearings (P1 ~ P4)
NOTE:
• The numbers stamped into the crankshaft
web and the numbers on the connecting rods
are used to determine the replacement big
end bearing sizes.
• “P1” ~ “P4” refer to the bearings shown in the
crankshaft illustration.
@
P1
P4
P2
P3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the connecting rod “P1” and the
crankshaft web “P1” numbers are “6” and “1”
respectively, then the bearing size for “P1” is:
Bearing size of P1:
“P1” (connecting rod) – “P1” (crankshaft web)
6 – 1 = 5 (yellow)
BEARING COLOR CODE
P1 P2 P3 P4
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 99
CONNECTING RODS AND PISTONS
ENG
EAS00271
EAS00404
INSTALLING THE CONNECTING RODS
AND PISTONS
The following procedure applies to all of the
pistons and connecting rods.
1. Install:
• top ring
• 2nd ring
• oil ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
@
2.
•
•
•
•
Install:
piston 1
connecting rod 2
piston pin 3
piston pin clip 4 New
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark a on the connecting rod left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
• Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
@
3. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
È Intake side
5 - 100
CONNECTING RODS AND PISTONS
4.
•
•
•
ENG
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Lubricate:
• bolt threads
• nut seats
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide grease
6.
•
•
•
Lubricate:
crankshaft pins
big end bearings
connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
• big end bearings
• connecting rod assembly 1
(into the cylinder and onto the crankshaft
pin)
• connecting rod cap
(onto the crankshaft pin)
NOTE:
• Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
• Be sure to reinstall each big end bearing in
its original place.
• While compressing the piston rings with piston ring compressor 2, install the connecting
rod assembly into the cylinder with the other
hand.
@
5 - 101
CONNECTING RODS AND PISTONS
ENG
• Make sure the “Y” marks a on the connecting rods face towards the left side of the
crankshaft.
• Make sure the characters b on both the connecting rod and connecting rod cap are
aligned.
Piston ring compressor
90890-05158
8. Align:
• bolt heads
(with the connecting rod)
9. Tighten:
• connecting rod nuts
WARNING
@
• Replace the connecting rod bolts and
nuts with new ones.
• Clean the connecting rod bolts and nuts.
NOTE:
The tightening procedure of the connecting rod
nuts is angle controlled, therefore tighten the
nuts using the following procedure.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the connecting rod nuts to the specified torque.
T.
R.
Connecting rod nut
1st
20 Nm (2.0 m · kg)
b. Tighten the connecting rod nuts further to
reach the specified angle 120°.
T.
R.
5 - 102
Connecting rod nut
Final
Specified angle 120°
6D
CONNECTING RODS AND PISTONS
ENG
WARNING
When the nuts are tightened more than the
specified angle, do not loosen the nut and
then retighten it.
Replace the nut with a new one and perform the procedure again.
CAUTION:
• Do not use a torque wrench to tighten the
nut to the specified angle.
• Tighten the nut until it is at the specified
angle.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60°.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 103
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
2
E
1
3
3
E
Order
Job/Part
Removing the crankshaft
Crankcase
Q’ty
Connecting rod caps
1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
1
5
5
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
Refer to “REMOVING/INSTALLING THE
CRANKSHAFT”.
For installation, reverse the removal
procedure.
5 - 104
CRANKSHAFT
ENG
EAS00387
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
• crankshaft journal lower bearings
(from the lower crankcase)
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
bearing so that it can be reinstalled in its original place.
@
EAS00396
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
Out of specification → Replace the crankshaft.
Maximum crankshaft runout
0.03 mm
2.
•
•
•
Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
• crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification → Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.027 ~ 0.045 mm
5 - 105
CRANKSHAFT
ENG
CAUTION:
@
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on
a bench.
c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crankcase.
NOTE:
Align the projections a of the crankshaft journal upper bearings with the notches b in the
upper crankcase.
@
2
22
22
12
21
d. Put a piece of Plastigauge® 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
@
e. Install the crankshaft journal lower bearings
into the lower crankcase and assemble the
crankcase halves.
NOTE:
• Align the projections a of the crankshaft
journal lower bearings with the notches b in
the lower crankcase.
• Do not move the crankshaft until the clearance measurement has been completed.
@
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
Refer to “ASSEMBLING THE CRANKCASE— CRANKCASE”.
g. Remove the lower crankcase and the crankshaft journal lower bearings.
5 - 106
CRANKSHAFT
22
2
1
22
22
ENG
h. Measure the compressed Plastigauge®
width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification,
select replacement crankshaft journal bearings.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Select:
• Crankshaft journal bearings (J1 ~ J5)
NOTE:
• The numbers stamped into the crankshaft
web and the numbers stamped into the lower
crankcase are used to determine the
replacement crankshaft journal bearing
sizes.
• “J1 ~ J5” refer to the bearings shown in the
crankshaft illustration.
• If “J1 ~ J5” are the same, use the same size
for all of the bearings.
@
J1
J2
J3
J4
J5
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
J1 J2 J3 J4 J5
Bearing size of J1:
“J1” (crankcase) – “J1” (crankshaft web)
+2
6 – 2 + 2 = 6 (pink)
BEARING COLOR CODE
2
black
3
brown
4
green
5
yellow
6
pink
7
red
8
white
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 107
CRANKSHAFT
ENG
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft journal upper bearings
(into the upper crankcase)
• crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
• Align the projections a on the crankshaft
journal upper bearings with the notches b in
the upper crankcase.
• Be sure to install each crankshaft journal
bearing in its original place.
@
2. Lubricate:
• crankshaft pins
• connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 108
TRANSMISSION
ENG
EAS00419
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the transmission, shift
drum assembly, and shift forks
Crankcase
Drive axle assembly
Bearing
Washer
Shift drum retainer
Long shift fork guide bar
Shift fork “L”
Shift fork “R”
Short shift fork guide bar
Spring
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
1
1
1
1
1
4
5 - 109
Refer to “INSTALLING THE TRANSMISSION”.
TRANSMISSION
Order
10
11
12
Job/Part
Shift drum assembly
Shift fork “C”
Main axle assembly
ENG
Q’ty
Remarks
1
Refer to “INSTALLING THE TRANSMISSION”.
1
1
Refer to “REMOVING/INSTALLING THE
TRANSMISSION”.
For installation, reverse the removal
procedure.
5 - 110
TRANSMISSION
ENG
New
New
M
M
M
M
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Q’ty
Remarks
Disassembling the main axle assemRemove the parts in the order listed.
bly
2nd pinion gear
1
Toothed lock washer
1
Toothed lock washer retainer
1
5th pinion gear
1
Toothed spacer
1
Toothed washer
2
Circlip
2
3rd pinion gear
1
4th pinion gear
1
Collar
1
5 - 111
TRANSMISSION
ENG
New
New
M
M
M
M
Order
A
B
C
Job/Part
Main axle/1st pinion gear
Bearing
Main axle bearing housing
Q’ty
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
5 - 112
TRANSMISSION
ENG
M
M
M
M
M
M
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the drive axle
assembly
Middle drive gear
Bearing
Washer
2nd wheel gear
Collar
washer
5th wheel gear
Circlip
Toothed washer
3rd wheel gear
Q’ty
1
1
1
1
1
1
1
2
2
1
5 - 113
Remarks
Remove the parts in the order listed.
TRANSMISSION
ENG
M
M
M
M
M
M
Order
A
B
C
D
E
F
G
H
I
Job/Part
Toothed spacer
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Washer
1st wheel gear
Bearing
Washer
Drive axle
Q’ty
1
1
1
1
1
1
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
5 - 114
TRANSMISSION
ENG
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
• bearing housing bolts 1
(with the Torx wrench T30)
2. Remove:
• main axle assembly
(from the clutch side)
NOTE:
Remove the main axle assembly with the slide
hammer bolt 1 and weight.
@
Slide hammer bolt
90890-01083
Weight
90890-01084
EAS00421
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.
5 - 115
TRANSMISSION
ENG
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
@
Do not attempt to straighten a bent shift
fork guide bar.
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.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift drum
assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift drum
assembly.
EAS00425
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
5 - 116
TRANSMISSION
ENG
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
3. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
4. 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.
5 - 117
ENG
TRANSMISSION
INSTALLING THE TRANSMISSION
1. Install:
• main axle assembly
T.
R.
R.
shift fork “C”
shift drum assembly
shift fork “R”
shift fork “L”
shift fork guide bars
shift drum retainer
drive axle assembly
T.
•
•
•
•
•
•
•
12 Nm (1.2 m · kg)
10 Nm (1.0 m · kg)
NOTE:
• When installing the main axle assembly, use
a pin to align the bearing housing bolt hole
with the corresponding hole in the upper
crankcase.
• The embossed marks on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R”, “C”, “L”.
• Make sure the drive axle bearing circlip 1 is
inserted into the grooves a in the upper
crankcase.
• The drive axle bearing pin 2 must face
towards the rear of the crankcase.
@
2. Check:
• transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
@
5 - 118
BALANCERS
ENG
BALANCERS
FRONT BALANCER
Order
1
2
3
4
5
6
7
Job/Part
Removing the front balancer
Crankcase
Balancer lever
Balancer shaft
Washer
Bearing
Balancer gear
Absorber
Balancer weight
Q’ty
1
1
2
2
1
4
1
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “INSTALLING THE FRONT
BALANCER”.
For installation, reverse the removal
procedure.
5 - 119
BALANCERS
ENG
REAR BALANCER
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the rear balancer
Throttle bodies
Clutch cover
Balancer cover
Balancer cover gasket
Balancer lever
Balancer shaft
Washer
Bearing
Balancer gear
Absorber
Balancer weight
Q’ty
1
1
1
1
2
2
1
4
1
Remarks
Remove the parts in the order listed.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
Refer to “CLUTCH”.
Refer to “INSTALLING THE REAR BALANCER”.
For installation, reverse the removal
procedure.
5 - 120
BALANCERS
ENG
CHECKING THE BALANCER
1. Check:
• front balancer gear
Damage/wear → Replace the front balancer gear and crankshaft.
• rear balancer gear
Damage/wear → Replace the rear balancer
gear and primary driven gear.
2. Check:
• balancer shaft 1
Cracks/damage/wear → Replace the balancer shaft and bearings.
Dirt → Clean.
• bearings 2
Damage/wear → Replace.
• absorbers
Damage/wear → Replace.
INSTALLING THE FRONT BALANCER
1. Install:
• balancer weight 1
• absorbers
• balancer gear 2
• bearings
• washers
NOTE:
Align the punch mark a in the balancer weight
with the mark b in the balancer gear.
2. Align:
• “T” mark on the pickup coil rotor
(with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the
pickup coil rotor with the crankcase mating
surface b.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 121
ENG
BALANCERS
3. Install:
• balancer shaft 1
NOTE:
• Align the punch mark a in the balancer
weight with the oil hole b in the upper crankcase.
• Make sure that the front balancer gear teeth
and the primary drive gear teeth mesh correctly.
• Make sure that the slot c is facing in the
direction indicated in the illustration when
installing the balancer shaft.
@
4. Install:
• balancer lever 1
• balancer lever bolt 2
LT
NOTE:
Temporarily tighten the balancer lever bolt.
T.
R.
5. Tighten:
• balancer shaft 1
0.4 Nm (0.04 m · kg)
NOTE:
Tighten the balancer shaft to the specified
torque by turning it counterclockwise, and then
turn it one scale back on the balancer lever
scale.
6. Tighten:
• balancer lever bolt 1
T.
R.
14 Nm (1.4 m · kg)
• balancer shaft pinch bolt 2
T.
R.
10 Nm (1.0 m · kg)
NOTE:
Make sure that the balancer shaft does not
rotate.
5 - 122
BALANCERS
ENG
7. Start the engine and check that there is no
abnormal noise coming from the balancer
gear. If noise is abnormal, adjust the gear
lash by turning the balancer shaft.
NOTE:
With each adjustment, turn the balancer shaft
one scale.
Clockwise
Decrease gear lash
Counterclockwise
Increase gear lash
INSTALLING THE REAR BALANCER
1. Install:
• balancer weight 1
• absorbers
• balancer gear 2
• bearings
• washers
NOTE:
Align the punch mark a in the balancer weight
with the mark b in the balancer gear.
2. Align:
• “T” mark on the pickup coil rotor
(with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the
pickup coil rotor with the crankcase mating
surface b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 123
BALANCERS
ENG
3. Install:
• balancer shaft 1
NOTE:
• Align the punch marks a in the balancer
weight with the oil hole b in the upper crankcase.
• Make sure that the rear balancer gear teeth
and the primary driven gear teeth mesh correctly.
• Make sure that the balancer gear punch
mark c is aligned with the primary driven
gear point d.
• Make sure that the slot e is facing in the
direction indicated in the illustration when
installing the balancer shaft.
@
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
4. Install:
• balancer lever 1
• balancer lever bolt 2
LT
NOTE:
Temporarily tighten the balancer lever bolt.
5 - 124
ENG
BALANCERS
T.
5. Tighten:
• balancer shaft 1
R.
0.4 Nm (0.04 m · kg)
NOTE:
Tighten the balancer shaft to the specified
torque by turning it counterclockwise, and then
turn it two scales back on the balancer lever
scale.
6. Tighten:
• balancer lever bolt 1
T.
R.
14 Nm (1.4 m · kg)
• balancer shaft pinch bolt 2
T.
R.
10 Nm (1.0 m · kg)
NOTE:
Make sure that the balancer shaft does not
rotate.
7. Start the engine and check that there is no
abnormal noise coming from the balancer
gear. If noise is abnormal, adjust the gear
lash by turning the balancer shaft.
NOTE:
With each adjustment, turn the balancer shaft
one scale.
Clockwise
Decrease gear lash
Counterclockwise
Increase gear lash
5 - 125
COOL
6
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR..................................................................6-4
OIL COOLER...................................................................................................6-5
CHECKING THE OIL COOLER ................................................................6-6
INSTALLING THE OIL COOLER .............................................................. 6-6
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT............................................................ 6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY................................... 6-11
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-11
WATER PUMP...............................................................................................6-12
DISASSEMBLING THE WATER PUMP.................................................. 6-15
CHECKING THE WATER PUMP ............................................................ 6-15
ASSEMBLING THE WATER PUMP........................................................ 6-16
INSTALLING THE WATER PUMP .......................................................... 6-18
COOL
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
Order
Job/Part
Removing the radiator
Rider seat/fuel tank
Q’ty
Side cowlings/front cowling assembly
Coolant
1
2
3
4
5
6
7
Radiator cap
Coolant reservoir breather hose
Coolant reservoir hose
Coolant reservoir cap cover
Coolant reservoir cap
Coolant reservoir
Water pump breather hose
1
1
1
1
1
1
1
6-1
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
RADIATOR
Order
8
9
10
11
12
13
14
15
16
17
18
19
Job/Part
Radiator outlet hose
Thermostat assembly breather hose
Conduit
Conduit hose
Radiator inlet hose
Plunger control unit hose 2
Oil cooler outlet hose
Horn connector
Radiator fan motor coupler
Radiator
Horn bracket (left and right)
Radiator fan
Q’ty
1
1
1
1
1
1
1
4
1
1
2
1
COOL
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
6-2
RADIATOR
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
@
2. Check:
• radiator hoses
Cracks/damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
93.3 ~ 122.7 kPa
(0.93 ~ 1.23 kg/cm2, 0.93 ~ 1.23 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and radiator
cap tester adapter 2 to the radiator cap 3.
Radiator cap tester
90890-01325
Radiator cap tester adapter
90890-01352
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-3
RADIATOR
COOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-4
OIL COOLER
COOL
EAS00457
OIL COOLER
Order
1
2
3
4
5
6
7
Job/Part
Removing the oil cooler
Engine oil
Radiator assembly
Water pump outlet hose
Water pump outlet pipe
Water jacket joint inlet hose
Water jacket joint
Oil cooler inlet hose
Oil cooler outlet hose
Oil cooler
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “RADIATOR”.
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
6-5
COOL
OIL COOLER
EAS00458
CHECKING THE OIL COOLER
1. Check:
• oil cooler
Cracks/damage → Replace.
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
Cracks/damage/wear → Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
T.
R.
2. Install:
• O-ring New
• oil cooler
12 Nm (1.2 m · kg)
NOTE:
Make sure the O-ring is positioned properly.
@
3. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
• crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
6-6
OIL COOLER
COOL
4. Check:
• cooling system
Leaks → Repair or replace any faulty part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-7
THERMOSTAT
COOL
EAS00460
THERMOSTAT
Order
Job/Part
Removing the thermostat assembly
Side cowlings/front cowling assembly
Q’ty
Coolant
Air cut-off valve assembly/hoses
1
2
3
4
5
6
Plunger control unit hose 1
Thermostat assembly inlet pipe
Coolant temperature sensor
Thermostat assembly breather hose
Radiator inlet hose
Thermostat assembly
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
6-8
THERMOSTAT
COOL
EAS00461
Order
1
2
3
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling
the
thermostat
assembly
Thermostat housing cover
1
Refer to “ASSEMBLING THE THERMOThermostat
1
STAT ASSEMBLY”.
Thermostat housing
1
For assembly, reverse the disassembly
procedure.
6-9
THERMOSTAT
COOL
EAS00463
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 71 ~ 85 °C → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermostat
2 Thermometer
3 Water
4 Container
È Fully closed
É Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or over cooling.
Opening (mm)
@
Temperature
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage → Replace.
3. Check:
• thermostat housing O-ring
• thermostat housing inlet pipe O-ring
Damage → Replace.
6 - 10
THERMOSTAT
COOL
EAS00464
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing 1
• thermostat 2
• thermostat housing cover
NOTE:
Install the thermostat with its breather hole a
a facing up.
@
EAS00466
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Lubricate:
• O-ring (thermostat assembly and thermostat assembly inlet pipe)
Recommended lubricant
LLC
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6 - 11
WATER PUMP
COOL
EAS00468
WATER PUMP
Order
Job/Part
Removing the water pump
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
It is not necessary to remove the water
pump unless the coolant level is
extremely low or the coolant contains
engine oil.
Right side cowling
Refer to “COWLINGS AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Engine oil
Coolant
6 - 12
WATER PUMP
Order
1
2
3
4
Job/Part
Water pump breather hose
Radiator outlet hose
Water pump outlet hose
Water pump
Q’ty
1
1
1
1
6 - 13
COOL
Remarks
Disconnect.
Disconnect.
Disconnect.
Refer to “INSTALLING THE WATER
PUMP”.
For installation, reverse the removal
procedure.
WATER PUMP
COOL
EAS00469
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the water pump
Water pump housing cover
O-ring
Circlip
Impeller shaft
Rubber damper holder
Rubber damper
Water pump seal
Oil seal
Bearing
Water pump housing
Q’ty
1
1
1
1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE WATER
PUMP”.
For assembly, reverse the disassembly
procedure.
6 - 14
WATER PUMP
COOL
EAS00470
DISASSEMBLING THE WATER PUMP
1. Remove:
• rubber damper holder 1
• rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
@
2. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing 2.
@
3. Remove:
• oil seal 1
• bearing 2
NOTE:
Tap out the bearing and oil seal from the outside of the water pump housing.
@
EAS00473
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover
• water pump housing
• impeller
• rubber damper
• rubber damper holder
• water pump seals
• oil seal
Cracks/damage/wear → Replace.
2. Check:
• bearing
Rough movement → Replace.
3. Check:
• water pump outlet pipe
• radiator outlet hose
Cracks/damage/wear → Replace.
6 - 15
WATER PUMP
COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
• oil seal 1 New
(into the water pump housing 2)
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its out surface.
• Install the oil seal with a socket that matches
its outside diameter.
@
2. Install:
• water pump seal 1 New
CAUTION:
@
Never lubricate the water pump seal surface with oil or grease.
NOTE:
• Install the water pump seal with the special
tools.
• Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3.
@
Mechanical seal installer
90890-04078 4
Middle driven shaft bearing driver
90890-04058 5
Yamaha bond #1215
90890-85505
È Push down.
3. Install:
• rubber damper 1 New
• rubber damper holder 2 New
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
@
6 - 16
COOL
WATER PUMP
4. Measure:
• impeller shaft tilt
Out of specification → Repeat steps (3) and
(4).
CAUTION:
@
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Max. impeller shaft tilt
0.15 mm
1 Straightedge
2 Impeller
5. Install:
• impeller 1
• circlip New
NOTE:
After installation, check that the impeller shaft
rotates smoothly.
@
6. Install:
• O-ring
New
NOTE:
Lubricate the O-ring with a thin coat of lithium
soap base grease.
@
7. Install:
• water pump housing
• water pump housing cover
T.
R.
10 Nm (1.0 m · kg)
WARNING
Always use a new copper washer.
6 - 17
COOL
WATER PUMP
EAS00478
INSTALLING THE WATER PUMP
1. Install:
• O-ring New
• water pump assembly 1
T.
R.
12 Nm (1.2 m · kg)
WARNING
@
• Align the slit a on the impeller shaft with
the projection b on the oil pump shaft.
• Lubricate the O-ring with a thin coat of
lithium soap base grease.
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
• crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace the faulty part.
4. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6 - 18
FI
7
FI
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................7-1
WIRING DIAGRAM ................................................................................... 7-2
ECU’S SELF-DIAGNOSTIC FUNCTION................................................... 7-3
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION) ..............................................................................7-7
TROUBLESHOOTING ..............................................................................7-8
THROTTLE BODIES ............................................................................... 7-33
CHECKING THE INJECTOR .................................................................. 7-37
CHECKING THE THROTTLE BODY ......................................................7-37
CHECKING THE PRESSURE REGULATOR .........................................7-37
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION .............................................. 7-38
AIR INDUCTION SYSTEM ............................................................................7-40
AIR INJECTION....................................................................................... 7-40
AIR CUT-OFF VALVE ............................................................................. 7-40
AIR INDUCTION SYSTEM DIAGRAMS.................................................. 7-41
AIR CUT-OFF VALVE ASSEMBLY AND
AIR INDUCTION SYSTEM HOSES .......................................................7-42
REED VALVES........................................................................................ 7-43
CHECKING THE AIR INDUCTION SYSTEM..........................................7-44
FI
FUEL INJECTION SYSTEM
FI
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 Ignition coil
2 Air filter case
3 Intake temperature
sensor
4 Fuel delivery hose
5 Fuel tank
6 Fuel pump
7 Fuel return hose
8 Intake air pressure
sensor
9 Throttle position sensor
0 Fuel injector
A O2 sensor
B Catalytic converter
C Crankshaft position
sensor
D Coolant temperature
sensor
E Spark plug
F Cylinder identification sensor
G Pressure regulator
H Battery
I ECU
7-1
J Atmospheric pressure
sensor
K Fuel injection system
relay
L Engine trouble warning light
M Lean angle cut-off
switch
N Air cut-off valve
7-2
B/R
R/B
R Br Sb
Br/R Lg B
Br/Y Br/R
R
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
{
L
G/Y
L
R/W
¢
£
B/R R/B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
†
Br/W
Br/G
B
B
W
W
W
B
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
L/Y L/B
L L/R
Br/R
B
2
W
3
Y
Y
Br
5
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Br
Y
Sb B Sb
Lg B Lg
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
B
B
L/R B
Y
Dg Ch
L
Y
Ch Dg
Br/W
A
Br/W
Br/W
B
Ch
Dg
(BROWN)
7
L
B/Y
L/Y
L/B
L/B
Y
B
R/Y
G/L
L/R
Y/B
L/W
R/W
0
R/W
L/W
G/B
A
G/B
R/Y
B
G
Y
ON
OFF
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
e
R/Y
R/W
L/W
R
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Sb
B/Y
R/B
L/W
Dg
B
Dg
Ch
B
Ch
Dg Ch
Br/W
B
(BLUE)
L/G
B
B
B
(BLUE)
k
j
R/L B
B L/R
B L/R
L/R B L/R
(BLACK)
B
L/R
B
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y
Y
Dg
Br/W
Ch
G
B
B
B
Dg
B
Ch
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
L Coolant temperature sensor
k
p
n
position
sensor
M Crankshaft
N ECU
O Cylinder #1 - injector
P Cylinder #2 - injector
Q Cylinder #3 - injector
R Cylinder #4 - injector
q
solenoid
S rAIr system
m
l
s s
W Speed sensor
å Ignition fuse
® Engine stop switch
™ Fuel injection system relay
G/L
Y
G/B G B
(BLUE)
(BLUE)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
(GRAY)
W
L/R
W
W
W
R
4
1 Main switch
5 Main fuse
6 Battery
7 Fuel injection system fuse
z
D Fuel pump
E O2 sensor
sensor
F Cylinder identification
t
G Throttle position sensor v w
u
H Intake air pressure sensor
u
I Atmospheric pressure sensor
J Lean angle cut-off switch
K Intake air temperature sensor
Br/Y
B
Br/Y
B
L
Br/B
L
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
ON
OFF
P
1
R
(BLACK)
B
R
R
R
R
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
R/L
L/Y
R/W
B/Y
B1
L/W
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
R/B
Gy/R
R/B
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
U
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
FUEL INJECTION SYSTEM
FI
WIRING DIAGRAM
FUEL INJECTION SYSTEM
FI
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to
alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected,
it becomes stored in the ECU memory in the form of a fault code.
ECU’s mode function
The ECU is equipped with a diagnosis mode, in addition to the normal mode in which the ECU operates normally.
Normal mode
• To check whether the warning light bulb is blown, the warning light illuminates for 1.4 seconds
after the main switch has been turned ON, and while the starter switch is being pressed.
• To inform the rider that the fuel injection stop function is active, the warning light blinks while the
start switch is being pressed to start the engine.
• If a malfunction in the system is detected by the self-diagnostic function, this mode provides an
appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by
illuminating a warning light.
• After the engine has been stopped, digital numbers representing the self-diagnostic fault codes
appear on the clock LCD. Once a self-diagnostic fault code has been displayed, it remains stored
in the ECU memory until a deletion operation is performed.
Diagnosis mode
• In this mode, diagnostic codes are input into the ECU in accordance with the number of times the
start switch has been operated.
• In accordance with the diagnostic codes, the ECU displays the values received from the sensors
and actuates the actuators.
• Whether or not the system is operating normally is determined by a human operator through the
observations of the values indicated by the engine trouble warning light or the actuating conditions
of the actuators.
7-3
FI
FUEL INJECTION SYSTEM
Engine trouble warning light indication and FI system operating conditions (normal mode)
Warning light
indication
ECU’s operating
condition
FI operating condition
Starting and driving
ON and OFF *1
Self-diagnostic function in operation
FI function in operation Able
Blinking *2
Warning control when
unable to start engine
Operation stopped
Continuous ON
Detecting malfunction
Able/Unable dependGives driving instrucing on self-diagnostic
tions with substitute
characteristics in accor- fault code
dance with the description of the malfunction.
OFF *3
Possibly a blown warning light bulb or a malfunction in power
supply system or ECU
*1
The warning light illuminates 1.4 seconds each
time the main switch is turned ON. The ECU
performs a self diagnosis during this time and
turns OFF the light thereafter.
Main switch Main switch
OFF
ON
Engine trouble
warning light
Light
OFF
Light ON for
1.4 seconds
Unable
Light
OFF
*2
Warning control when unable to start engine
This control is effected when any one of the
conditions listed below is present and the
starter switch is turned ON:
a. Battery voltage below the specified value
(defective Fuel injection system relay,
engine stop switch turned OFF, or drained
battery)
b. One of the fault codes listed below has
been detected (self-diagnostic code 12, 19,
30, 33, 34, 41, or 50 is output):
(12: faulty crankshaft position sensor signal)
(19: open circuit in sidestand input line)
(30: a fall has been detected)
(33, 34: faulty ignition)
(41: open or short circuit in lean angle cutoff switch)
(50: ECU memory check error)
Initialize
7-4
FUEL INJECTION SYSTEM
*3
Function to check for blown warning light bulb
The engine trouble warning light illuminates 1
for 1.4 seconds after the main switch has been
turned “ON” and while the starter switch is
being pressed. If the warning light does not
illuminate under these conditions, a problem
may have possibly occurred, such as a blown
warning light bulb. Therefore, take an appropriate corrective action by referring to the troubleshooting section.
140 160 180
120
200
100
220
80
6
7 8
5
60
240
40
260
20
F
280
0
4
L
L
Km/h
3
x1000
r/min
2
1 0
E
H
TRIP
km
mile
km
mile
TRIP
000
SELECT
FI
RESET
Determining the area of the malfunction through the self-diagnostic fault code number
The possible location of the system in which a problem may be occurring can be determined by
observing the self-diagnostic fault code number that appears on the multi-function meter and crossreferencing it on the fault code number table. When used in conjunction with the troubleshooting
details, and by checking the possible items one by one, you will be able to identify the cause of the
problem in order to carry out an accurate repair work.
Warning of the occurrence of a malfunction appears on the multi-function meter.
Determine the area of the problem by referring to the self-diagnostic fault code number.
Turn off the main switch.
Repair the problem area by referring to the troubleshooting details.
Turn “ON” the main switch in order to revert to normal operation, and erase the fault code from
memory. (Once a fault code is detected by the ECU, it remains stored in the ECU memory even
after the main switch has been turned “OFF”.)
7-5
FUEL INJECTION SYSTEM
FI
* Table of self-diagnostic fault code numbers displayed on meter
No.
11
12
13
Symptom
No normal signals are received
from the cylinder identification
sensor.
No normal signals are received
from the crankshaft position sensor.
Intake air pressure sensor - open
or short circuit detected.
Able/
unable to
start
Able/
unable to
drive
Unable
Unable
31
The amount of air-fuel ratio feedback compensation is maintained
continuously in the vicinity of the
upper limit (lean air-fuel ratio).
Able
Able
32
The amount of air-fuel ratio feedback compensation is maintained
continuously in the vicinity of the
lower limit (rich air-fuel ratio).
Able
Able
Able
Able
Able
Able
Able/
unable to
start
Able/
unable to
drive
No.
Able
Able
30
Symptom
The motorcycle has overturned.
Unable
Able
Unable
Able
Open circuit detected in the primary wire of the ignition coil
(#1,4).
14
Faulty intake air pressure sensor
pipe system; a hose is detached,
causing the constant application
of atmospheric pressure to the
sensor; or, the hose is clogged.
Able
Able
33
15
Throttle position sensor - open or
short circuit detected.
Able
Able
34
Open circuit detected in the primary wire of the ignition coil (#2, 3).
16
A stuck throttle position sensor is
detected.
Able
Able
41
Lean angle cut-off switch - open
or short circuit detected.
Unable
Unable
Able
Able
19
Open circuit is detected in the
input line from the sidestand
switch to the ECU.
Unable
Unable
42
No normal signals are received
from the speed sensor; or, an
open or short circuit is detected in
the neutral switch.
21
Coolant temperature sensor open or short circuit detected.
Able
Able
43
The ECU is unable to monitor the
battery voltage (an open circuit in
the line to the ECU).
Able
Able
22
Intake temperature sensor - open
or short circuit detected.
Able
Able
44
An error is detected while reading
or writing on EEPROM (CO
adjustment value).
Able
Able
50
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
Unable
Unable
23
Atmospheric pressure sensor open or short circuit detected.
Able
Able
24
No normal signals are received
from the O2 sensor.
Able
Able
• How to erase the self-diagnostic fault code from memory:
If the ECU detects a normal signal upon the completion of the repair of the malfunction, the selfdiagnostic fault code disappears from the meter and is replaced by the normal clock display. However, the self-diagnostic fault code of the previous malfunction remains in the ECU memory as
part of the malfunction history. To erase the self-diagnostic fault code from the malfunction history,
the operation for diagnostic code 62 must be performed in the diagnosis mode.
7-6
FUEL INJECTION SYSTEM
FI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU
illuminates the engine trouble warning light and provides the engine with substitute characteristic
operation instructions that are appropriate for the type of the malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for every sensor, in order to provide the engine with substitute characteristics
operation instructions that enable the engine to continue to operate (or to stop its operation,
depending on circumstances).
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed
value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions
are given in the table below.
Table of substitute characteristic operation control by self-diagnostic fault code
Fail-safe action
Able/unable to
start
Able/unable to
drive
Cylinder identification
sensor
Continues to operate the engine based on the results
of the cylinder identification that existed up to that
point.
Able
Able
12
Crankshaft position sensor
• Stops the engine (by stopping the injection and
ignition).
Unable
Unable
13
14
Intake air pressure sensor
(open or short circuit)
(pipe system)
• Fixes the intake air pressure to 760 mmHg.
Able
Able
15
16
Throttle position sensor
(open or short circuit)
(stuck)
• Fixes the throttle position sensor to fully open.
Able
Able
Sidestand switch
(open circuit in wire to
ECU)
-- (No start)
19
Unable
Unable
21
Coolant temperature sensor
• Fixes the coolant temperature to 60 °C.
Able
Able
22
Intake temperature sensor
• Fixes the intake temperature to 20 °C.
Able
Able
23
Atmospheric pressure
sensor
• Fixes the atmospheric pressure to 760 mmHg.
Able
Able
--
24
31
32
O2 sensor
(inactive)
(compensation stuck to
upper limit)
(compensation stuck to
lower limit)
Able
Able
Faulty ignition
• Fuel is cut off only to the cylinder in which a malfunction is detected.
Able
(depending on
the number of
faulty cylinders)
Able
(depending on
the number of
faulty cylinders)
30
41
Lean angle cut-off switch
(latch up detected)
(open or short circuit)
• Turns OFF the fuel injection system relay of the fuel
system.
Unable
Unable
42
Speed sensor, neutral
switch
• Fixes the gear to the top gear.
Able
Able
43
Fuel system voltage
(monitor voltage)
• Fixes the battery voltage to 12 V.
Able
Able
Error in writing the
amount of CO adjustment on EEPROM
--
44
Able
Able
50
ECU internal malfunction
(memory check error)
--
Unable
Unable
Code No.
11
Item
33
34
7-7
FUEL INJECTION SYSTEM
FI
TROUBLESHOOTING
Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected)
By entering a diagnostic code in the ECU through the use of the “SELECT” and “RESET” buttons on
the multi-function meter, the sensor output values can be displayed and the actuators can be operated in accordance with the code that has been entered.
The technician determines whether or not the operation is normal by verifying the values displayed
on the multi-function meter or the operating conditions of the actuators. These modes can be used
to detect and check the problems that are otherwise difficult to detect in the diagnosis mode.
Basic operation procedure
Operation preparation
• Verify the self-diagnostic fault code number that is displayed on the meter.
• Based on the self-diagnostic fault code number, select the applicable sensor or actuator from the
diagnostic code table.
• If a diagnostic code is available, proceed with the operation procedure given below in order to
verify the operating conditions of the applicable sensor or actuator.
Operation procedure (make sure to turn “OFF” the main switch upon completing the operation preparation)
Setting the ECU in the diagnosis mode
1. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8
seconds or more).
* All indications on the meter disappear
except the clock and trip indications.
* Letters “dIAG” appear on the clock LCD.
OFF
F
L
L
E
RESET
L
L
7-8
Main switch
OFF
F
E
After “dIAG” appears as a result of pressing
the “SELECT” button, simultaneously press
the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection.
km
mile
km
mile
RESET
SELECT
Selecting the diagnosis mode
Using the “SELECT” button, select either the
CO adjustment mode (which appears as
“CO”) or the diagnosis mode (which appears
as “dIAG”).
H
TRIP
TRIP
000
SELECT
ON
H
TRIP
km
mile
km
mile
TRIP
000
SELECT
ON
RESET
Main switch
FUEL INJECTION SYSTEM
Verifying the operation of various sensors and
actuators
1. Disconnect the wiring harness coupler from
the fuel pump.
2. Turn the engine stop switch “OFF”.
· Turn the engine stop switch “ON” if diagnostic code numbers 03 and 09 are
shown.
3. Select the diagnostic code number that
applies to the item that was verified with the
self-diagnostic fault code number, and
enter it on the meter by operating the
“SELECT” or “RESET” button.
* “RESET” button
Decrement (press 1 second or longer → auto)
“SELECT” button
Increment (press 1 second or longer → auto)
* Diagnostic code number appears on clock
LCD (01 ~ 70)
4. Verifying the operation of the displayed
diagnostic code
· Verifying various sensors
The data representing the operating conditions of the sensors appears on the trip
LCD (throttle position sensor angle, coolant temperature, atmospheric pressure,
etc.)
· Verifying the operation of actuators
Start the operation by turning the stop
switch “ON” (injectors, relay, ignition coil,
AIS, etc.)
* If the stop switch is “ON”, turn it “OFF”;
then, turn it back “ON”.
5. Check the results by referring to the sensor
operation data verification table or the actuator operation verification table.
Perform individual repairs on the areas where
malfunctions have been identified.
7-9
FI
F
F
L
L
E
SELECT
L
H
TRIP
L
km
mile
km
mile
TRIP
000
E
RESET
SELECT
SELECT
(01 70)
km
mile
km
mile
RESET
RESET
(01 70)
F
L
L
E
H
TRIP
TRIP
000
H
TRIP
km
mile
km
mile
TRIP
000
SELECT
RESET
FUEL INJECTION SYSTEM
Erase the codes appearing on the meter upon
the completion of the operation (reinstating the
ECU).
* Verify the reinstatement procedures
detailed in the troubleshooting details in
order to carry out the reinstatement operation that is applicable to the malfunctioning
item.
Refer to the troubleshooting details.
Erase the fault code from memory.
* Perform the operation for diagnostic code
62.
7 - 10
FI
FUEL INJECTION SYSTEM
FI
Self-diagnostic fault codes, symptoms, and probable causes
Diagnostic code indication
Code No.
Symptom
No normal signals are received from
the cylinder identification sensor.
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective cylinder identification sensor.
Malfunction in ECU.
Improperly installed sensor.
—
•
•
•
•
•
Open or short circuit in wiring harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
—
Intake air pressure sensor - open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
03
Faulty intake air pressure sensor pipe
system; a hose is detached, causing
constant application of the atmospheric pressure to the sensor; or, the
hose is clogged.
• Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction of the intake air pressure sensor in the intermediate electrical potential.
• Malfunction of the atmospheric pressure sensor in the intermediate electrical potential.
• Malfunction in ECU.
03
02
Or, intake air pressure sensor - open
or short circuit detected.
•
•
•
•
03
Or, a stuck throttle position sensor is
detected.
• Open or short circuit in wiring sub lead.
• Open or short circuit in wiring harness.
• Defective sensor (stuck throttle position sensor).
01
Throttle position sensor - open or
short circuit detected.
•
•
•
•
•
01
No normal signals are received from
the crankshaft position sensor.
12
14
15
16
19
21
22
Diagnostic code
•
•
•
•
•
11
13
Probable cause of malfunction
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
A stuck throttle position sensor is
detected.
Or,
Faulty intake air pressure sensor pipe
system; a hose is detached, causing
constant application of the atmospheric pressure to the sensor; or, the
hose is clogged.
•
•
•
•
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective sensor (stuck throttle position sensor).
Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction of the intake air pressure sensor in the intermediate electrical potential.
• Malfunction of the atmospheric pressure sensor in the intermediate electrical potential.
• Malfunction in ECU.
Open circuit in the input line from the
sidestand switch to the ECU is
detected when the start switch is
pressed.
• Open or short circuit in wiring harness.
• Malfunction in ECU.
Coolant temperature sensor - open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
06
Intake temperature sensor - open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective intake temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
05
7 - 11
01
03
02
20
FUEL INJECTION SYSTEM
Code No.
Symptom
FI
Probable cause of malfunction
Diagnostic code
Atmospheric pressure sensor - open
or short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective atmospheric pressure sensor.
Improperly installed sensor.
Malfunction in ECU.
02
No normal signals are received from
the O2 sensor.
•
•
•
•
Open or short circuit in wiring harness.
Defective O2 sensor.
Malfunction in ECU.
Improperly installed sensor.
—
The motorcycle has overturned.
• Overturned.
• Malfunction in ECU.
08
The amount of air-fuel ratio feedback
compensation is maintained continuously in the vicinity of the upper limit
(lean air-fuel ratio).
•
•
•
•
•
•
Open or short circuit in wiring harness.
Fuel pressure too low.
Clogged injectors.
Defective O2 sensor (unable to output a rich signal).
Malfunction in ECU.
Malfunction in other areas of the fuel system.
—
The amount of air-fuel ratio feedback
compensation is maintained continuously in the vicinity of the lower limit
(rich air-fuel ratio).
•
•
•
•
•
•
Open or short circuit in wiring harness.
Fuel pressure too high.
Faulty injectors (excessive injection volume).
Defective O2 sensor (unable to output a lean signal).
Malfunction in ECU.
Malfunction in other areas of the fuel system.
—
Open circuit is detected in the primary
wire of the ignition coil (#1, 4).
•
•
•
•
Open or short circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cutoff circuit system.
30
Open circuit is detected in the primary
wire of the ignition coil (#2, 3).
•
•
•
•
Open or short circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cutoff circuit system.
31
Lean angle cut-off switch - open or
short circuit detected.
• Open or short circuit in wiring harness.
• Defective lean angle cut-off switch.
• Malfunction in ECU.
08
No normal signals are received from
the speed sensor; or, an open or
short circuit is detected in the neutral
switch.
•
•
•
•
•
•
07
21
43
The ECU is unable to monitor the battery voltage (an open circuit in the
monitor line to the ECU).
• Open circuit in wiring harness.
• Malfunction in ECU.
44
An error is detected while reading or
writing on EEPROM.
• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory).
50
Faulty ECU memory. When this malfunction is detected, the 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.)
23
24
30
31
32
33
34
41
42
Open or short circuit in wiring harness.
Defective speed sensor.
Malfunction in vehicle speed sensor detected unit.
Defective neutral switch.
Malfunction in the engine side of the neutral switch.
Malfunction in ECU.
7 - 12
—
60
—
FI
FUEL INJECTION SYSTEM
Sensor operation data display verification table
NOTE:
• Check the intake temperature and coolant temperature as close as possible to the area in which
the respective sensor is mounted.
• If it is not possible to check it with an atmospheric pressure gauge, judge it by using 760 mmHg as
the standard.
• If it is not possible to check the intake temperature, use the ambient temperature as reference
(use the compared values for reference).
Diag code
Item
Description of action
Data displayed on meter
(reference value)
Throttle angle
Displays the throttle angle.
• Check with throttle fully closed.
• Check with throttle fully open.
0 ~ 125 degrees
• Fully closed position (15 ~ 17)
• Fully open position (97 ~ 100)
Atmospheric pressure
Displays the atmospheric pressure.
* Use an atmospheric pressure gauge to check the atmospheric pressure.
Compare it to the value displayed on the meter.
Pressure difference
(atmospheric pressure - intake air pressure)
Displays the pressure difference (atmospheric pressure intake air pressure).
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
10 ~ 200 mmHg
Intake temperature
Displays the intake air temperature.
* Check the temperature in the air cleaner case.
Compare it to the value displayed on the meter.
Coolant temperature
Displays the coolant temperature.
* Check the temperature of the coolant.
Compare it to the value displayed on the meter.
Vehicle speed pulse
Displays the accumulation of the vehicle pulses that are generated when the tire is spun.
(0 ~ 999; resets to 0 after 999)
OK if the numbers appear on
the meter.
08
Lean angle cut-off
switch
Displays the lean angle cut-off switch values.
Upright: 0.4 ~ 1.4 V
Overturned: 3.8 ~ 4.2 V
09
Fuel system voltage
(battery voltage)
Displays the fuel system voltage (battery voltage).
Engine stop switch is on.
0 ~ 18.7 V
Normally, approximately 12.0 V
Sidestand switch
Displays that the switch is ON or OFF. (When the gear is in a
position other than neutral.)
Stand retracted: ON
Stand extended: OFF
Neutral switch
Displays that the switch is ON or OFF.
Neutral: ON
In gear: OFF
E2PROM fault code
display
• Transmits the abnormal portion of the data in the E2PROM
that has been detected as a self-diagnostic fault code 44.
• If multiple malfunctions have been detected, different codes
are displayed at 2-second intervals, and this process is
repeated.
(01 ~ 04) Displays the cylinder
number.
(00) Displays when there is no
malfunction.
Malfunction history
code display
• Displays the codes of the history of the self-diagnosis malfunctions (i.e., a code of a malfunction that occurred once
and which has been corrected).
• If multiple malfunctions have been detected, different codes
are displayed at 2-second intervals, and this process is
repeated.
11 ~ 50
(00) Displays when there is no
malfunction.
Malfunction history
code erasure
• Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past history.
• Erases only the history codes when the engine stop switch
is turned from OFF to ON. If the engine stop switch is ON,
turn it OFF once, and then turn it back ON.
00 ~ 21
(00) Displays when there is no
malfunction.
Control number
• Displays the program control number.
00 ~ 255
01
02
03
05
06
07
20
21
60
61
62
70
7 - 13
FUEL INJECTION SYSTEM
FI
Actuator operation verification table
Diag code
Item
Data displayed on meter
(reference value)
Ignition coil #1, 4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coils #1, and 4 for five times every second and illuminates the
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check that spark is generated,
5 times with the engine stop
switch ON.
Ignition coils #2, 3
Take the same actions as No. 30 above on ignition coils #2,
and 3.
Same as above.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Same as above
Injector #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the injector five times every second and illuminates the engine trouble
warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the operating sound of
the injector five times with
engine stop switch ON.
Injector #2
Take the same actions as No. 36 above on injector #2.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Same as above
Injector #3
Take the same actions as No. 36 above on injector #3.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Same as above
Injector #4
Take the same actions as No. 36 on injector #4.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Same as above
AI system solenoid
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the AI
system solenoid five times every second and illuminates the
engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the operating sound of
the AI system solenoid.
Same as above
Fuel injection system
relay
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the fuel
injection system relay five times every second and illuminates
the engine trouble warning light (the light is OFF when the
relay is ON, and the light is ON when the relay is OFF).
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the fuel injection system
relay operating sound.
Same as above
Radiator fan motor
relay
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the radiator fan motor relay five times every 5 seconds and illuminates
the engine trouble warning light. (ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the radiator fan motor
relay operating sound.
Same as above
Headlight relay 1
Take the same actions as in No. 51 above, on the headlight
relay 1. (ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the relay operating
sound.
Same as above
30
31
36
37
38
39
48
50
51
52
Description of action
7 - 14
FI
FUEL INJECTION SYSTEM
Troubleshooting
Basic procedure 1
Inspect battery and fuse
OK
NG
Replace fuse
Recharge or replace battery
Check engine trouble warning light
After main switch is turned ON, light turns ON 1.4 seconds and then turns OFF.
NG
OK
Light does not turn OFF.
Light does not turn ON
Proceed with troubleshooting through the selfdiagnostic function
Refer to “Troubleshooting
details”.
Check the starting disable warning function through the engine
trouble warning light. The warning light blinks during cranking
when the stop switch is OFF.
NG
Inspect and repair the wiring
harness.
Only the engine trouble
warning light does not turn
ON.
All indicator lights do not turn
ON.
Inspect and repair blown
light bulb or wiring harness.
Inspect and repair the power
supply circuit.
OK
Start the engine.
OK
NG
Normal
Light turns ON only when the
start switch is operated.
The warning light turns ON
and the diagnostic code is
displayed.
Inspect and repair the battery and the fuel injection
system relay.
Proceed with troubleshooting through the selfdiagnostic function
Refer to “Troubleshooting
details”.
7 - 15
FUEL INJECTION SYSTEM
FI
Troubleshooting details
Troubleshooting the self-diagnostic fault code
Code No.
11
Symptom
No normal signals are received from the cylinder identification sensor.
Used diagnostic code No.
Inspection operation item
Operation item and countermeasure
Reinstatement
method
Installed state of sensor
Check the installed area for looseness or
pinching.
Defective cylinder identification sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstated by
starting the engine
and operating it at
idle.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit.
Between main wiring harness and sub lead
Blue - Blue
White/Black - White
Black/Blue - Black/Blue
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Cylinder identification sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Code No.
12
Symptom
No normal signals are received from the crankshaft position sensor.
Used diagnostic code No.
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Installed state of sensor
Check the installed area for looseness or
pinching.
Defective crankshaft position sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstated by
cranking the
engine.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit between the main wiring harnesses.
Gray - Gray
Black/Blue - Black/Blue
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Crankshaft position sensor coupler
Main wiring harness ECU coupler
7 - 16
FUEL INJECTION SYSTEM
Code No.
13
Symptom
FI
Intake air pressure sensor - open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective intake air pressure sensor
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstated by turning the main switch
ON.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
Sub lead
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7 - 17
FUEL INJECTION SYSTEM
Code No.
14
Used diagnostic code
Symptom
FI
1 Intake air pressure sensor - pipe system malfunction (clogged or
detached hose).
2 Intake air pressure sensor - open or short circuit detected.
3 Stuck throttle position sensor detected.
No. 03 (intake air pressure sensor)
No. 02 (atmospheric pressure sensor)
No. 01 (throttle position sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1 Intake air pressure sensor hose detached, Repair or replace the sensor hose.
clogged, kinked, or pinched.
Inspect and repair the connection.
Intake air pressure sensor malfunction at
Replace it if there is a malfunction.
intermediate electrical potential.
Atmospheric pressure sensor malfunction at
intermediate electrical potential.
Reinstated by
starting the engine
and operating it at
idle.
2 Open or short circuit in wiring harness or
sub lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
Sub lead
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
Defective intake air pressure sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
3 Open or short circuit in wiring harness or
sub lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
Sub lead
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
Defective throttle position sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Throttle position sensor lead wire open circuit
output voltage check
(B/L - Y)
Black/Blue - Yellow
Open circuit item:
Output voltage
Ground wire open circuit:
5V
Output wire open circuit:
0V
Power supply wire open circuit: 0 V
Check for open circuit and replace the throttle
position sensor.
Common to 1, 2, and 3:
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Intake air pressure sensor coupler
Main wiring harness ECU coupler
7 - 18
Reinstated by
starting the engine,
operating it at idle,
and then by racing
it.
Reinstated by
starting the engine
and operating it at
idle.
FUEL INJECTION SYSTEM
Code No.
15
Symptom
FI
Throttle position sensor - open or short circuit detected.
Used diagnostic code No. 01 (throttle position sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective throttle position sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstated by turning the main switch
ON.
Throttle position sensor lead wire open circuit
output voltage check
(B/L - Y)
Black/Blue - Yellow
Open circuit item:
Output voltage
Ground wire open circuit:
5V
Output wire open circuit:
0V
Power supply wire open circuit: 0 V
Check for open circuit and replace the throttle
position sensor.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
Sub lead
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
Installed state of throttle position sensor.
Check the installed area for looseness or
pinching.
Check that it is installed in the specified position.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Throttle position sensor coupler
Main wiring harness ECU coupler
7 - 19
FUEL INJECTION SYSTEM
Code No.
16
Used diagnostic code
Symptom
FI
1 Stuck throttle position sensor detected.
2 Intake air pressure sensor - pipe system malfunction (clogged or
detached hose).
No. 03 (intake air pressure sensor)
No. 02 (atmospheric pressure sensor)
No. 01 (throttle position sensor)
Inspection operation item and probable cause Operation item and countermeasure
1 Defective throttle position sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
2 Open or short circuit in wiring harness or
sub lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
Sub lead
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
1 Installed state of throttle position sensor.
Check the installed area for looseness or
pinching.
Check that it is installed in the specified
position.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstatement
method
Reinstated by
starting the engine,
operating it at idle,
Throttle position sensor lead wire open circuit Open circuit item:
Output voltage and then racing it.
output voltage check
Ground wire open circuit:
5V
(B/L - Y)
Output wire open circuit:
0V
Black/Blue - Yellow
Power supply wire open circuit: 0 V
Check for open circuit and replace the throttle
position sensor.
2 Intake air pressure sensor hose detached, Repair or replace the sensor hose.
clogged, kinked, or pinched.
Inspect and repair the connection.
Intake air pressure sensor malfunction at
Replace it if there is a malfunction.
intermediate electrical potential.
Atmospheric pressure sensor malfunction at
intermediate electrical potential.
Common to 1 and 2:
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Throttle position sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7 - 20
FUEL INJECTION SYSTEM
Code No.
19
FI
Symptom
Open circuit is detected in the input line from the sidestand switch to the
ECU.
Used diagnostic code No. 20 (sidestand switch)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective sidestand switch
Replace if defective.
If the transmission
Refer to “CHECKING THE SWITCHES” in
is in gear, it is reinchapter 8.
stated by retracting
Open or short circuit in wiring harness or sub Repair or replace if there is an open or short the sidestand.
If the transmission
lead.
circuit.
is in neutral, it is
(Between ECU and sidestand)
Connected state of connector
If there is a malfunction, repair it and connect it reinstated by
reconnecting the
Inspect the coupler for any pins that may
securely.
wiring.
have pulled out.
Main wiring harness ECU coupler
Check the locking condition of the coupler.
(No. 43 pin, black)
(Alarm coupler)
ECU coupler illustration
(Indicate No. 43 pin)
Code No.
21
Symptom Open or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Installed state of sensor
Check the installed area for looseness or
Reinstated by turnpinching.
ing the main switch
ON.
Defective coolant temperature sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Open or short circuit in wiring harness or sub Repair or replace if there is an open or short
lead.
circuit.
Main wiring harness
Black/Blue - Black/Blue
Green/White - Green/White
Connected state of connector
If there is a malfunction, repair it and connect it
Inspect the coupler for any pins that may
securely.
have pulled out.
Coolant temperature sensor coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
Code No.
22
Symptom Open or short circuit detected from the intake temperature sensor.
Used diagnostic code No. 05 (intake temperature sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Installed state of sensor
Check the installed area for looseness or
Reinstated by turnpinching.
ing the main switch
ON.
Defective intake temperature sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Open or short circuit in wiring harness or sub Repair or replace if there is an open or short
lead.
circuit.
Main wiring harness
Black/Blue - Black/Blue
Brown/White - Brown/White
Connected state of connector
If there is a malfunction, repair it and connect it
Inspect the coupler for any pins that may
securely.
have pulled out.
Intake temperature sensor coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
7 - 21
FUEL INJECTION SYSTEM
Code No.
23
Symptom
FI
Open or short circuit detected from the atmospheric pressure sensor.
Used diagnostic code No. 02 (atmospheric pressure sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective atmospheric pressure sensor.
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
Reinstated by turning the main switch
ON.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Blue - Blue
Black/Blue - Black/Blue
Pink - Pink
Installed state of atmospheric pressure sensor Check the installed area for looseness or
pinching.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Code No.
24
Symptom
If there is a malfunction, repair it and connect it
securely.
Atmospheric pressure sensor coupler
Main wiring harness ECU coupler
No normal signal is received from the O2 sensor.
Used diagnostic code No.
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective O2 sensor.
Replace if defective.
Open or short circuit in wiring harness or sub
lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - White
Gray/Green - Blue
Reinstated by
starting the engine,
operating it at idle,
and then racing it
after it has warmed
up.
Installed state of O2 sensor
Check the installed area for looseness or
pinching.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
O2 sensor coupler
Main wiring ECU harness coupler
Sub-wire harness coupler
Check fuel pressure
Inspect fault codes 31/32.
Refer to “CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION”.
7 - 22
FUEL INJECTION SYSTEM
Code No.
30
Symptom
FI
The motorcycle has overturned.
Used diagnostic code No. 08 (lean angle cut-off switch)
Inspection operation item and probable cause Operation item and countermeasure
Defective lean angle cut-off switch
Reinstatement
method
Reinstated by turning the main switch
The motorcycle has overturned.
Raise the motorcycle upright.
ON (however, the
Installed state of the lean angle cut-off switch Check the installed area for looseness or
engine cannot be
pinching.
restarted unless
Connected state of connector
If there is a malfunction, repair it and connect it the main switch is
first turned OFF).
Inspect the coupler for any pins that may
securely.
have pulled out.
Lean angle cut-off switch coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
Code No.
31
Symptom
Replace if defective.
The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit.
Used diagnostic code No. 01 (throttle position sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective O2 sensor
(unable to output a rich signal).
Replace if defective.
Clogged injector.
Replace if defective.
Refer to “CHECKING THE INJECTOR”.
Reinstated by
starting the engine,
operating it at idle,
and then racing it
after it has warmed
up.
Open circuit or ground short in wiring harness Repair or replace if there is an open or short
or sub lead.
circuit.
Main wiring harness
Black/Blue - White
Gray/Green - Blue
The fuel pressure is too low.
Compare the fuel pressure at idle and with
throttle open.
About the same → Normal
Too low →
Inspect the fuel pump.
Replace if defective.
Refer to “CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION”.
Inspect the delivery hose Repair or replace if there is a malfunction.
for pinching or kinking.
Inspect the pressure reg- Replace if defective.
ulator.
Refer to “CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION”.
Inspect the throttle posi- Execute diagnostic code 01.
tion sensor.
Other:
Malfunction in the fuel system (disconnection, etc.).
Improper sealing of the intake system.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Repair or replace if there is a malfunction.
If there is a malfunction, repair it and connect it
securely.
O2 sensor coupler
Engine wiring harness coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7 - 23
FUEL INJECTION SYSTEM
Code No.
32
Symptom
FI
The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (air-fuel ratio is rich).
Used diagnostic code No. 01 (throttle position sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective O2 sensor
(unable to output a lean signal).
Reinstated by
starting the engine,
operating it at idle,
and then racing it
after it has warmed
up.
Replace if defective.
Excessive volume of fuel injected by injector.
Open circuit on the 5 V side or short circuit in
wiring harness or sub lead.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - White
Gray/Green - Blue
The fuel pressure is too high.
Compare the fuel pressure at idle and with
throttle open.
About the same → Normal
Too high →
Inspect the pressure reg- Replace if defective.
ulator.
Refer to “CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION”.
Inspect the pressure reg- Repair or replace if there is a malfunction.
ulator hose for pinching or
kinking.
Inspect the fuel return
Repair or replace if there is a malfunction.
hose for pinching or kinking.
Inspect the throttle posi- Execute diagnostic code 01.
tion sensor.
Other:
Repair or replace if there is a malfunction.
Malfunction in the fuel system (clogging,
etc.).
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
O2 sensor coupler
Sub wiring harness coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7 - 24
FUEL INJECTION SYSTEM
Code No.
33
Symptom
FI
Malfunction detected in the primary wire of the ignition coil (#1, 4).
Used diagnostic code No. 30 (ignition coil #1, 4)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective ignition coil (test the primary and
secondary coils for continuity).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Open or short circuit in lead wire.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Orange - Orange
Red/Black - Red/Black
Reinstated by
starting the engine
and operating it at
idle.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler - Orange
Main wiring harness ECU coupler
Code No.
34
Symptom
Malfunction detected in the primary wire of the ignition coil (#2, 3).
Used diagnostic code No. 31 (ignition coil #2, 3)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective ignition coil (test the primary and
secondary coils for continuity).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Open or short circuit in lead wire.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Gray/Red - Gray/Red
Red/Black - Red/Black
Reinstated by
starting the engine
and operating it at
idle.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler - Gray/Red
Main wiring harness ECU coupler
Code No.
41
Symptom
Open or short circuit detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective lean angle cut-off switch
Replace if defective.
Open or short circuit in lead wire.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Black/Blue - Black/Blue
Yellow/Green - Yellow/Green
Red/White - Red/White
Reinstated by turning the main switch
ON.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
7 - 25
FUEL INJECTION SYSTEM
Code No.
42
Used diagnostic code
Symptom
FI
1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.
No. 07 (speed sensor)
No. 21 (neutral switch)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1 Defective speed sensor
Replace if defective.
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
1 Open or short circuit in lead wire.
1 Gear for detecting vehicle speed has broken.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Blue - Blue
White/Yellow - White/Yellow
Black/Blue - Black/Blue
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
Reinstated by
starting the engine,
and inputting the
vehicle speed signals by operating
the motorcycle at a
low speed of 20 to
30 km/h.
1 Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Speed sensor coupler
Main wiring harness ECU coupler
2 Defective neutral switch
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
2 Faulty shift drum
(neutral detection area)
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
2 Open or short circuit in lead wire
Repair or replace if there is an open or short
circuit.
Main wiring harness
Sky blue/Sky blue
2 Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Neutral switch coupler
Main wiring harness ECU coupler
Code No.
43
Symptom
The ECU is unable to monitor the battery voltage.
Used diagnostic code No. 50 (fuel injection system relay)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Malfunction in ECU
Fuel injection system relay is on.
Open or short circuit in the wiring harness.
Repair or replace if there is an open or short
circuit.
Main wiring harness
Red - Red
Red/Black - Red/Black
Red/Blue - Red/Blue
Blue/Yellow - Blue/Yellow
Reinstated by
starting the engine
and operating it at
idle.
Malfunction or open circuit in fuel injection sys- Replace if defective.
tem relay
Refer to “FUEL INJECTION SYSTEM” in
chapter 8.
If there is no malfunction with the fuel injection
system relay, replace the ECU.
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Fuel injection system relay coupler
ECU coupler
7 - 26
FUEL INJECTION SYSTEM
Code No.
44
Symptom
FI
Error is detected while reading or writing on EEPROM
(CO adjustment value).
Used diagnostic No. 60 (EEPROM improper cylinder indication)
Inspection operation item and probable cause Operation item and countermeasure
Malfunction in ECU
Code No.
50
Reinstatement
method
Execute diagnostic code 60
Reinstated by turn* Check the faulty cylinder. (If there are mul- ing the main switch
tiple cylinders, the number of the faulty
ON.
cylinders appear alternately at 2-second
intervals.)
* Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS
VOLUME” in chapter 3.
Replace ECU if defective.
Symptom
Faulty ECU memory. (When this malfunction is detected in the ECU, the
fault code number might not appear on the meter.)
Used diagnostic code No.
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Malfunction in ECU
Reinstated by turning the main switch
ON.
Replace the ECU.
7 - 27
FUEL INJECTION SYSTEM
FI
Diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected)
Even if the malfunctions of some of the sensors do not appear on the meter because they are not
detected by the self-diagnostic function, they can be inspected in the diagnosis mode.
Basic procedure
Check the condition and the symptom of the malfunction of the motorcycle.
Check the errors displayed on the meter.
Estimate the area of the malfunction by referring to the troubleshooting details.
Refer to “Troubleshooting details”.
If there is a diagnostic code number for the inspection method for the probable location of the malfunction, check the operating condition of the affected sensor or actuator in the diagnosis mode.
Using the results of the diagnosis mode inspection as reference, estimate the cause of the malfunction and carry out the inspection and repair of the affected area.
Troubleshooting details
Troubleshooting the sensors with no malfunctions detected, and special indications
Symptom
Probable malfunction area
The engine trouble warning light does not illuminate when the start switch is pressed.
• Open or short circuit in start switch
• Open or short circuit in wiring harness
• Open circuit in warning light bulb
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 indicated on
the left.
• Open or short circuit in start switch
Inspect the handlebar switch for continuity.
Refer to “CHECKING THE SWITCHES” in chapter 8.
Defective: replace
• Open or short circuit in wiring harness
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Open circuit in warning light bulb
Inspect the bulb for continuity.
Defective: replace
7 - 28
FUEL INJECTION SYSTEM
Symptom
Probable malfunction area
FI
The headlight does not turn ON or OFF.
•
•
•
•
•
Malfunction in the headlight relay 1
Malfunction in the headlight
Open or short circuit in the headlight wiring harness
Malfunction in the handlebar switch
Open circuit in the headlight bulb
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1.
• Execute diagnostic code No. 52 (check the
operation of the headlight relay 1).
(Check the operation of the headlight.)
* Classify the malfunctions:
Malfunction related to the relay
Malfunction related to the wiring harness
Malfunction in the headlight itself
• Relay does not operate (as checked by sound or tester).
Check the headlight relay 2.
Refer to “LIGHTING SYSTEM” in chapter 8.
Defective: replace
Inspect the wiring harness and the couplers for continuity.
Defective: repair or replace
Replace
• The relay operates but the headlight does not illuminate.
Inspect the headlight bulb.
Blown bulb: replace
Check the headlight relay 2 contact point for continuity.
Refer to “LIGHTING SYSTEM” in chapter 8.
Defective: replace
Check the handlebar switch.
Defective: repair or replace
Inspect the wiring harness and the couplers for continuity.
Defective: repair or replace
7 - 29
FUEL INJECTION SYSTEM
Symptom
Probable malfunction area
FI
Fan does not operate.
• Malfunction in radiator fan motor relay
• Malfunction in fan
• Open or short circuit in fan wiring harness
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Execute diagnostic code No. 51.
(Check the operation of the radiator fan motor
relay.)
(Check the operation of the fan motor.)
* Classify the malfunctions:
Malfunction related to the relay
Malfunction related to the wiring harness
Malfunction in the fan itself
• Relay does not operate.
Check the radiator fan motor relay.
Refer to “COOLING SYSTEM” in chapter 8.
Defective: replace
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Replace
• Relay operates but fan does not operate.
Inspect the fan.
Refer to “COOLING SYSTEM” in chapter 8.
Defective: replace
Check the continuity at the contact point of the radiator fan
motor relay.
Refer to “COOLING SYSTEM” in chapter 8.
Defective: replace
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Normal according to the diagnosis mode
Inspect the coolant temperature sensor (by executing diagnostic code No. 06).
Refer to “COOLING SYSTEM” in chapter 8.
Defective: replace
Symptom
Probable malfunction area
Clock LCD displays “Er-1”. (No signals are received from the ECU.)
• Open or short circuit in communication line
• Malfunction in meter
• Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
7 - 30
FUEL INJECTION SYSTEM
Symptom
Probable malfunction area
FI
Clock LCD displays “Er-2”. (No signals are received from the ECU within the specified duration.)
• Improper operation of communication line
• Malfunction in meter
• Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Symptom
Probable malfunction area
Clock LCD displays “Er-3”. (Data from the ECU cannot be received correctly.)
• Improper operation of communication line
• Malfunction in meter
• Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Symptom
Probable malfunction area
Clock LCD displays “Er-4”. (Non-registered data has been received from the meter.)
• Improper operation of communication line
• Malfunction in meter
• Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
7 - 31
FUEL INJECTION SYSTEM
Symptom
Probable malfunction area
FI
Sidestand switch does not function (the engine does not stop when the stand is extended).
• Short circuit in the input line to ECU
• Malfunction in the starter circuit cut-off relay
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
• Execute diagnostic code 21
• Meter does not display ON/OFF.
Enable the meter to display the ON/OFF states
Inspect the wiring harness and couplers for continuity.
of the sidestand switch (in gear other than neuDefective: repair or replace
tral).
* To distinguish whether the problem is in the
Inspect the sidestand switch.
switch or in other areas.
Refer to “CHECKING THE SWITCHES” in chapter 8.
Defective: replace
Symptom
Probable malfunction area
Engine trouble warning light blinks while the start switch is being pressed (to warn that the engine
is unable to start).
•
•
•
•
•
•
•
•
Malfunction in Fuel injection system relay
Open circuit in wiring harness
Disconnected battery
Defective crankshaft position sensor
Defective sidestand switch
Tripped lean angle cut-off switch
Open circuit in ignition coil primary line
ECU memory check error
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1.
• Execute diagnostic code 50
To trip the Fuel injection system relay.
• Fuel injection system relay does not trip.
Inspect the coil side of the fuel injection system relay.
Refer to “FUEL INJECTION SYSTEM” in chapter 8.
Defective: replace
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• Execute diagnostic code 09
To check the monitor voltage.
* To distinguish whether the problem is in the
relay or in other areas.
• Normal voltage is not displayed.
Inspect the contact side of the fuel injection system relay.
Refer to “FUEL INJECTION SYSTEM” in chapter 8.
Defective: replace
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
• If a self-diagnostic code is displayed:
Inspect the battery.
Defective: replace or recharge
Inspect and repair the applicable area of the malfunction.
7 - 32
FUEL INJECTION SYSTEM
FI
THROTTLE BODIES
7
7
5
3
5
5
5
10
10
10
6
10
4
2
8
1
9
Order
Job/Part
Removing the throttle bodies
Seats/fuel tank/T-bar/rubber sheet
Q’ty
Air filter case
Coolant
1
2
3
4
5
6
O2 sensor coupler
Cylinder identification sensor coupler
Sub-wire harness 2 coupler
Throttle stop screw
Throttle body joint clamp screw
Throttle bodies
1
1
2
1
8
1
7 - 33
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
FUEL INJECTION SYSTEM
FI
7
7
5
3
5
5
5
10
10
10
6
10
4
2
8
1
9
Order
7
8
9
10
Job/Part
Throttle cable
Plunger control unit hose 1
Plunger control unit hose 2
Throttle body joint
Q’ty
Remarks
2
Disconnect.
1
Disconnect.
1
Disconnect.
4
For installation, reverse the removal
procedure.
7 - 34
FI
FUEL INJECTION SYSTEM
2
7
3
4
11
9
5
6
1
12
8
10
13
14
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the injector
Throttle position sensor coupler
Intake air pressure sensor
Cylinder #1-injector coupler
Cylinder #2-injector coupler
Cylinder #3-injector coupler
Cylinder #4-injector coupler
Subwire harness 2
Negative pressure hose
Fuel injection pipe
Pressure regulator
Q’ty
1
1
1
1
1
1
1
1
1
1
7 - 35
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
FI
FUEL INJECTION SYSTEM
2
7
3
4
11
9
5
6
1
12
8
13
10
14
Order
11
12
13
14
Job/Part
Intake air pressure sensor
Fuel distributor
Injector
Throttle position sensor
Q’ty
1
1
4
1
Remarks
For installation, reverse the removal
procedure.
7 - 36
FUEL INJECTION SYSTEM
FI
CAUTION:
The throttle bodies should not be disassembled unnecessarily.
CHECKING THE INJECTOR
1. Check:
• injector
Damage → Replace.
CHECKING THE THROTTLE BODY
1. Check:
• throttle body
Cracks/damage → Replace the throttle
bodies.
2. Check:
• fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of passages with compressed
air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE PRESSURE REGULATOR
1. Check:
• pressure regulator
Damage → Replace.
7 - 37
FUEL INJECTION SYSTEM
FI
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel tank.
Refer to “SEATS AND FUEL TANK” in chapter 3.
b. Disconnect the negative pressure hose 1
from the pressure regulator at the joint.
c. Connect the vacuum/pressure pump gauge
set 2 onto the negative pressure hose from
the pressure regulator.
d. Connect the pressure gauge 3 and adapter
4 onto the fuel injector pipe.
Vacuum/pressure pump gauge
set
90890-06756
Pressure gauge
90890-03153
Adapter
90890-03176
e. Install the fuel tank.
Refer to “SEATS AND FUEL TANK” in chapter 3.
f. Start the engine.
g. Measure the fuel pressure.
Fuel pressure
250 kPa (2.5 kgf/cm2, 2.5 bar)
7 - 38
FUEL INJECTION SYSTEM
FI
h. Use the vacuum pressure pump gauge set
to adjust the fuel pressure in relation to the
vacuum pressure as described below.
NOTE:
The vacuum pressure should not exceed
100 kPa (1 mmHg).
Increase the vacuum pressure →
Fuel pressure is decreased
Decrease the vacuum pressure →
Fuel pressure is increased
Faulty → Replace the pressure regulator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 39
AIR INDUCTION SYSTEM
FI
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the
emission of hydrocarbons.
When there is negative pressure at the
exhaust port, the reed valve opens, allowing
secondary air to flow into the exhaust port. The
required temperature for burning the unburned
exhaust gases is approximately 600 to 700 °C.
EAS00508
AIR CUT-OFF VALVE
The air cut-off valve is controlled by the signals
from the ECU in accordance with the combustion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the motorcycle
is being driven. However, if the coolant temperature is below the specified value, the air
cut-off valve remains open and allows the air
to flow into the exhaust pipe until the temperature becomes higher than the specified value.
È From the air filter case
É To the reed valve
7 - 40
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
2
3
4
È To cylinder #4
É To cylinder #3
Ê To cylinder #2
Ë To cylinder #1
1
1 Air cut-off valve
2 Reed valve
3 Air-filter case
7 - 41
FI
FI
AIR INDUCTION SYSTEM
AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES
5
1
3
6
2
2
3
4
9
2
7
10
8
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Removing the air cut-off valve
Remove the parts in the order listed.
assembly and hoses
Rider seat/fuel tank/T-bar/rubber sheet
Refer to “SEATS AND FUEL TANK” in
chapter 3.
Air cut-off valve assembly
1
Hose 1
3
Hose 2
2
Pipe 1
1
Hose 3
1
Pipe 2
1
Hose 4
1
Hose 5
1
Resonator hose
1
Pipe 3
1
For installation, reverse the removal
procedure.
7 - 42
AIR INDUCTION SYSTEM
FI
REED VALVES
Order
1
2
3
4
5
Job/Part
Removing the reed valves
Air cut-off valve assembly/hoses
Thermostat assembly
Spark plug caps
Reed valve cover (1)
Reed valve cover (2, 3)
Reed valve cover (4)
Reed valve assembly
Plate
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “THERMOSTAT” in chapter 6.
1
1
1
4
4
For installation, reverse the removal
procedure.
7 - 43
AIR INDUCTION SYSTEM
FI
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connection → Connect properly.
Cracks/damage → Replace.
• pipes
Cracks/damage → Replace.
2.
•
•
•
Check:
fibre reed
fibre reed stopper
reed valve seat
Cracks/damage → Replace the reed valve
assembly.
3. Check:
• air cut-off valve
Cracks/damage → Replace.
7 - 44
–
ELEC
+
8
ELEC
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................ 8-1
CHECKING SWITCH CONTINUITY................................................................8-3
CHECKING THE SWITCHES..........................................................................8-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-7
TYPES OF BULBS .................................................................................... 8-7
CHECKING THE CONDITION OF THE BULBS ....................................... 8-7
CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-9
IGNITION SYSTEM ....................................................................................... 8-10
CIRCUIT DIAGRAM ................................................................................ 8-10
TROUBLESHOOTING ............................................................................8-11
ELECTRIC STARTING SYSTEM .................................................................. 8-15
CIRCUIT DIAGRAM ................................................................................ 8-15
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-16
TROUBLESHOOTING ............................................................................8-17
STARTER MOTOR........................................................................................ 8-21
CHECKING THE STARTER MOTOR .....................................................8-24
ASSEMBLING THE STARTER MOTOR................................................. 8-26
CHARGING SYSTEM....................................................................................8-27
CIRCUIT DIAGRAM ................................................................................ 8-27
TROUBLESHOOTING ............................................................................8-28
LIGHTING SYSTEM ......................................................................................8-30
CIRCUIT DIAGRAM ................................................................................ 8-30
TROUBLESHOOTING ............................................................................8-31
CHECKING THE LIGHTING SYSTEM....................................................8-33
SIGNALING SYSTEM ...................................................................................8-37
CIRCUIT DIAGRAM ................................................................................ 8-37
TROUBLESHOOTING ............................................................................8-39
CHECKING THE SIGNALING SYSTEM ................................................. 8-40
COOLING SYSTEM....................................................................................... 8-47
CIRCUIT DIAGRAM ................................................................................ 8-47
TROUBLESHOOTING ............................................................................8-48
–
+
ELEC
FUEL INJECTION SYSTEM..........................................................................8-52
CIRCUIT DIAGRAM ................................................................................ 8-52
TROUBLESHOOTING ............................................................................8-53
CHECKING THE FUEL PUMP................................................................8-59
CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR .8-60
WINDSHIELD DRIVE SYSTEM..................................................................... 8-64
CIRCUIT DIAGRAM ................................................................................ 8-64
TROUBLESHOOTING ............................................................................8-65
–
+
ELECTRICAL COMPONENTS
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
9 Wire harness
0 Neutral switch
A Sidestand switch
B Oil level switch
C Rear brake switch
D Horn
E Ignition coil
F Main fuse
1 Windshield drive unit
2 Battery
3 Starter relay
4 Fuel injection system fuse
5 Front brake switch
6 Clutch switch
7 Fuse box
8 Radiator fan motor
8-1
ELEC
–
+
ELECTRICAL COMPONENTS
1 Coolant temperature sensor
2 Intake air pressure sensor
3 Intake air temperature sensor
4 Atmospheric pressure sensor
5 Lean angle cut-off switch
6 ECU
7 Starting circuit cut-off relay
8 Speed sensor
ELEC
9 Cylinder identification sensor
0 O2 sensor
A Crankshaft position sensor
B Headlight relay 1
C Headlight relay 2
D Fuel injection system relay
E Turn signal relay
F Radiator fan motor relay
8-2
–
+
CHECKING SWITCH CONTINUITY
ELEC
–
+
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
@
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
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.
@
R
Br Br/R L L/R L/B L/Y
ON
OFF
P
R Br
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
L/B L/R Br/R
L/Y
L
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
@
The example illustration on the left shows
that:
There is continuity between red, brown/red
and blue/red when the switch is set to “P”.
There is continuity between red, brown and
brown/red, between blue and blue/red,
between blue/black and blue/yellow when the
switch is set to “ON”.
8-3
CHECKING SWITCH CONTINUITY
8-4
ELEC
–
+
CHECKING THE SWITCHES
ELEC
–
+
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
L/Y
L/Y
B/Y
B/Y
R/W Br
R/B B
G/Y L/W
L/B Br/W
R/Y P
Lg B
R Br Br/R L L/R L/B L/Y
ON
OFF
P
(BROWN)
Y Dg
Sb Ch
L/Y B/Y
(BLACK) (BLACK)
L/Y L/B
L L/R
Br/R
R
Br
R/Y
L
L/B
(BLUE)
(BROWN)
(RED)
G/Y
Br
R/Y Y
R/Y L L/B
Lg B Sb
•
UP
R/Y L/B
DOWN
R/W R/B
Dg Br/W Ch
B P
L/W B
B
B
(BROWN)
Sb
Dg
Br/W
Ch
B
B
(BLUE)
Dg Br/W Ch
ON
OFF
8-5
Sb
CHECKING THE SWITCHES
1 Main fuse
2 Main switch
3 Clutch switch
4 Pass switch
5 Dimmer switch
6 Horn switch
7 Windshield position switch
8 Turn signal switch
9 Front brake light switch
0 Light switch
A Engine stop switch
B Start switch
C Rear brake light switch
D Neutral switch
E Sidestand switch
F Hazard switch
G Fuse
8-6
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for continuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs D and E are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
8-7
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
WARNING
@
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
@
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-9
8 - 10
Br/Y
B
Br/Y
B
L
Br/B
L
B
L
G/Y
G/Y
A
G/Y
L
G/Y
L
A
L
R/W
¢
£
L
B
{
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
B/R R/B
ON
OFF
P
1
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
Br/W
Br/G
B
B
W
W
W
B
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
B
2
L/Y L/B
L L/R
Br/R
†
R
(BLACK)
B
R
W
3
Y
Y
Br
5
4
Br
Y
•
(BROWN)
R/Y
L
L/B
(BROWN)
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
R
(GRAY)
W
L/R
W
W
W
R
R
R
R
B/R
R/B
R Br Sb
Br/R Lg B
z
Br/Y Br/R
Sb B Sb
Lg B Lg
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
B
B
t
L/R B
Y
Dg Ch
L
Y
Ch Dg
B
u
Br/W
A
Br/W
u
Dg
vw
Ch
(BROWN)
Y
(BROWN)
R/Y
L
L/B
Br
¶
B
B
(BLUE)
(BLUE)
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
Y Dg
Sb Ch
L/Y B/Y
Dg Y
Ch Sb
B/Y L/Y
7
L
B/Y
B/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
L/Y
e
R/Y
L/Y
•
L/B A L/B
R/Y A R/Y
L/B Br/W
R/Y P
Lg B
Br/W G/B
P R/Y
B Lg
R
L/W R/W
8
ß
9
B
B
R
B
R
R
R
R
R
R
d
R/W A R/W
1 Main switch
5 Main fuse
6 Battery
A Starting circuit cut-off relay
C Sidestand switch
J Lean angle cut-off switch
M Crankshaft position sensor
N ECU
T Cylinder #1, #4 – ignition coil
U Cylinder #2, #3 – ignition coil
V Spark plug
å Ignition fuse
® Engine stop switch
Br/W
R/W Br
R/B B
G/Y L/W
B
6
(BROWN)
B
B
R
R/G
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
R/B
Gy/R
R/B
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
U
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
IGNITION SYSTEM
ELEC
–
+
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00737
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The ignition system fails to operate (no
spark or intermittent spark).
Procedure
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. crankshaft position sensor resistance
8. main switch
9. engine stop switch
10.neutral switch
11.sidestand switch
12.starting circuit cut-off relay
13.wiring connections
(of the entire ignition system)
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00741
3. Spark plugs
NOTE:
• Before troubleshooting, remove the following
part(s):
1) Seat
2) Fuel tank and T-bar
3) Side cowlings
4) Front cowling assembly
5) Air filter case
• Troubleshoot with the following special
tool(s).
@
The following procedure applies to all of the
spark plugs.
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR8E (NGK)
U24ESR-N (DENSO)
Spark plug gap
0.7 ~ 0.8 mm
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
Ignition checker
90890-06754
Pocket tester
90890-03112
YES
NO
EAS00738
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
Replace the fuse(s).
8 - 11
Re-gap or replace
the spark plug.
–
ELEC
IGNITION SYSTEM
+
EAS00743
4. Ignition spark gap
The following procedure applies to all of the
spark plugs. Disconnect the spark plug cap
from the spark plug.
• Disconnect the spark plug cap from the
spark plug.
• Connect the ignition checker 1 as shown.
2 Spark plug cap
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
Spark plug cap resistance
10 kΩ at 20 °C
• Is the spark plug cap OK?
NO
YES
Replace the spark
plug cap.
EAS00747
6. Ignition coil resistance
Minimum ignition spark gap
6.0 mm
• Is there a spark and is the spark gap within
specification?
NO
YES
The following procedure applies to all of the
ignition coils.
• Disconnect the ignition coil leads from the
wire harness.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Tester positive probe → red/black
Tester negative probe → orange (gray/red)
The ignition system
is OK.
EAS00745
5. Spark plug cap resistance
The following procedure applies to all of the
spark plug caps.
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.
• Measure the primary coil resistance.
Primary coil resistance
1.53 ~ 2.07 Ω at 20 °C
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
8 - 12
IGNITION SYSTEM
Tester negative probe →
spark plug lead 1
Tester positive probe → spark plug lead 2
ELEC
–
+
Crankshaft position sensor resistance
420 ~ 569 Ω at 20 °C
(between gray and black)
• Is the crankshaft position sensor OK?
YES
NO
Replace the crankshaft position sensor.
EAS00749
8. Main switch
• Measure the secondary coil resistance.
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Secondary coil resistance
12 ~ 18 kΩ at 20 °C
• Is the ignition coil OK?
YES
NO
NO
YES
Replace the main
switch.
Replace the ignition
coil.
EAS00750
9. Engine stop switch
EAS00748
7. Crankshaft position sensor resistance
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
Replace the right
handlebar switch.
Tester positive probe → gray 1
Tester negative probe → black 2
EAS00751
10.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
• Measure the crankshaft position sensor
resistance.
8 - 13
NO
Replace the neutral
switch.
IGNITION SYSTEM
ELEC
–
+
EAS00752
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
11.Sidestand switch
@
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
@
• Are the tester readings correct?
NO
YES
YES
Replace the sidestand switch.
Replace the starting
circuit cut-off relay.
EAS00753
12.Starting circuit cut-off relay
EAS00754
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Check the starting circuit cut-off relay for
continuity.
Tester positive probe →
blue/green 1 ContinuTester negative probe →
ity
blue/yellow 2
13.Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly connected and without defects?
YES
Replace the ECU.
Tester positive probe →
blue/yellow 1 No contiTester negative probe →
nuity
blue/green 2
Lg R/B L/W
L/G L/Y Sb B/Y
NO
B
8 - 14
NO
Properly connect or
repair the ignition
system’s wiring.
8 - 15
R
B/R
R/B
R Br Sb
Br/R Lg B
z
Br/Y Br/R
Br/Y
B
Br/Y
B
L
Br/B
L
B
L
G/Y
Sb B Sb
Lg B Lg
B
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
G/Y
A
G/Y
L
G/Y
L
A
L
R/W
¢
£
L
{
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
B/R R/B
ON
OFF
P
1
B
B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
L/R B
Y
Dg Ch
t
Br/W
Br/G
B
B
W
W
W
L
Y
Ch Dg
B
B
W
3
Y
u
Y
Br
5
4
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Dg
vw
Ch
(BROWN)
Br
Y
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
(BLUE)
(BLUE)
7
L
B/Y
L/Y
e
R/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
R
(GRAY)
W
L/R
W
W
W
u
Br/W
A
Br/W
Br/W
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
B
2
L/Y L/B
L L/R
Br/R
†
R
(BLACK)
B
R
R
R
R
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
R/B
Gy/R
U
V
1 Main switch
5 Main fuse
6 Battery
8 Starter relay
9 Starter motor
0 Diode
A Starting circuit cut-off relay
B Neutral switch
C Sidestand switch
e Clutch switch
å Ignition fuse
® Engine stop switch
© Start switch
R/B
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00756
M
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
• The transmission is in neutral (the neutral
switch is closed).
• The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above conditions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the starter switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE SIDESTAND IS UP
AND THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Diode (starting circuit cut-off relay)
8 Clutch switch
9 Sidestand switch
0 Neutral switch
A Start switch
B Starter relay
C Starter motor
8 - 16
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. Battery
3. starter motor
4. starting circuit cut-off relay
5. starter circuit cut-off relay (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00758
3. Starter motor
NOTE:
• Before troubleshooting, remove the following
part(s):
1) seats
2) fuel tank
3) inner panels (front cowling)
4) air filter case
• Troubleshoot with the following special
tool(s).
@
• Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3.
Pocket tester
90890-03112
WARNING
@
EAS00738
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
• A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
@
YES
NO
• Does the starter motor turn?
YES
NO
Replace the fuse(s).
Repair or replace the
starter motor.
8 - 17
ELECTRIC STARTING SYSTEM
EAS00759
4. Starting circuit cut-off relay
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay
terminals as shown.
Battery positive terminal → red/black 1
Battery negative terminal →
black/yellow 2
Tester positive probe → blue/white 3
Tester negative probe → black 4
–
+
Tester positive probe →
sky blue 1
Tester negative probe →
light green 2
Tester positive probe →
sky blue 1
Tester negative probe →
black/yellow 3 Continuity
Tester positive probe →
sky blue 1
Tester negative probe →
blue/yellow 4
Tester positive probe →
blue/green 5
Tester negative probe →
blue/yellow 4
+
Tester positive probe →
light green 2
Tester negative probe →
sky blue 1
Lg R/B L/W
L/G L/Y Sb B/Y
ELEC
B
• Does the starting circuit cut-off relay have
continuity between blue/white and black?
NO
YES
Tester positive probe →
black/yellow 3
Tester negative probe →
sky blue 1 No continuity
Tester positive probe →
blue/yellow 4
Tester negative probe →
sky blue 1
Replace the starting
circuit cut-off relay.
EAS00760
5. Starting circuit cut-off relay (diode)
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Measure the starting circuit cut-off relay for
continuity as follows.
Tester positive probe →
blue/yellow 4
Tester negative probe →
blue/green 5
Lg R/B L/W
L/G L/Y Sb B/Y
8 - 18
B
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00749
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
@
7. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
@
• Are the testing readings correct?
YES
NO
NO
YES
Replace the main
switch.
Replace the starting
circuit cut-off relay.
EAS00750
8. Engine stop switch
EAS00761
6. Starter relay
• Disconnect the starter relay from the coupler.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminals as
shown.
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
Replace the right
handlebar switch.
Battery positive terminal → red/white 1
Battery negative terminal → blue/white 2
EAS00751
Tester positive probe → red 3
Tester negative probe → black 4
9. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
R
YES
R
NO
L/ W R/ W
Replace the neutral
switch.
B
EAS00752
• Does the starter relay have continuity
between red and black?
YES
NO
10.Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
YES
Replace the starter
relay.
NO
Replace the sidestand switch.
8 - 19
ELECTRIC STARTING SYSTEM
EAS00763
11.Clutch switch
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
EAS00764
12.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
13.Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly connected and without defects?
YES
Replace the ECU.
NO
Properly connect or
repair the starting
system’s wiring.
8 - 20
ELEC
–
+
STARTER MOTOR
ELEC
–
+
EAS00767
STARTER MOTOR
Order
1
2
Job/Part
Removing the starter motor
Throttle bodies
Starter motor lead
Starter motor
Q’ty
1
1
Remarks
Remove the parts in the order listed.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
Disconnect.
For installation, reverse the removal
procedure.
8 - 21
STARTER MOTOR
ELEC
–
New
New
New
T.
R.
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembly the starter motor
O-ring
Starter motor front cover
Brush
Brush seat
Washer
Lock washer
Oil seal
Bearing
Starter motor rear cover
Collar
4 Nm (0.4 m • kg)
Q’ty
1
1
2
1
1
1
1
1
1
1
8 - 22
Remarks
Remove the parts in the order listed.
+
STARTER MOTOR
ELEC
–
+
New
New
New
T.
R.
Order
A
B
C
Job/Part
O-ring
Starter motor yoke
Armature assembly
4 Nm (0.4 m • kg)
Q’ty
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
8 - 23
STARTER MOTOR
ELEC
–
+
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit
23.5 mm
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
1.5 mm
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
@
8 - 24
STARTER MOTOR
ELEC
–
+
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.024 ~ 0.030 Ω at 20 °C
Insulation resistance 2
Above 1 MΩ at 20 °C
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit
3.65 mm
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
5.28 ~ 7.92 N (540 ~ 800 gf)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
8 - 25
ELEC
STARTER MOTOR
–
+
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush seat 1
NOTE:
Align the slot a on the brush seat with the tab
b in the starter motor front cover.
@
2.
•
•
•
Install:
starter motor yoke 1
starter motor front cover 2
starter motor rear cover 3
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
rear covers.
@
R.
8 - 26
New
T.
3. Install:
• O-rings
• bolts
4 Nm (0.4 m · kg)
–
ELEC
CHARGING SYSTEM
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
4
R/G
R
R/B
L/W
R
R
A
R
B
R
W
W
W
2
(BLACK)
W
W
W
R
3
W
B
W
W
ON
OFF
P
B L/Y
L/R L
Br/R
B
(RED)
(RED)
B
R
Br
Br/L
L
R
R
R
B
B
B
B
B
B
B
B
B
B
L/W
B
B
B
B
(BLACK)
¢
R
Br/L
R/W
R/B
R/W L/W
¶
Br R/W
B R/B
L/W Y
R/W Br
R/B B
G/Y L/W
(BROWN)
(BROWN)
R/Y
L
L/B
R/Y
L
L/B
(BROWN)
R
R/B
C
B
R
R/B
®
ß
R
G/W B
R/B
•
R/L B
©
™
R/L
L/Y
(BROWN)
Br
R/Y
L/B
L
Br
B
R
R/L
R/L
L/Y
B R/B
R/L
B
L/Y
B
L/Y
(BLACK)
R/W A R/W
R/Y
B/Y
L/Y
d
R/W
å
Br/L
Br/B
L
R/W
Br/W G/B
P R/Y
B Lg
L/B Br/W
R/Y P
Lg B
Br/G
Dg Y
Ch Sb
B/Y L/Y
Y Dg
Sb Ch
L/Y B/Y
(BLUE)
(BLUE)
~
Br/R
Br/G
A
Br/G
L/R
L
}
x
Br/W
Br/G
B/Y
B/Y
g
h
i
j
UP
DOWN
(BLACK) (BLACK)
Y
L/B A L/B
R/Y A R/Y
B
B
(BROWN)
(BLACK) (BLACK)
L/R
L/Y
Br
Br/G
{
B
L/Y
R/Y
f
e
G/Y
y
L/B
R/Y
o
R/Y
G/L
L/B
Y
Y/B
Br
Y
Y/B
G/L
Y/B A Y/B
(BROWN)
Br/W
G/B
Lg
Sb
Dg Ch
Br/W
Y
A
Y
G/B
A
G/B
k
Dg
Br/W
Ch
k
G/L
Br/W
A
Br/W
G/L
Y
G/B G B
(BLACK)
Sb
Lg
R/B
B/R
B
Sb B Sb
Lg B Lg
B/R
R/B
L/R B L/R
B/R R/B
Sb
B
Sb Br/Y R
B Lg Br/R
L/G
B
(BLUE)
•
ç
|
B
L
B
B
Br
Br/L
B
L
Sb
0
†
Br/B
Br/B
A
Br/B
G/Y
A
G/Y
B
B
(BLUE)
B
B
Y
L
A
L
Sb
L/W
L/W
R/W
B
Br/L
G/Y
L/G
C
R/W
9
B
B
B
B
B
B
B1
B
£
L
Sb
R
B
R
Br/L
§
R/W
L/W R/W
8
B
B
L/G
L/Y
B
B
Br/B
L/Y
B
Br/R L/R
Br/Y
R
B
L/Y L/B
L L/R
Br/R
Sb
7
R
1
B/Y
R
6
(GRAY)
Lg R/B
L/G L/Y
R
R
R
B
Lg
5
R
B
B
B/R
R/B
Y
L/R
Ch
Dg
B L/R
8 - 27
p
Y
B
G
G/B
n
Dg
Br/W
Ch
Dg
Br/W
Ch
ON
OFF
Dg
B
Dg
Ch
B
Ch
Dg
Ch
2 Rectifier/regulator
3 Generator
5 Main fuse
6 Battery
CHARGING SYSTEM
EAS00774
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator assembly resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1) front cowling assembly
2) fuel tank
3) air filter case
• Troubleshoot with the following special
tool(s).
@
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00775
3. Charging voltage
• Connect the engine tachometer to the spark
plug lead of cylinder #1.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Engine tachometer
90890-06760
Pocket tester
90890-03112
Tester positive probe →
positive battery terminal
Tester negative probe →
negative battery terminal
EAS00738
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
YES
NO
Replace the fuse.
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
Charging voltage
14 V at 5,000 r/min
8 - 28
CHARGING SYSTEM
ELEC
–
+
EAS00779
NOTE:
Make sure the battery is fully charged.
5. Wiring
@
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
@
• Is the charging voltage within specification?
NO
YES
The charging circuit
is OK.
YES
EAS00776
Replace the rectifier/
regulator.
4. Stator assembly resistance
• Remove the generator cover.
• Connect the pocket tester (Ω × 1) to the stator assembly coupler as shown.
Tester positive probe → white 1
Tester negative probe → white 2
Tester positive probe → white 1
Tester negative probe → white 3
Ω ×1
+
W
W
W
• Measure the stator coil resistances.
Stator coil resistance
0.15 ~ 0.23 Ω at 20 °C
• Is the stator coil OK?
YES
NO
Replace the stator
assembly.
8 - 29
NO
Properly connect or
repair the charging
system’s wiring.
8 - 30
R
R Br Sb
Br/R Lg B
B/R
R/B
B
L
G/Y
Sb B Sb
Lg B Lg
B
{
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
G/Y
A
G/Y
L
A
L
L
G/Y
L
R/W
¢
£
B/R R/B
B
B
B/R
R/B
R
Br/L
L
B
L/Y
Br/R
Br/L
Br/L
Br/L
B
L/R
}
L/R
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
†
L/R B
Y
Dg Ch
t
Br/W
Br/G
B
B
W
W
W
L
Y
Ch Dg
B
B
W
3
Y
u
Y
Br
5
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Dg
vw
Ch
(BROWN)
Br
Y
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
(BLUE)
(BLUE)
7
L
B/Y
L/Y
e
R/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
Br
¶
B
B
B
R
B
R
R
R
R
R
R
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
(GRAY)
W
L/R
W
W
W
u
Br/W
A
Br/W
Br/W
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
L/Y L/B
L L/R
Br/R
B
2
R
4
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
L/Y
Br/Y B Dg
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
U
T
V
V
o Headlight relay 1
p Headlight relay 2
r Auxiliary light
s Headlight
u Tail/brake light
} Parking lighting fuse
ç Headlight fuse
ß Light switch
R/B
Gy/R
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
1 Main switch
5 Main fuse
6 Battery
N ECU
] High beam indicator light
b Meter light
f Pass switch
g Dimmer switch
z
Br/Y Br/R
Br/Y
B
Br/Y
B
L
Br/B
L
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
ON
OFF
P
1
R
(BLACK)
B
R
R
R
R
LIGHTING SYSTEM
ELEC
–
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
+
LIGHTING SYSTEM
EAS00781
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Any of the following fail to light: headlight, high beam indicator light, taillight,
auxiliary light or meter light.
Minimum open-circuit voltage
12.8 V or more at 20 °C
Check:
1. main, parking lighting and headlight fuses
2. battery
3. main switch
4. light switch
5. dimmer switch
6. pass switch
7. headlight relay 1
8. headlight relay 2
9. wiring connections
(of the entire lighting system)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank
2) front cowling assembly
3) rear cover
• Troubleshoot with the following special
tool(s).
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch.
Pocket tester
90890-03112
EAS00783
4. Light switch
EAS00738
1. Main, parking lighting and headlight fuses
• Check the main, parking lighting and headlight fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, parking lighting and headlight
fuses OK?
YES
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the light switch OK?
NO
Replace the fuse(s).
8 - 31
YES
NO
The light switch is
faulty. Replace the
right handlebar
switch.
LIGHTING SYSTEM
ELEC
–
+
EAS00784
• Does the headlight relay 1 have continuity
between red/yellow and green/blue?
5. Dimmer switch
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
NO
YES
Replace the headlight relay 1.
NO
YES
The dimmer switch is
faulty. Replace the
left handlebar switch.
8. Headlight relay 2
• Disconnect the headlight relay 2 from the
wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 2 terminal
as shown.
• Check the headlight relay 2 of continuity.
EAS00786
6. Pass switch
• Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the pass switch OK?
Tester positive probe → green/blue 1
Tester negative probe → green 2
NO
YES
The pass switch is
faulty. Replace the
left handlebar switch.
B
7. Headlight relay 1
G G/B
Y
• Disconnect the headlight relay 1 from the
wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 1 terminal
as shown.
• Check the headlight relay 1 for continuity.
Battery positive terminal → blue/black 1
Battery negative terminal →
yellow/black 2
Tester positive probe → red/yellow 3
Tester negative probe → green/blue 4
+
Y/B
L/B
G/L
R/Y
8 - 32
G/L
LIGHTING SYSTEM
Battery positive terminal → green/black 3
Battery negative terminal → black 4
Tester positive probe → green/blue 5
Tester negative probe → yellow 6
ELEC
+
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
1. Headlight bulb and socket
• Check the headlight bulb and socket for
continuity.
• Are the headlight bulb and socket OK?
+
NO
YES
B
–
G G/B
Y
Replace the headlight bulb, socket or
both.
G/L
• Does the headlight relay 2 have continuity
between green/blue and green or yellow?
2. Voltage
YES
NO
• Connect the pocket tester (DC 20 V) to the
headlight coupler and meter light assembly
coupler as shown.
Replace the headlight relay 2.
È When the dimmer switch is set to “
É When the dimmer switch is set to “
EAS00787
9. Wiring
”
”
Headlight coupler
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly connected and without defects?
DC 20V
G
+
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
Y
NO
Properly connect or
repair the lighting
system’s wiring.
B
Headlight
Tester positive probe →
yellow 1 or green 2
Tester negative probe → black 3
8 - 33
ELEC
LIGHTING SYSTEM
–
+
EAS00789
High beam indicator light
Tester positive probe → yellow 4
Tester negative probe → black/white 5
2. The meter light fails to come on.
1. Meter light bulb and socket
• Check the meter light bulb and socket for
continuity.
• Are the meter light bulb and socket OK?
Meter assembly coupler
NO
YES
R/G B/W
R/W G/W Y/L
Br/R
Lg
Replace the meter
light bulb, socket or
both.
W
Y
Ch
Dg
L
•
•
•
•
Set the main switch to “ON”.
Set the light switch to “
”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) of green on the
headlight coupler.
• Is the voltage within specification?
YES
This circuit is OK.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Tester positive probe → blue 1
Tester negative probe → black/white 2
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
R/G B/W
R/W G/W Y/L
Br/R
Lg
W
Y
Ch
Dg
L
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue 1 on
the meter assembly coupler.
• Is the voltage within specification?
YES
This circuit is OK.
8 - 34
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be
repaired.
LIGHTING SYSTEM
–
ELEC
+
EAS00790
EAS00791
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
4. The auxiliary light fails to come on.
1. Auxiliary light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
• Are the tail/brake light bulb and socket OK?
• Check the auxiliary light bulb and socket for
continuity.
• Are the auxiliary light bulb and socket OK?
NO
YES
NO
YES
Replace the tail/
brake light bulb,
socket or both.
Replace the auxiliary
light bulb, socket or
both.
2. Voltage
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
• Connect the pocket tester (DC 20 V) to the
auxiliary light couplers (wire harness side)
as shown.
Tester positive probe → blue/red 1
Tester negative probe → black 2
Tester positive probe → blue/red 1
Tester negative probe → black 2
B
L
Y
Ch Dg
L/R B
B
Y
L/R
Dg Ch
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue/red 1
on the tail/brake light coupler (wire harness
side).
• Is the voltage within specification?
YES
This circuit is OK.
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue/red 1
on the auxiliary light couplers (wire harness
side).
• Is the voltage within specification?
NO
wiring circuit from the
main switch to the
tail/brake light coupler is faulty and
must be repaired.
YES
This circuit is OK.
8 - 35
NO
The wiring circuit
from the main switch
to the auxiliary light
couplers is faulty and
must be repaired.
LIGHTING SYSTEM
8 - 36
ELEC
–
+
8 - 37
R
B/R
R/B
R Br Sb
Br/R Lg B
z
Br/Y Br/R
Br/Y
B
Br/Y
B
L
Br/B
L
B
L
G/Y
Sb B Sb
Lg B Lg
B
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
G/Y
A
G/Y
L
G/Y
L
A
L
R/W
¢
£
L
{
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
B/R R/B
ON
OFF
P
1
B
B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
L/R B
Y
Dg Ch
t
Br/W
Br/G
B
B
W
W
W
L
Y
Ch Dg
B
B
W
3
Y
u
Y
Br
5
4
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Dg
vw
Ch
(BROWN)
Br
Y
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
(BLUE)
(BLUE)
7
L
B/Y
L/Y
e
R/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
R
(GRAY)
W
L/R
W
W
W
u
Br/W
A
Br/W
Br/W
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
B
2
L/Y L/B
L L/R
Br/R
†
R
(BLACK)
B
R
R
R
R
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
R/B
Gy/R
R/B
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
U
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
SIGNALING SYSTEM
ELEC
–
+
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
1 Main switch
4 Backup fuse (odometer, clock and windshield)
5 Main fuse
6 Battery
A Starting circuit cut-off relay
B Neutral switch
D Fuel pump
Y Oil level warning light
Z Neutral indicator light
[ Multi-function meter
\ Engine trouble warning light
_ Left turn signal indicator light
a Right turn signal indicator light
c Oil level switch
i Turn signal switch
j Horn switch
k Horn
l Front turn signal light (left)
m Front turn signal light (right)
n Hazard switch
u Tail/brake light
v Rear turn signal light (left)
w Rear turn signal light (right)
x Rear brake light switch
y Turn signal relay
z Windshield drive unit
~ Hazard lighting fuse
† Signaling system fuse
£ Windshield motor fuse
¶ Front brake light switch
8 - 38
ELEC
–
+
SIGNALING SYSTEM
EAS00794
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
• Any of the following fail to light: flasher
light, brake light or an indicator light.
• The horn fails to sound.
Check:
1. main, signaling system, hazard lighting,
windshield motor and backup fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank
2) front cowling assembly
3) air filter case
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
Pocket tester
90890-03112
• Check the main, signaling system, hazard
lighting, windshield motor and backup fuses
for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, signaling system, hazard
lighting, windshield motor and backup fuses
OK?
YES
NO
Replace the fuse(s).
NO
Replace the main
switch.
EAS00738
1. Main, signaling system, hazard lighting,
windshield motor and backup fuses
NO
EAS00795
4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8 - 39
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
ELEC
–
+
EAS00796
3. Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
• Disconnect the black connector at the horn
terminal.
• Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
NO
YES
Br
Replace the left handlebar switch.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
Tester positive probe → brown 1
Tester negative probe → ground
Br
NO
Replace the horn.
P
• Set the main switch to “ON”.
• Measure the voltage (12 V) of black/white at
the horn terminal.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
8 - 40
YES
The horn is OK.
ELEC
SIGNALING SYSTEM
–
+
EAS00797
2. The tail/brake light fails to come on.
3. Voltage
1. Tail/brake light bulb and socket
• Connect the pocket tester (DC 20 V) to the
tail light assembly coupler (wire harness
side) as shown.
• Check the tail/brake light bulb and socket
for continuity.
• Are the tail/brake light bulb and socket OK?
YES
Tester positive probe → yellow 1
Tester negative probe → black 2
NO
Replace the tail/
brake light bulb,
socket or both.
B
L
Y
Ch Dg
L/R B
Y
Dg Ch
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
NO
Replace the brake
light switch.
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (12 V) of yellow 1 on
the tail light assembly coupler (wire harness
side).
• Is the voltage within specification?
YES
This circuit is OK.
8 - 41
NO
The wiring circuit
from the main switch
to the tail light
assembly coupler is
faulty and must be
repaired.
SIGNALING SYSTEM
ELEC
–
+
EAS00799
3. The turn signal light, turn signal indicator
light or both fail to blink.
1. Turn signal indicator light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
• Are the turn signal light bulb and socket
OK?
YES
3. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler as shown.
Tester positive probe → brown/green 1
Tester negative probe → ground
NO
Br/W
Replace the turn signal light bulb, socket
or both.
2. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
Br/G
• Set the main switch to “ON”.
• Measure the voltage (12 V) on brown/green
1 at the turn signal relay coupler.
• Is the voltage within specification?
NO
YES
YES
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and must be
repaired.
Replace the left handlebar switch.
4. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler as shown.
Tester positive probe → brown/white 1
Tester negative probe → ground
Br/W
Br/G
8 - 42
SIGNALING SYSTEM
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12 V) on brown/white
1 at the turn signal relay coupler.
• Is the voltage within specification?
YES
The turn signal relay
is faulty and must be
replaced.
This circuit is OK.
5. Voltage
• Connect the pocket tester (DC 20 V) to the
front turn signal light connectors (wire harness side), tail light assembly coupler (wire
harness side) or meter assembly coupler as
shown.
È Front turn signal light
É Rear turn signal light
Ê Turn signal indicator light
+
NO
The wiring circuit
from the turn signal
switch to the front
turn signal light connectors (wire harness
side), tail light
assembly coupler
(wire harness side)
or meter assembly
coupler is faulty and
must be repaired.
EAS00800
4. The neutral indicator light fails to come on.
Left turn signal light
Tester positive probe → chocolate 1
Tester negative probe → ground
Right turn signal light
Tester positive probe → dark green 2
Tester negative probe → ground
É
È
Ch
–
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12 V) of the chocolate
1 or dark green 2.
• Is the voltage within specification?
NO
YES
ELEC
1. Neutral indicator light bulb and socket
• Check the neutral indicator light bulb and
socket for continuity.
• Are the neutral indicator light bulb and
socket OK?
YES
Dg
Ch
Replace the neutral
indicator light bulb,
socket or both.
B
Dg Y L
Dg Y L/R
Ch
B
NO
2. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
Ê
YES
R/G B/W
R/W G/W Y/L
Br/R
Lg
Replace the neutral
switch.
W
Y
Ch
Dg
NO
L
8 - 43
ELEC
SIGNALING SYSTEM
–
+
EAS00753
3. Starting circuit cut-off relay
4. Voltage
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Check the starting circuit cut-off relay for
continuity.
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Tester positive probe → brown/red 1
Tester negative probe → light green 2
Tester positive probe →
sky blue 1 ContinuTester negative probe →
ity
light green 2
R/G B/W
R/W G/W Y/L
Tester positive probe →
light green 2 No continuity
Tester negative probe →
sky blue 1
Replace the windshield drive unit.
Lg R/B L/W
B
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
@
@
• Are the tester readings correct?
YES
Lg
W
Y
Ch
Dg
L
• Set the main switch to “ON”.
• Measure the voltage (12 V).
• Is the voltage within specification?
YES
L/G L/Y Sb B/Y
Br/R
NO
Replace the starting
circuit cut-off relay.
8 - 44
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be
repaired.
ELEC
SIGNALING SYSTEM
–
+
EAS00802
5. The oil level warning light fails to come on.
3. Voltage
1. Oil level warning light bulb and socket
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
• Check the oil level warning light bulb and
socket for continuity.
• Are the oil level warning light bulb and
socket OK?
YES
Tester positive probe → white 1
Tester negative probe → black/white 2
NO
Replace the oil level
warning light bulb,
socket or both.
R/G B/W
R/W G/W Y/L
2. Oil level switch
• Drain the engine oil and remove the engine
oil level switch from the oil pan.
• Check the engine oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine oil level switch OK?
YES
NO
Br/R
Lg
W
Y
Ch
Dg
L
• Set the main switch to “ON”.
• Measure the voltage (5 V) of white 1 and
black/white 2 at the meter assembly coupler.
• Is the voltage within specification?
YES
This circuit is OK.
Replace the engine
oil level switch.
8 - 45
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be
repaired.
ELEC
SIGNALING SYSTEM
–
+
EAS00804
6. The fuel level gauge fails to operate.
2. Voltage
1. Fuel sender
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
• Drain the fuel from the fuel tank and remove
the fuel pump from the fuel tank.
• Connect the pocket tester (Ω × 10) to the
fuel sender terminals as shown.
Tester positive probe → green/white 1
Tester negative probe → black/white 2
Tester positive probe → green/white 1
Tester negative probe → black 2
R/G B/W
R/W G/W Y/L
B
G/W
R/L
B
NOTE:
Measure the resistances when the float arm
is in contact with the full position and empty
position of the stopper.
YES
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be
repaired.
• Is the fuel sender OK?
YES
Lg
W
Y
Ch
Dg
L
• Set the main switch to “ON”.
• Measure the voltage (12 V) of green/white
1 and black/white 2 at the meter assembly coupler.
• Is the voltage within specification?
• Measure the fuel sender resistances.
Fuel sender resistance
Full position of the float
19 ~ 21 Ω at 20 °C
Empty position of the float
139 ~ 141 Ω at 20 °C
Br/R
NO
Replace the fuel
pump.
8 - 46
NO
Replace the meter
assembly.
8 - 47
R
R Br Sb
Br/R Lg B
B/R
R/B
B
L
G/Y
Sb B Sb
Lg B Lg
B
{
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
G/Y
A
G/Y
L
A
L
L
G/Y
L
R/W
¢
£
B/R R/B
B
B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
†
L/R B
Y
Dg Ch
t
Br/W
Br/G
B
B
W
W
W
L
Y
Ch Dg
B
B
W
3
Y
u
Y
Br
5
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Dg
vw
Ch
(BROWN)
Br
Y
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
(BLUE)
(BLUE)
7
L
B/Y
L/Y
e
R/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
(GRAY)
W
L/R
W
W
W
u
Br/W
A
Br/W
Br/W
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
L/Y L/B
L L/R
Br/R
B
2
R
4
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
R/B
Gy/R
R/B
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
U
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
N ECU
{ Radiator fan motor
| Radiator fan motor relay
å Ignition fuse
¢ Radiator fan motor fuse
V
V
1 Main switch
5 Main fuse
6 Battery
L Coolant temperature
sensor
z
Br/Y Br/R
Br/Y
B
Br/Y
B
L
Br/B
L
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
ON
OFF
P
1
R
(BLACK)
B
R
R
R
R
COOLING SYSTEM
ELEC
–
+
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EAS00808
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
• The radiator fan motor fails to turn.
• The coolant temperature gauge needle
fails to move when the engine is warm.
Minimum open-circuit voltage
12.8 V or more at 20 °C
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections
(the entire cooling system)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank and T-bar
2) front cowling assembly
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
Pocket tester
90890-03112
NO
Replace the main
switch.
EAS00738
1. Main, ignition, and radiator fan motor fuses
• Check the main, ignition, and radiator fan
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and radiator fan
motor fuses OK?
YES
NO
NO
Replace the fuse(s).
8 - 48
COOLING SYSTEM
ELEC
–
+
EAS00809
4. Radiator fan motor (test 1)
6. Radiator fan motor relay
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (12 V) as shown.
• Disconnect the radiator fan motor relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor terminal
as shown.
• Check the radiator fan motor of continuity.
Battery positive lead → blue 1
Battery negative lead → black 2
Battery positive terminal → red/white 1
Battery negative terminal →
green/yellow 2
Tester positive probe → brown/black 3
Tester negative probe → blue 4
+
• Does the radiator fan motor turn?
NO
YES
G/Y
R/W
L
Br/B
The radiator fan
motor is faulty and
must be replaced.
• Does the radiator fan motor have continuity
between brown/black and blue?
EAS00810
5. Radiator fan motor (test 2)
YES
• Disconnect the coolant temperature sensor
coupler from the coolant temperature sensor.
• Connect the green/white 1 and black/blue
2 terminals with a jumper lead 3 shown.
G/W B/L
• Does the radiator fan motor turn?
YES
NO
The radiator fan
motor is faulty and
must be replaced.
8 - 49
NO
Replace the radiator
fan motor.
COOLING SYSTEM
ELEC
–
+
EAS00811
7. Coolant temperature sensor
• Remove the coolant temperature sensor
from the thermostat assembly inlet pipe.
• Connect the pocket tester (Ω × 1) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor in
a container filled with coolant 2.
NOTE:
Make sure that the coolant temperature sensor terminals do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool
down to the specified temperature.
• Check the coolant temperature sensor for
continuity at the temperatures indicated
below.
Coolant temperature
Test step Coolant temperature
sensor
Continuity
1
Less than 105 °C
NO
2
More than 105 °C
YES
3
More than 100 °C
YES
4
Less than 100 °C
NO
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
100 °C
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
105 °C
È The coolant temperature sensor circuit is open
and the radiator fan is off.
É The coolant temperature sensor circuit is
closed and the radiator fan is on.
WARNING
@
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
• Does the coolant temperature sensor operate
properly as described above?
YES
NO
Replace the coolant
temperature sensor.
T.
R.
Coolant temperature sensor
20 Nm (2.0 m · kg)
Three bond sealock®10
8 - 50
COOLING SYSTEM
EAS00813
8. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly connected and without defects?
YES
Replace the ECU.
NO
Properly connect or
repair the cooling
system’s wiring.
8 - 51
ELEC
–
+
8 - 52
B/R
R/B
R Br Sb
Br/R Lg B
Br/Y Br/R
R
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
{
L
G/Y
L
R/W
¢
£
B/R R/B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
†
Br/W
Br/G
B
B
W
W
W
B
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
L/Y L/B
L L/R
Br/R
B
2
W
3
Y
Y
Br
5
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Br
Y
Sb B Sb
Lg B Lg
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
B
B
L/R B
Y
Dg Ch
L
Y
Ch Dg
Br/W
A
Br/W
Br/W
B
Ch
Dg
(BROWN)
7
L
B/Y
L/Y
L/B
L/B
Y
B
R/Y
G/L
B L/R
B L/R
L/R B L/R
(BLACK)
B
L/R
B
L/R
Y/B
L/W
R/W
0
R/W
L/W
G/B
A
G/B
R/Y
B
G
Y
ON
OFF
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
e
R/Y
R/W
L/W
R
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Sb
B/Y
R/B
L/W
Dg
B
Dg
Ch
B
Ch
Dg Ch
Br/W
B
(BLUE)
L/G
B
B
B
(BLUE)
k
j
R/L B
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y
Y
Dg
Br/W
Ch
G
B
B
B
Dg
B
Ch
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
L Coolant temperature sensor
k
p
position
sensor
M Crankshaft
n
N ECU
O Cylinder #1 - injector
P Cylinder #2 - injector
Q Cylinder #3 - injector
R Cylinder #4 - injector
system solenoid
SqAI
rr
m
l
s s
W Speed sensor
å Ignition fuse
® Engine stop switch
™ Fuel injection system relay
G/L
Y
G/B G B
(BLUE)
(BLUE)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
(GRAY)
W
L/R
W
W
W
R
4
1 Main switch
5 Main fuse
6 Battery
7 Fuel injection system fuse
z
D Fuel pump
E O2 sensor
sensor
F Cylinder identification
t
G Throttle position sensor v w
u
H Intake air pressure sensor
u
I Atmospheric pressure sensor
J Lean angle cut-off switch
K Intake air temperature sensor
Br/Y
B
Br/Y
B
L
Br/B
L
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
ON
OFF
P
1
R
(BLACK)
B
R
R
R
R
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
R/L
L/Y
R/W
B/Y
B1
L/W
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
R/B
Gy/R
R/B
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
U
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
FUEL INJECTION SYSTEM
ELEC
–
+
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM
FUEL INJECTION SYSTEM
EAS00816
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
If the fuel injection system fails to operate.
Check:
1. main, fuel injection system and ignition
fuses
2. battery
3. main switch
4. engine stop switch
5. fuel injection system relay
6. fuel pump resistance
7. crankshaft position sensor
8. cylinder indication sensor
9. speed sensor
10.coolant temperature sensor
11.intake air temperature sensor
12.intake air pressure sensor
13.atmospheric pressure sensor
14.AI system solenoid
15.wiring connections
(the entire fuel system)
Minimum open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank
2) front cowling assembly
3) air filter case
• Troubleshoot with the following special
tool(s).
YES
NO
@
Replace the main
switch.
EAS00750
4. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
Pocket tester
90890-03112
YES
NO
EAS00738
1. Main, fuel injection system and ignition
fuses
• Check the main, fuel injection system and
ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, fuel injection system and ignition fuses OK?
YES
NO
Replace the fuse(s).
8 - 53
Replace the right
handlebar switch.
EAS00759
–
ELEC
FUEL INJECTION SYSTEM
+
EAS00817
5. Fuel injection system relay
6. Fuel pump resistance
• Disconnect the fuel injection system relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the fuel injection system relay
terminals as shown.
• Disconnect the fuel pump coupler from the
fuel pump.
• Connect the pocket tester (Ω × 1) to the fuel
pump coupler as shown.
Battery positive terminal → red/black 1
Battery negative terminal → blue/yellow 2
Tester positive probe → red/blue 1
Tester negative probe → black 2
Tester positive probe → red 3
Tester negative probe → red/blue 4
B
G/W
R/L
B
R
R/L
R/B
L/Y
• Measure the fuel pump resistance.
+
Fuel pump resistance
0.2 ~ 3.0 Ω at 20°C
• Does the fuel injection system relay have
continuity between blue/white and black?
YES
• Is the fuel pump OK?
Replace the fuel
injection system
relay.
NO
YES
NO
Replace the fuel
pump.
EAS00748
7. Crankshaft position sensor resistance
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
Tester positive probe → gray 1
Tester negative probe → black 2
• Measure the crankshaft position sensor
resistance.
8 - 54
ELEC
FUEL INJECTION SYSTEM
+
9. Speed sensor output voltage
Crankshaft position sensor resistance
420 ~ 569 Ω at 20 °C
(between gray and black)
• Measure the speed sensor output voltage.
• Connect the pocket tester (DC 20 V) to the
speed sensor coupler terminal as shown.
• Is the crankshaft position sensor OK?
Tester positive probe → white 1
Tester negative probe → black/blue 2
NO
YES
–
Replace the crankshaft position sensor.
8. Cylinder identification sensor output voltage
• Connect the pocket tester (DC 20 V) to the
cylinder identification sensor coupler terminal as shown.
W L/Y
L W/B
B/L
B/L
• Measure the speed sensor output voltage.
Tester positive probe → white 1
Tester negative probe → black/blue 2
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less
• Is the speed sensor OK?
W L/Y
L W/B
B/L
B/L
YES
NO
Replace the speed
sensor.
• Set the main switch to “ON”.
• Measure the cylinder identification sensor
output voltage.
Cylinder identification sensor
output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less
• Is the cylinder identification sensor OK?
YES
NO
Replace the cylinder
identification sensor.
8 - 55
FUEL INJECTION SYSTEM
ELEC
–
+
EAS00811
10.Coolant temperature sensor
• Remove the coolant temperature sensor
from the thermostat assembly inlet pipe.
• Connect the pocket tester (Ω × 1) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor in
a container filled with coolant 2.
NOTE:
Make sure that the coolant temperature sensor terminals do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool
down to the specified temperature.
• Check the coolant temperature sensor for
continuity at the temperatures indicated
below.
Coolant temperature
Test step Coolant temperature
sensor
Continuity
1
Less than 105 °C
NO
2
More than 105 °C
YES
3
More than 100 °C
YES
4
Less than 100 °C
NO
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
100 °C
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
105 °C
È The coolant temperature sensor circuit is open
and the radiator fan is off.
É The coolant temperature sensor circuit is
closed and the radiator fan is on.
WARNING
@
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
• Does the coolant temperature sensor operate
properly as described above?
YES
NO
Replace the coolant
temperature sensor.
T.
R.
Coolant temperature sensor
20 Nm (2.0 m · kg)
Three bond sealock®10
8 - 56
FUEL INJECTION SYSTEM
ELEC
–
+
11.Intake air temperature sensor resistance
12.Intake air pressure sensor output voltage
• Remove the intake air temperature sensor
from the air filter case.
• Connect the pocket tester (Ω × 100) to the
intake air temperature sensor terminal as
shown.
• Connect the pocket tester (DC 20 V) to the
intake air intake air pressure sensor coupler
terminal as shown.
Tester positive probe → brown/white 1
Tester negative probe → black/blue 2
Tester positive probe → blue 1
Tester negative probe → black/blue 2
L B/L P/W
Br/W B/L
• Measure the intake air temperature sensor
resistance.
Intake air temperature sensor
resistance
450 ~ 550 Ω at 20 °C
• Set the main switch to “ON”.
• Measure the intake air pressure sensor output voltage.
Intake air pressure sensor output
voltage
3.75 ~ 4.25 D.C V
• Is the intake air pressure sensor OK?
WARNING
YES
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace
it.
T.
Intake air temperature sensor
18 Nm (1.8 m · kg)
R.
• Is the intake air temperature sensor OK?
YES
NO
Replace the intake air
temperature sensor.
8 - 57
NO
Replace the intake air
pressure sensor.
FUEL INJECTION SYSTEM
13.Atmospheric pressure sensor output voltage
ELEC
–
+
14.AI system solenoid
• Connect the pocket tester (DC 20 V) to the
atmospheric pressure sensor coupler terminal as shown.
• Remove the AI system solenoid coupler
from the wire harness.
• Connect the pocket tester (Ω × 1) to the AI
system solenoid terminal as shown.
Tester positive probe → blue 1
Tester negative probe → black/blue 2
Tester positive probe → brown 1
Tester negative probe → brown/red 2
L B/L P
Br
• Set the main switch to “ON”.
• Measure the atmospheric pressure sensor
output voltage.
Atmospheric pressure sensor
output voltage
3.75 ~ 4.25 DCV
Br/R
• Measure the AI system solenoid resistance.
AI system solenoid resistance
19 ~ 25 Ω at 20 °C
• Is the AI system solenoid OK?
YES
NO
• Is the atmospheric pressure sensor OK?
YES
Replace the AI system solenoid.
NO
Replace the atmospheric pressure
sensor.
EAS00818
15.Wiring
• Check the entire fuel injection system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the fuel injection system’s wiring properly
connected and without defects?
YES
Replace the ECU.
8 - 58
NO
Properly connect or
repair the fuel injection system’s wiring.
FUEL INJECTION SYSTEM
ELEC
–
+
EAS00819
CHECKING THE FUEL PUMP
WARNING
@
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
• Stop the engine before 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. Check:
• fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the plug 1 to fuel return hose end.
b. Fill the fuel tank.
c. Put the end of the fuel hose into an open
container.
d. Connect the battery (12 V) to the fuel pump
terminals as shown.
Battery positive lead → red/blue 2
Battery negative lead → black 3
B R/L
e. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace
the fuel pump.
G/W B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
+
8 - 59
FUEL INJECTION SYSTEM
ELEC
–
+
EAS00502
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor,
the engine idling speed should be properly
adjusted.
1. Check:
• throttle position sensor
(installed on the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
L
Y
B/L
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Tester positive probe → blue terminal 1
Tester negative tester probe →
black/blue terminal 2
c. Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 kΩ at 20 °C
(blue — black/blue)
d. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Tester positive probe → yellow terminal 3
Tester negative probe →
black/blue terminal 2
e. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
Out of specification or the resistance
changes abruptly → Go to step 2 below.
8 - 60
FUEL INJECTION SYSTEM
ELEC
–
+
Throttle position sensor resistance
(520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ) at
20 °C
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• throttle position sensor
(removed from the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
L
Y
B/L
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from
the throttle body.
c. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Tester positive probe → blue terminal 1
Tester negative probe →
black/blue terminal 2
d. Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 kΩ at 20 °C
(blue — black/blue)
8 - 61
FUEL INJECTION SYSTEM
ELEC
–
+
e. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Tester positive probe → yellow terminal 3
Tester negative probe →
black/blue terminal 2
f. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
The resistance does not change or it
changes abruptly → Replace the throttle
position sensor.
The slot is worn or broken → Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
Throttle position sensor resistance
0 ~ 5 ± 1.0 kΩ at 20 °C
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
L
Y
B/L
Tester positive probe → blue terminal 1
Tester negative probe →
black/blue terminal 2
c. Measure the throttle position sensor maximum resistance.
d. Calculate the throttle position sensor maximum resistance when the throttle is closed.
Throttle position sensor maximum resistance (throttle is fully closed) =
Maximum resistance × (0.13 ~ 0.15)
8 - 62
FUEL INJECTION SYSTEM
ELEC
–
+
Example:
If the maximum resistance = 5 kΩ, then the
throttle position sensor’s maximum resistance
when the throttle is fully closed should be:
5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω
Lift the throttle body assembly slightly out of
the intake manifolds. Loosen the throttle position sensor screws 4.
Connect the pocket tester (Ω × 100) to the
throttle position sensor.
Tester positive probe →
yellow terminal 3
Tester negative probe →
black/blue terminal 2
e. Adjust the throttle position sensor angle so
the measured resistance is within the specified range.
Throttle position sensor resistance
650 ~ 750 Ω
(yellow — black/blue)
After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 63
8 - 64
R
B/R
R/B
R Br Sb
Br/R Lg B
z
Br/Y Br/R
Br/Y
B
Br/Y
B
L
Br/B
L
B
L
G/Y
Sb B Sb
Lg B Lg
B
B/R
R/B
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
G/Y
A
G/Y
L
G/Y
L
A
L
R/W
¢
£
L
{
(BLACK) (BLACK)
R/W
|
Br/B
Br/B
Br/B
A
Br/B
Br/Y
B/R R/B
ON
OFF
P
1
B
B
B/R
R/B
R
Br/L
L
B
B
L/Y
L/R
}
L/R
Br/R
Br/L
Br/L
Br/L
Br/R L/R
Br/L
R
B
B
B
B
B
B
B
B
~
å
ç
L/R B
Y
Dg Ch
t
Br/W
Br/G
B
B
W
W
W
L
Y
Ch Dg
B
B
W
3
Y
u
Y
Br
5
4
R/Y
L
L/B
(BROWN)
R/Y
L
L/B
(BROWN)
Dg
vw
Ch
(BROWN)
Br
Y
B L/R
B L/R
q
L/R B L/R
(BLACK)
G/L
Y
G/B G B
(BLUE)
(BLUE)
7
L
B/Y
L/Y
e
R/Y
L/W
L/R
Y
B
L/R
p
Y/B
B
B
rr
L/B
R/Y
G/L
R
B/Y
L/Y
L/B
R/W
B
Y G
G
G/B
B
B
B
B
B
R/Y
Y
Y
G
G
Y
Dg
Br/W
Ch
G/B
A
G/B
s s
Y G
G/L
L/W
R/W
0
R/W
L/W
B
B
ON
OFF
n
L/Y
B
L/Y
Dg
Br/W
Ch
G/B
DOWN
UP
h
R/L
R/L
L/Y
B R/B
R/L
R
™
R/B
R/L
L/Y
R
R
R/B
C
B
R
R/B
g
Dg
Br/W
Ch
R/B
R/W L/W
Y
A
Y
f
©
®
Y/B
G/L
Y/B A Y/B
o
L/B
R/Y
(BLACK) (BLACK)
B/Y
L/Y
•
ß
9
B
R
L/W R/W
8
L/B A L/B
R/Y A R/Y
Y Dg
Sb Ch
L/Y B/Y
L/B Br/W
R/Y P
Lg B
d
Br
¶
B
B
B
R
B
R
R
R
R
R
R
Dg Y
Ch Sb
B/Y L/Y
Br/W G/B
P R/Y
B Lg
R/W A R/W
Y
(BROWN)
(BROWN)
B
6
R/W Br
R/B B
G/Y L/W
•
B
B
R
R/G
Br R/W
B R/B
L/W Y
B
B
(BROWN)
x
W
R
(GRAY)
W
L/R
W
W
W
u
Br/W
A
Br/W
Br/W
y
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
(BLACK)
Br
B
B
B
B
B
B
B
B1
B
B
B
B
B
(BLACK)
§
B
B
R
Br/L
(RED)
(RED)
R
Br
B L/Y
L/R L
Br/R
B
2
L/Y L/B
L L/R
Br/R
†
R
(BLACK)
B
R
R
R
R
Lg
Sb
B
Sb
Sb
Sb
Lg
i
B
Dg
Dg
B
Dg
B
k
k
j
R/L B
B
l
Ch
Ch
B
Ch
(BLUE)
L/G
B
B
B
(BLUE)
B
D
B
Br
P
Br
P
P
L B L
B
R/L G/W
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B
L/G
L/G
C
L/Y
A
Dg Ch
Br/W
m
B
Sb
B/Y
R/B
L/W
W
W
C
W
c
R/G
C
R/G
G/W
A
G/W
Lg
A
Lg
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
X
Gy/G
W
L
E
Y B/L
J
I
H
G
(BLACK)
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
`
a
b
\
]
R/W
Y/G
B/L
L
B/L
P
L
B/L
P/W
B/L
Y
L
B/L
[
Z
Y
(GRAY)
R/W Y/G B/L
(BLACK)
P B/L L
(BLACK)
P/W B/L L
(BLACK)
L
L W/B
B/L
L
W/B
B/L
W L/Y
F
(DARK GRAY) (DARK GRAY)
Gy/G B/L
R/L D R/L
G/W B/W Y/B Br/B
L/B
G/Y L
WIRE HARNESS
R/Y Y Lg Br/G
Br/W G/B
R/W
B/L E B/L
L D L
Y E Y
B/W
Y/L
Lg
B/L
Y/L C Y/L
B/W A B/W
Br/W
L
B/L
L W/Y
G/W
(BLACK)
K
(BLACK)
Br/W B/L
B/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
L
W
B/L
W/Y
B/L
M
Gy
B/L
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
Gy
R/L
L/Y
R/W
B/Y
B1
L/W
B
SUB-WIRE
HARNESS 1
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
C
WIRE HARNESS
W Y/L R
R/G
SUB-WIRE
HARNESS 1
R Y/L W
R/G
B/W
B3
N
W
Y/L
Br/R
G/Y
Y/B
R/B
G/B
L/B
O/B
O
Gy/R
(BLACK)
O
D
WIRE HARNESS
R/L R/B G/B
L/B O/B L
T
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
WIRE HARNESS
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
W L/Y
Gy
B
Gy
B/L
Br/G Lg Y R/Y
R/W
G/B Br/W
SUB-WIRE
HARNESS 1
Br/B Y/B B/W G/W
L G/Y
L/B
Gy/G E Gy/G
A
V
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
(BLACK)
Br/R
O/B
L/B
G/B
R/B
Br/R R/W
Br Br/R
S
R
Q
P
O
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 2
Gy/G Y W/B
B/L P/W
WIRE HARNESS
(BLACK)
E
W/B Y Gy/G
P/W B/L
R/B
Gy/R
U
V
1 Main switch
4 Backup fuse (odometer, clock and windshield)
5 Main fuse
6 Battery
A Starting circuit cut-off relay
B Neutral switch
Z Neutral indicator light
h Windshield position switch
z Windshield drive unit
£ Windshield motor fuse
R/B
WINDSHIELD DRIVE SYSTEM
ELEC
–
+
WINDSHIELD DRIVE SYSTEM
CIRCUIT DIAGRAM
WINDSHIELD DRIVE SYSTEM
TROUBLESHOOTING
ELEC
–
+
EAS00739
2. Battery
The windshield fails to operate.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, windshield motor and backup fuses
2. battery
3. main switch
4. windshield position adjusting switch
5. wiring connections
(of the windshield drive system)
Minimum open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank
2) front cowling assembly
3) air filter case
• Troubleshoot with the following special
tool(s).
NO
@
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
YES
EAS00738
NO
1. Main, windshield motor and backup fuses
• Check the main, windshield motor and
backup fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, windshield motor and backup
fuses OK?
YES
NO
Replace the fuse(s).
Replace the main
switch.
4. Windshield position adjusting switch
• Check the windshield position adjusting
switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the windshield position adjusting switch
OK?
YES
NO
Replace the left handlebar switch.
8 - 65
WINDSHIELD DRIVE SYSTEM
EAS00795
5. Wiring
• Check the entire windshield drive system’s
wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the windshield drive system’s wiring
properly connected and without defects?
YES
Replace the windshield drive unit.
NO
Properly connect or
repair the windshield
drive system’s wiring.
NOTE:
• If the windshield is up, it will go down when
the gear is in the neutral position and the
main switch is set to “OFF”.
• The neutral indicator light will blink until the
windshield has stopped and is all the way
down. If the neutral indicator light does not
turn off, replace the windshield drive unit.
8 - 66
ELEC
–
+
TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING PROBLEMS ................................................................................. 9-1
ENGINE..................................................................................................... 9-1
FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEMS ..........................................................................9-2
INCORRECT ENGINE IDLING SPEED........................................................... 9-2
ENGINE..................................................................................................... 9-2
FUEL SYSTEM.......................................................................................... 9-2
ELECTRICAL SYSTEMS ..........................................................................9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................9-3
ENGINE..................................................................................................... 9-3
FUEL SYSTEM.......................................................................................... 9-3
FAULTY GEAR SHIFTING..............................................................................9-3
SHIFTING IS DIFFICULT ..........................................................................9-3
SHIFT PEDAL DOES NOT MOVE ............................................................ 9-3
JUMPS OUT OF GEAR.............................................................................9-3
FAULTY CLUTCH ........................................................................................... 9-4
CLUTCH SLIPS......................................................................................... 9-4
CLUTCH DRAGS ......................................................................................9-4
OVERHEATING............................................................................................... 9-4
ENGINE..................................................................................................... 9-4
COOLING SYSTEM .................................................................................. 9-4
FUEL SYSTEM.......................................................................................... 9-4
CHASSIS...................................................................................................9-4
ELECTRICAL SYSTEMS ..........................................................................9-4
POOR BRAKING PERFORMANCE................................................................9-5
FAULTY FRONT FORK LEGS........................................................................ 9-5
LEAKING OIL ............................................................................................ 9-5
MALFUNCTION......................................................................................... 9-5
UNSTABLE HANDLING.................................................................................. 9-6
TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-6
HEADLIGHT DOES NOT LIGHT............................................................... 9-6
HEADLIGHT BULB BURNT OUT.............................................................. 9-6
TAIL/BRAKE LIGHT DOES NOT LIGHT................................................... 9-6
TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-6
TURN SIGNAL DOES NOT LIGHT ........................................................... 9-6
TURN SIGNAL BLINKS SLOWLY............................................................. 9-6
TURN SIGNAL REMAINS LIT...................................................................9-6
TURN SIGNAL BLINKS QUICKLY............................................................ 9-7
HORN DOES NOT SOUND ...................................................................... 9-7
STARTING PROBLEMS
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
@
STARTING PROBLEMS
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel tank drain hose
• Deteriorated or contaminated fuel
Fuel pump
• Faulty fuel pump
• Faulty fuel pump relay
Throttle body(-ies)
• Deteriorated or contaminated fuel
• Sucked-in air
ENGINE
Cylinder(s) and cylinder head(s)
• Loose spark plug
• Loose cylinder head
• 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
Piston(s) and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Improperly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
9-1
STARTING PROBLEMS/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
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
Ignition coil(s)
• Cracked or broken ignition coil
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
TRBL
SHTG
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
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
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS00846
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
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
Ignition coil(s)
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Cracked or broken ignition coil
Ignition system
• Faulty ignitor unit
• Faulty pickup coil
• Broken generator rotor woodruff key
ENGINE
Cylinder(s) and cylinder head(s)
• Incorrect valve clearance
• Damaged valve train components
Air filter
• Clogged air filter element
FUEL SYSTEM
Throttle body(-ies)
• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improperly adjusted engine idling speed
(throttle stop screw)
• Improper throttle cable free play
• Flooded throttle body
• Faulty air induction system
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY GEAR SHIFTING
TRBL
SHTG
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
• Clogged air filter element
FUEL SYSTEM
Fuel pump
• Faulty fuel pump
EAS00850
FAULTY GEAR SHIFTING
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
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
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
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
9-3
FAULTY CLUTCH/OVERHEATING
TRBL
SHTG
EAS00852
FAULTY CLUTCH
CLUTCH DRAGS
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
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
CLUTCH SLIPS
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
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS00855
OVERHEATING
FUEL SYSTEM
Throttle body(-ies)
• Faulty throttle body(-ies)
• Damaged or loose throttle body joint
Air filter
• Clogged air filter element
CHASSIS
Brake(s)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty ECU
ENGINE
• Clogged coolant passages
• Heavy carbon buildup in cylinder head(s)
and piston(s)
Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
• Damaged or faulty water pump
• Thermostat stays closed
• Clogged or damaged oil cooler
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
9-4
POOR BRAKING PERFORMANCE/
FAULTY FRONT FORK LEGS
TRBL
SHTG
EAS00857
POOR BRAKING PERFORMANCE
•
•
•
•
•
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
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
EAS00860
FAULTY FRONT FORK LEGS
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
LEAKING OIL
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
• Loose drain bolt
• Damaged drain bolt gasket
9-5
UNSTABLE HANDLING/
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
EAS00863
UNSTABLE HANDLING
Rear shock absorber assembly(-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
Handlebars
• Bent or improperly installed right handlebar
• Bent or improperly installed left handlebar
Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
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
Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
TURN SIGNAL DOES NOT LIGHT
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal relay
• Burnt-out turn signal bulb
HEADLIGHT DOES NOT LIGHT
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
• Faulty headlight relay 1
• Faulty headlight relay 2
• Faulty ECU
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT LIGHT
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
9-6
FAULTY LIGHTING OR SIGNALING SYSTEM
TURN SIGNAL BLINKS QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal 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
9-7
TRBL
SHTG
FJR1300 WIRING DIAGRAM (for Europe)
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
z
{
|
}
~
å
ç
†
¢
£
Main switch
Rectifier/regulator
Generator
Backup fuse (odometer, clock and windshield)
Main fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Diode
Starting circuit cut-off relay
Neutral switch
Sidestand switch
Fuel pump
O2 sensor
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Lean angle cut-off switch
Intake air temperature sensor
Coolant temperature sensor
Crankshaft position sensor
ECU
Cylinder #1 - injector
Cylinder #2 - injector
Cylinder #3 - injector
Cylinder #4 - injector
AI system solenoid
Cylinder #1, #4 - ignition coil
Cylinder #2, #3 - ignition coil
Spark plug
Speed sensor
Meter assembly
Oil level warning light
Neutral indicator light
Multi-function meter
Engine trouble warning light
High beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Left handlebar switch
Clutch switch
Pass switch
Dimmer switch
Windshield position switch
Turn signal switch
Horn switch
Horn
Front turn signal light (left)
Front turn signal light (right)
Hazard switch
Headlight relay 1
Headlight relay 2
Headlight assembly
Auxiliary light
Headlight
Taillight assembly
Tail/brake light
Rear turn signal light (left)
Rear turn signal light (right)
Rear brake light switch
Turn signal relay
Windshield drive unit
Radiator fan motor
Radiator fan motor relay
Parking lighting fuse
Hazard lighting fuse
Ignition fuse
Headlight fuse
Signaling system fuse
Radiator fan motor fuse
Windshield motor fuse
§
•
¶
ß
®
©
™
CYCLELOCK
Right handlebar switch
Front brake light switch
Light switch
Engine stop switch
Start switch
Fuel injection system relay
COLOR CODE
B .............Black
Br............Brown
Ch...........Chocolate
Dg...........Dark green
G.............Green
Gy...........Gray
L .............Blue
Lg ...........Light green
O.............Orange
P .............Pink
R.............Red
Sb ...........Sky blue
W ............White
Y .............Yellow
B/L ..........Black/Blue
B/R .........Black/Red
B/W.........Black/White
B/Y..........Black/Yellow
Br/B ........Brown/Black
Br/G ........Brown/Green
Br/L.........Brown/Blue
Br/R ........Brown/Red
Br/W .......Brown/White
Br/Y ........Brown/Yellow
G/B .........Green/Black
G/L..........Green/Blue
G/W ........Green/White
G/Y .........Green/Yellow
Gy/G .......Gray/Green
Gy/R .......Gray/Red
L/B ..........Blue/Black
L/G..........Blue/Green
L/R..........Blue/Red
L/W .........Blue/White
L/Y ..........Blue/Yellow
O/B .........Orange/Black
P/W.........Pink/White
R/B .........Red/Black
R/G .........Red/Green
R/L..........Red/Blue
R/W ........Red/White
R/Y .........Red/Yellow
W/B.........White/Black
W/Y.........White/Yellow
Y/B..........Yellow/Black
Y/G .........Yellow/Green
Y/L ..........Yellow/Blue
FJR1300 WIRING DIAGRAM (for Oceania)
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
z
{
Main switch
Rectifier/regulator
Generator
Backup fuse (odometer, clock and windshield)
Main fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Diode
Starting circuit cut-off relay
Neutral switch
Sidestand switch
Fuel pump
O2 sensor
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Lean angle cut-off switch
Intake air temperature sensor
Coolant temperature sensor
Crankshaft position sensor
ECU
Cylinder #1 - injector
Cylinder #2 - injector
Cylinder #3 - injector
Cylinder #4 - injector
AI system solenoid
Cylinder #1, #4 - ignition coil
Cylinder #2, #3 - ignition coil
Spark plug
Speed sensor
Meter assembly
Oil level warning light
Neutral indicator light
Multi-function meter
Engine trouble warning light
High beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Left handlebar switch
Clutch switch
Pass switch
Dimmer switch
Windshield position switch
Turn signal switch
Horn switch
Horn
Front turn signal light (left)
Front turn signal light (right)
Hazard switch
Headlight relay 1
Headlight relay 2
Headlight assembly
Headlight
Taillight assembly
Tail/brake light
Rear turn signal light (left)
Rear turn signal light (right)
Rear brake light switch
Turn signal relay
Windshield drive unit
Radiator fan motor
Radiator fan motor relay
|
}
~
å
ç
†
¢
£
§
•
Ignition fuse
Headlight fuse
Signaling system fuse
Radiator fan motor fuse
Windshield motor fuse
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuel injection system relay
COLOR CODE
B .............Black
Br............Brown
Ch...........Chocolate
Dg...........Dark green
G.............Green
Gy...........Gray
L .............Blue
Lg ...........Light green
O.............Orange
P .............Pink
R.............Red
Sb ...........Sky blue
W ............White
Y .............Yellow
B/L ..........Black/Blue
B/R .........Black/Red
B/W.........Black/White
B/Y..........Black/Yellow
Br/B ........Brown/Black
Br/G ........Brown/Green
Br/L.........Brown/Blue
Br/R ........Brown/Red
Br/W .......Brown/White
Br/Y ........Brown/Yellow
G/B .........Green/Black
G/L..........Green/Blue
G/W ........Green/White
G/Y .........Green/Yellow
Gy/G .......Gray/Green
Gy/R .......Gray/Red
L/B ..........Blue/Black
L/G..........Blue/Green
L/R..........Blue/Red
L/W .........Blue/White
L/Y ..........Blue/Yellow
O/B .........Orange/Black
P/W.........Pink/White
R/B .........Red/Black
R/G .........Red/Green
R/L..........Red/Blue
R/W ........Red/White
R/Y .........Red/Yellow
W/B.........White/Black
W/Y.........White/Yellow
Y/B..........Yellow/Black
Y/G .........Yellow/Green
Y/L ..........Yellow/Blue
FJR1300 WIRNING DIAGRAM (for Europe)
4
R/G
R
R
A
R
W
W
W
2
(BLACK)
W
W
W
R
3
W
B
W
W
R
R
ON
OFF
P
L/Y L/B
L L/R
Br/R
B L/Y
L/R L
Br/R
B
(RED)
(RED)
B
R
Br
Br/L
L
B/Y
Sb
L/Y
R
R
C
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
D
E
W Y/L R
R/G
R Y/L W
R/G
R/L R/B G/B
L/B O/B L
G/B R/B R/L
L O/B L/B
SUB-WIRE
HARNESS 1
WIRE HARNESS
L/G
SUB-WIRE
HARNESS 1
WIRE HARNESS
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 2
8
L/W
L/W
B
B
(BLUE)
R/W
B
Sb
0
B
9
B/L
W
Gy/G B/L
B
B
Gy/G
L/G
B
E
L
O
(DARK GRAY) (DARK GRAY)
R/B D R/B
B
R/L R/B
P
B
B
B
B
B
B
B
B
B
B
B
B
R/B
R/W L/W
•
B
B
B
B
B
B
B1
B
£
R/W Br
R/B B
G/Y L/W
(BROWN)
(BROWN)
R/Y
L
L/B
R/Y
L
L/B
(BROWN)
Br/L
¶
Br R/W
B R/B
L/W Y
B
B
B
(BLACK)
¢
L
R/L B
©
(BROWN)
Br
R/Y
L/B
Br
B
B
(BLACK)
G/Y
G/Y
A
G/Y
Br/W G/B
P R/Y
B Lg
R/W
~
Br/R
Br/G
Br/G
A
Br/G
L/R
L/B Br/W
R/Y P
Lg B
Br/W
Br/G
Dg Y
Ch Sb
B/Y L/Y
Y Dg
Sb Ch
L/Y B/Y
(BLUE)
(BLUE)
x
{
L/R
Y E Y
R/L L/B
(GRAY)
R/B
G/B
L/B
O/B
R
O/B D O/B
L/Y
h
L/Y
B/Y
i
R/G
C
R/G
G/W
A
G/W
j
UP
P/W E P/W
L
B/L
P
(GRAY)
S
Br/R
G/Y
Y/B
Br/R
Br/W
Y/L
B/W
DOWN
B/Y
P
B/L
Br/R R/W
W
G/W
L
(BLACK)
G/W B/L
(BLACK) (BLACK)
Y
y
Y
L/B
R/Y
Y/B
Br
Y
Y/B
G/L
Y/B A Y/B
(BROWN)
G/B
Lg
Sb
Dg Ch
Br/W
G/L
Y
G/B G B
Br/Y Br/R
Z
G
G/B
(BLACK)
k
Dg
Br/W
Ch
k
Dg
Br/W
Ch
Dg
Br/W
Ch
Br
R/W
P
R/G
G/W
W
Y
Ch
B
Ch
Ch
Dg
L/R B L/R
B/R R/B
[
Y/L
Y/L C Y/L
B/W
B/W A B/W
O
W
C
W
ON
OFF
Dg
B
Dg
Lg
P
Br
n
Sb B Sb
Lg B Lg
B/R
R/B
Y
Br/R
G/B
A
G/B
p
Y
B
X
B
Y
A
Y
o
R/Y
G/L
L/B
Br/W
A
Br/W
L B L
L
\
]
R/B
`
a
b
B/L
W/Y
W
B/R
R/B
Dg
Y
L/R
Ch
Dg
L/R
t
L/R
Y G
vw
u
u
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
W
G
Y
rr
B L/R
(BLACK)
Y G
q
B L
Y
Ch Dg
Ch
B L/R
B
B
s s
B
B
c
m
G
Y
l
B
B
B
B
B
B
B
B
T
V
U
V
Gy/R
L
B
B
L/R B
Y
Dg Ch
B3
L W/Y
W L/Y
B/L
B/L
R/W
Br Br/R
R/W
Y/G
B/L
Lg
A
Lg
R/L
N
(BLACK)
g
O/B
R/LO/B
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
B/L E B/L
L D L
K
f
e
R/L
Gy
R/Y
G/L
Br/Y
B
Br/Y
R
B/L
Y
L
L/B
O
Gy/R
Br/W B/L
L/B A L/B
R/Y A R/Y
B
B
(BROWN)
Br/W
B/R
R/B
Q
L/B D L/B
Br
Br/G
(BLACK) (BLACK)
B
(GRAY)
(BLACK)
B/L
B/L
B/Y
L/Y
d
å
L
A
L
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
B1 G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
R/L
L/Y
R/W
B/Y
B1
L/W
L
B/L
P/W
R/L
R/LG/B
M
R/W A R/W
G/Y
Sb Br/Y R
B Lg Br/R
J
R/W Y/G B/L
R/W
L
Gy
B
R/Y
}
R Br Sb
Br/R Lg B
I
P B/L L
(GRAY)
L
z
H
(BLACK)
Br
Br/L
Sb
Lg
R/B
B/R
B
B/L
G
Y B/L
P/W B/L L
R
L/Y
B
L/Y
(BLACK)
L W/B
B/L
W/B E W/B
G/B
Gy
B
R/L
R/L
L/Y
B R/B
R/L
B
W L/Y
(BLACK)
™
R/L
L/Y
L
W/B
B/L
D
R/B
•
L
ç
|
B
L
R
Gy
B/L
R/L G/W
G/W B
†
Br/L
Br/L
B
L
R
R/B
C
B
R
R/B
®
ß
Y
R/W
R/L
R/W
L/Y
§
Br/B
L
R/B
(BLUE)
(GRAY)
B
B
Br/B
SUB-WIRE
HARNESS 2
Gy/G E Gy/G
Sb
F
R
(BLACK)
WIRE HARNESS
L/G
C
R/W
G/B D G/B
Br/B
Br/B
A
Br/B
Gy/G Y W/B
B/L P/W
(BLACK)
B
Br/R L/R
Br/Y
W/B Y Gy/G
P/W B/L
R/L D R/L
L/W
B
R
Br/L
Dg B Br/Y
L/Y
R/L R/B L L/R Ch Sb Lg
Br/G Lg Y R/Y
R/W
G/B Br/W
Sb
R
7
B
Br/B Y/B B/W G/W
L G/Y
L/B
L/W R/W
B
1
Lg R/B L/W
L/G L/Y Sb B/Y B
G/W B/W Y/B Br/B
L/B
G/Y L
R
6
(GRAY)
R
R/Y Y Lg Br/G
Br/W G/B
R/W
R
R
B
R
B
Lg
5
R
B
A
R/B
L/W
R
R
R/B
FJR1300 WIRNING DIAGRAM (for Oceania)
4
R/G
R
A
R
L/W
R
W
W
W
2
(BLACK)
W
W
W
W
B
R
3
W
W
R
1
R
Br
B
R
Br/L
R
R
L/Y
Br/R Y/B B/W G/W
L G/Y
L/B
Br/G Lg Y R/Y
R/W
G/B Br/W
L/Y
Dg B Br/Y
R/L R/B L L/R Ch Sb Lg
SUB-WIRE
HARNESS 1
WIRE HARNESS
L/G
Br/Y B Dg
L/Y
Lg Sb Ch L/R L R/B R/L
W Y/L R
R/G
R Y/L W
R/G
R/L R/B G/B
L/B O/B L
G/B R/B R/L
L O/B L/B
SUB-WIRE
HARNESS 1
WIRE HARNESS
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 2
W/B Y Gy/G
P/W B/L
(BLACK)
WIRE HARNESS
SUB-WIRE
HARNESS 2
L/W
Gy/G E Gy/G
Sb
L/W
B
B
(BLUE)
R/W
Sb
0
B
B
B
Gy/G
B/L
W
Gy/G B/L
L/G
B
L
E
O
(DARK GRAY) (DARK GRAY)
R/B D R/B
R/B
R/L
(BLUE)
B
R/W
R/L R/B
(GRAY)
W/L
Br/L L/Y
P
G/B D G/B
F
R/B
R/W
†
R
R/B
C
B
R
R/B
L/W
¢
R
R/W B/R
R/W B
B/W L/W
G/W B/W
(BLACK)
(BLACK)
R/L B
§
£
Y
Br
B
B
å
Br/L
R
(BLACK)
|
R/W
G/Y
G/Y
A
G/Y
Br/G
A
Br/G
Br/W G/B
P R/Y
B Lg
L/B Br/W
R/Y P
Lg B
Dg Y
Ch Sb
B/Y L/Y
Y Dg
Sb Ch
L/Y B/Y
(BLUE)
(BLUE)
w
z
x
Br/W
Br/G
L/Y
g
h
B/Y
i
R/G
C
R/G
G/W
A
G/W
j
UP
L/Y
DOWN
B/Y
P
Y/B
Y/B
G/L
Y/B A Y/B
(BROWN)
G/B
Lg
Sb
Dg Ch
Br/W
L
B/L
P
(GRAY)
S
Br/R
G/Y
Y/B
Br/R
Br/W
Y/L
B/W
Br/R R/W
W
G/W
(BLACK)
G/L
Y
G/B G B
k
Dg
Br/W
Ch
k
p
G
G/B
Y
B
Y
Z
Dg
Br/W
Ch
Dg
Br/W
Ch
Br
R/W
P
R/G
G/W
W
ON
OFF
[
Y/L
Y/L C Y/L
B/W
B/W A B/W
O
W
C
W
Y
Dg
B
Dg
Lg
P
Br
n
Sb B Sb
Lg B Lg
Ch
B
Ch
Ch
B/R
R/B
Dg
B/R R/B
L B L
L
\
]
R/B
`
a
b
B/L
W/Y
W
B/R
R/B
Dg
Y
L
Ch
Ch
Y G
s
(BLACK)
Y G
q
B
L
Y
Ch Dg
uv
t
c
G
Y
t
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
W
Dg
r r
B
B
m
G
Y
l
B
B
B
B
B
B
B
B
T
V
U
V
Gy/R
L
B
B
L B
Y
Dg Ch
B3
L W/Y
W L/Y
B/L
B/L
R/W
Br Br/R
L
Br/R
G/B
A
G/B
R/L
N
R/W
Y/G
B/L
B/L
X
B
Y
A
Y
o
R/Y
G/L
(BLACK)
R
P/W E P/W
Lg
A
Lg
O/B
R/LO/B
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
G/W B/L
L/B
R/Y
Br
Y
Br/Y Br/R
B/R
R/B
R
O/B D O/B
Gy
B/L E B/L
L D L
(BLACK) (BLACK)
Y
Br/W
A
Br/W
Sb Br/Y R
B Lg Br/R
R/L L/B
(BLACK)
f
R/L
(GRAY)
R/B
G/B
L/B
O/B
K
G/L
Br/Y
B
Br/Y
R Br Sb
Br/R Lg B
Y E Y
L/B
O
Gy/R
Br/W B/L
L/B
Y
Br/W
y
B/L
Y
L
R/Y
e
L/B A L/B
R/Y A R/Y
B
B
(BROWN)
(BLACK) (BLACK)
Sb
Lg
R/B
B/R
B
Q
L/B D L/B
Br
Br/G
B
(GRAY)
(BLACK)
B/L
B/Y
L/Y
d
L
B
L
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
W/L G/YY/G B/Y W
B/L Y/B L/Y G/W Gy Y/L R/L
Br/R
R/L
L/Y
R/W
B/Y
W/L
L/W
L
B/L
P/W
R/L
R/LG/B
M
B/L
R/Y
R/W
G/Y
B
L
Gy
B
R/W A R/W
Br/L
L
A
L
J
(GRAY)
{
L
(BLACK)
R/W Y/G B/L
}
Br/R
L
R/W
I
P B/L L
Br
Br/L
Br/R
H
~
R
B/L
G
Y B/L
P/W B/L L
L/Y
B
L/Y
Br/B
Br/B
A
Br/R
L W/B
B/L
W/B E W/B
G/B
Gy
B/W
R/L
R/L
L/Y
B R/B
R/L
Br/L
W L/Y
(BLACK)
•
ç
L
W/B
B/L
R/L G/W
L
Br R/W
B R/B
L/W Y
Gy
B/L
D
R/B
R/L
L/Y
Br/Y
Gy/G Y W/B
B/L P/W
(BLACK)
L/G
C
R/W
9
(RED)
G/W B/W Y/B Br/B
L/B
G/Y L
Sb
8
W/L
L/Y
(RED)
R/Y Y Lg Br/G
Br/W G/B
R/W
Lg R/B L/W
L/G L/Y Sb B/Y L/W
R/L D R/L
B
B
L/B
L/Y
Sb
R
L/W
B
B
E
L/W R/W
B
ON
OFF
B/Y
7
R
D
R
R
6
(GRAY)
C
R
R
R
B
Lg
5
R
B
A
R/B
L/W
R
R
R/B
FJR1300R WIRING DIAGRAM
4 clock & windshield)
Backup (odometer,
R/G
R
R/B
L/W
R
R
A
R
L/W
B
R
W
W
W
Reg/
2
Rect.
(BLACK)
W
W
W
W
B
R
3
Gen.
W
W
R
R
R
R
R
Br
ON
OFF
R
Br/L
B
L/B
L/Y
W/L
L/Y
(RED)
(RED)
Sb
L/Y
Br/G Lg
R/Y
R/W
G/B Br/W
L/Y
R/L R/B L
Dg B Br/Y
Ch Sb Lg
Br/Y B Dg
Lg Sb Ch
L/Y
L R/B R/L
W Y/L R
R/G
EE
D
D
R Y/L W
R/G
R/L R/B G/B
L/B O/B L
G/B R/B R/L
L O/B L/B
SUB-WIRE
HARNESS 1
SUB-WIRE
HARNESS 1
WIRE HARNESS
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 2
L/W
Switch
C
Sb
L/W
Sb
0
Diode
B
B
Starter
Motor
B
E
Gy/G
B/L
W
Gy/G B/L
L/G
B
L
INJECTORS
E
(DARK GRAY) (DARK GRAY)
(BLUE)
R/W
D
R/B D R/B
(GRAY)
D
G/B D G/B
Cylinder
ID
Sensor
RIGHT
¢ HANDLEBAR SWITCHES
Front
£
Brake
R
R/B
C
B
R
R/B
Engine
§
Stop
R
G/W B
L
•
Start
R/L
L/Y
Y
R/L B
Br
Fuel Pump
B
R
Br/L
P B/L L
Ignition
}
Br/L
Dg
R/Y
B
Br/W L/Y Lg
Ch B/Y Sb P G/B
R/W
B/Y
L/Y
G/Y
L
G/Y
A
G/Y
L/Y
A
Br/L
{ Marker
Tail/
B
L
Rear
v
Brake
L
w
Br/W
Br/G
Y/B
P
Lg
Sb
Dg Ch
Br/W
B/L
A
Headlight G/L
Relay #2o
B/R
R/B
G
G/B
Y
B
Dg
Br/W
Ch
Dg
Br/W
Ch
j
R/W
P
R/G
G/W
W
Y/L
B/W
B3
Br/R R/W
R/W
G/W
HORNS
ON
OFF
Ch
B
L B L
L
Dg
TAILLIGHTS
r
L
Y
Ch Dg
t Right
u Turn
W
Ch
Tail/s
brake
B
sLeft
B
G
Y
B
l
Right
k
Left
level
B
FRONT SIGNAL
LIGHTS
Turn
B
BB
B
B
B/W A B/W
IGNITION COILS and
SPARK PLUGS
C
R/B
Meter Assembly
B
#1 T
& #4
V
#2 U
& #3
V
Gy/R
Right
a
L
b
Dash light
(BLACK)
Y G
q q
B
High]
Beam
R/G B/W
Br/R
W
R/W G/W Y/L Lg Y Ch Dg L
c
Oil
G
Y
B/W
B/L
W/Y
W
L
HEADLIGHTS
p
B
L
Dg
Y G
Y/L C Y/L
Left`
Dg
B
B
A
Y/L
Engine
\
Ch
B/R
R/B
Lg
W
C
C
W
B/R
R/B
Ch
Oil
Y
Multifunction
[
Meter
L W/Y
W L/Y
B/L
B/L
R/B
Speed Sensor
R/W
Br Br/R
O
B
BB
B
Dg Ch
L B
Y
Dg Ch
Br/R
(BLACK)
Br
Br
Dg
B
B
L Y
R
Air Injection
SSolenoid
Br/R
G/Y
Y/B
P
j
Hazard
m
Switch
Sb B Sb
Lg B Lg
Sb Br/Y R
B Lg Br/R
(GRAY)
Barbarian
Jumper
Neutral
Z
Dg
Br/W
Ch
R/L
Y/R
LTemp
Coolant
X
B
B/R R/B
R Br Sb
Br/R Lg B
Br/W
R
4
O/B
R/LO/B
ECU
N
R/W
Y/G
B/L
A
Y
x
E
P/W E P/W
L
B/L
P
Br/R
G/B
A
G/B
(BLACK)
Sb
Lg
R/B
B/R
B
W/B
B/L
L
Y
P/W
P
Br/W
G/W
Y/G
W/Y
Gy/G
E
D
G/W B/L
A
Y/B
G/L
Y/B A Y/B
G/L
Y
G/B G B
A
Br/Y Br/R
Windshield
Drive Unit
D
O/B D O/B
Gy
B/L E B/L
L D L
R/L
R/L L/B
Lg
Headlight
Br
Y
Br/W
A
Br/W
B
E
Y E Y
A
C A
Lg
DOWN
B/Y
R/G
C
R/G
G/W
A
G/W
n
Relay #1
(BROWN)
Br/W
Br/Y
B
Br/Y
Horn
i
L/B
R/Y
R/Y
G/L
L/B
Y
Turn
Signal
Relay
B/L
Y
L
Q
3
L/B
(GRAY)
R/B
G/B
L/B
O/B
Br/W B/L
Turn
Signal
h
UP
G/B
A
A
L/B A L/B
R/Y A R/Y
B
B
(BROWN)
(BLACK) (BLACK)
B
D
L/B D L/B
O
Gy/R
Br
Br/G
y
Fan Motor
Windshield
Position
g
f
Dimmer
L/Y
B/Y
L
(BLACK)
(BLACK) (BLACK)
Br/G
A
Br/G
(GRAY)
(BLACK)
Br/G
A
L/W
Y W/Y P P/W R/W Br/W B/W W/B Gy/G L
O/B L/B G/B R/B
B3 Gy/R O
W/L G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy Y/R R/L Y/R Br/R
R/L
L/Y
R/W
B/Y
W/L
L/W
L
B/L
P/W
R/L
R/LG/B
M
Intake K
Air Temp
Dg
R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
|
Hazard
Br/L
Gy
B
P
2
G/B
Gy
B/L
R/Y
e
Clutch
L
E
W/B E W/B
B/L
d
LEFT HANDLEBAR
SWITCHES
G/Y
B
L
J
Lean Angle cut- off
A
R/W A R/W
R/Y
R/W
z
A
A
L
(BLACK)
R/W Y/G B/L
~
Headlight
Br/B
L
R/W
I
Atmos. Press.
Br
Br/L
Br/B
H
(GRAY)
A
Fan
Relay
G
(BLACK)
å
Signals/Brake
R
B/L
Intake Air Press.
B
Br/B
Br/B
A
Br/B
Y B/L
P/W B/L L
L/Y
B
L/Y
ç Fan
Rad
L W/B
B/L
Throttle Position
B/W
B
B
W L/Y
(BLACK)
R/L
R/L
L/Y
B R/B
R/L
Br/L
L
W/B
B/L
D
R/B
F.I.
¶
Relay
Windshield
†
Br/Y
F
Gy
B/L
R/L G/W
CB
R/L
R/L R/B
Crankshaft
Position
Sensor
W/L
R/B
R/W L/W
O
1
R/B
O2 Sensor
Neutral
Switch
Br/L L/Y
(BLACK)
SUB-WIRE
HARNESS 2
Gy/G E Gy/G
G
B
(BLUE)
R/W
9
(BLACK)
(BLACK)
WIRE HARNESS
D
R/W
B
R/W B/R
R/W B
B/W L/W
Gy/G Y W/B
B/L P/W
(BLACK)
L/G Sidestand
Starter
8 Relay
Br R/W
B R/B
L/W Y
W/B Y Gy/G
P/W B/L
R/L D R/L
B
B
B
L/G
Sb
L/W
B
Main
Sw.
B/Y
R
B
1
Br/B Y/B B/W G/W
L G/Y
L/B
WIRE HARNESS
L/W R/W
Battery
6
(GRAY)
G/W B/W Y/B Br/B
L/B
G/Y L
C
C
R
Fuel
7
Injection
R
R/Y
Lg Br/G
Br/W G/B
R/W
Lg R/B L/W
L/G L/Y Sb B/Y L/W
BB
R
R
R
AA
Starter cut-off relay
5
Main
R
Colour Code:
B..................Black
Br.................Brown
Ch................Chocolate
Dg................Dark Green
G..................Green
Gy................Gray
L ..................Blue
Lg.................Light Green
O..................Orange
P.................. Pink
R.................. Red
Sb.................Sky Blue
W..................White
Y...................Yellow
Lg
The "Barbarian Jumper Mod"
The "Barbarian Jumper Mod"
Index
Home
Tom Barber (aka Barbarian) and Dwayne Verhey (aka Torch) from the
FJROwners online forum figured out how to enable a North American spec'd
FJR1300 to have it's EFI's CO setting adjusted, like the European and OZ/NZ
models allow. On 03/05/03 Torch provided the following text and photos:
Note: there is a companion Web page documenting how to adjust the CO
setting.
The FJR has the capability to adjust the overall fuel injector map for each
individual cylinder right from the dashboard. The procedure is welldocumented in the European and Oceanic service manuals, and requires the
use of CO measuring instruments.
But the Yamaha decided to lock out this capability in the bikes they shipped
to North America. It was a conscious decision: they will tell a dealer how to
override the lock-out if the dealer can prove the need, but it's a big secret
from everyone else.
Not any more. This will explain how you can Europeanize (is that a word?)
your FJR so you can have it properly serviced at any shop. Or even at home if
you have the proper equipment. All you have to do is move one little wire:
the Barbarian Jumper (named after the nickname of the fellow who
discovered it.)
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (1 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
First, remove the seat and two left sidecovers. As with the dash panels,
Yamaha used a variety of fasteners on this job, including Allen head
fasteners, push-pin fasteners, and 1/4 turn Philips head fasteners. See your
owner's manual for a more complete description of removing each. Don't
forget the two underneath the sidecover.
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (2 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
Next, remove the airbox cover. At least all 4 of these are the same 1/4 turn
fastener. Unfortunately, the one indicated by the screwdriver is recessed and
a PITA.
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (3 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
With the covers out of the way, the ECU is now accessible. Squeeze the black
latch on the top of the connector as you pull it out of the ECU.
On the underside of the connector are 3 white bars. Using a fingernail or
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (4 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
small screwdriver, push the left one (as pictured) in about 1/32". This unlocks
the wires in the connector.
Pin #27 is the 5th from the left on the bottom row. It houses a yellow wire
with a red stripe -- 1/2 of the Barbarian Jumper. Carefully remove this wire
from the connector. Make sure you have the wire for pin 27 -- the other half
of the jumper is only 2 pins away at 29, and we want to leave that half there.
Do not pull on wires -- if they are pulled even slightly out you will not be able
to re-lock the connector. Also, the metal terminal ends are very fragile and
difficult to replace if you separate the wire from the terminal. Push the wire
out gently as shown in the next picture."
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (5 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
Using a small piece of stiff wire (I used some .030 MIG wire, but a paperclip
or safety pin would probably work) gently push up from the ECU side of the
connector to lift the wire to pin 27 and the white plug in pin 25. Do not force
anything! The metal terminal ends on the wires are fragile and easily
damaged. Lift the pin out with tweezers or needlenose pliers.
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (6 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
The plug is small. Very small. And bouncy. It can travel a surprising distance
when deflected off the airbox. If you drop it you are in for more fun than a
snipe hunt. Do not ask me how I know this. Use tweezers.
Put the plug in pin 27. Put the wire you removed in pin 25. Make sure they
are fully seated and then re-lock the connector by pressing the left hand (as
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (7 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
pictured) white bar on the top of the connector down until flush (about 1/32")
It does not take a lot of force, so if it doesn't want to go you probably have a
wire pulled slightly out. Make sure all the wires in the left 1/3 of the
connector are fully seated and try again.
When you are all done, insert the connector into the ECU until the latch
clicks. If you did it right, it should look like this now. Your FJR1300 is now
ready for you to tackle the CO Adjustment procedure, documented here also.
Note: No ECUs were harmed in the making of this web page.
Before attempting this mod there was a great deal of discussion and analysis
(on the FJROwners online forum) of the comparative wiring diagrams and
possible operating parameters of the unit. Then the signal levels of the
various ECU pins were sampled with a high impedance probe and oscilloscope
to clarify any ambiguities.
I may be curious, but I ain't stupid.
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (8 of 9) [15/05/2003 5:41:02 PM]
The "Barbarian Jumper Mod"
Nonetheless: all the standard disclaimers apply: Do this at your own risk. I
am not responsible if you let the smoke out of your ECU. YMMV. Etc.
-- Torch.
Copyright © 2003, by H. Marc Lewis, Tom Barber, and Dwayne Verhey.
All rights reserved.
http://www.micapeak.com/bike/FJR1300/howto/jumper.html (9 of 9) [15/05/2003 5:41:02 PM]
Installing Riv-Nut ports in the FJR's Headers
Installing Riv-Nut ports in the FJR's
Headers
Index
Home
On 03/05/03 Dwayne Verhey (aka Torch) from the FJROwners online forum
wrote this Web page describing how to install "Riv-nuts" into the FJR1300's
header pipes. This is required to properly modify the EFI's CO setting, like the
European and OZ/NZ models allow.
Note: there are companion Web pages documenting how to do the Barbarian
Jumper mod and how to adjust the CO setting.
These are riv-nuts (or rivet nuts, or thread inserts depending on the
manufacturer.) They are a hollow, threaded rivet that can be installed on the
headers "blind" -- that is, without removing the headers. Yamaha instructs North
American dealers to install these if it is necessary to check the CO adjustment of
the fuel injection system.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (1 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
This is a riv-nut tool. Similar to a standard pop rivet gun, but with
interchangeable adapters and anvils sized for the insert being installed. The
appropriate adapter is screwed into the tool, followed by the corresponding anvil.
In use the riv-nut is threaded onto the adapter, inserted into the hole, and
compressed against the anvil when the handle is squeezed to draw the adapter
inwards. After installation, the removal knob is turned counter-clockwise to
unscrew the adapter from the insert.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (2 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
First a hole is drilled into the pipe where the port is required. European and
Oceanic models have ports installed from the factory. Migmagal reports they are
located "About 5 inches after the cylinder exits on each tube" and Woody concurs
saying they are "about 125mm from the top of the exhaust ports". For clarity,
these pictures are of a sample installed on a piece of scrap 1 1/2" exhaust pipe.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (3 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
Here the riv-nut is assembled on the tool and inserted into the hole ready to go.
One squeeze of the handle is sufficient. Attempting to compress the riv-nut
further will only strip the threads. As described earlier, unscrew the tool from the
insert using the removal knob.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (4 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
The end result. The upper portion of the riv-nut has been mushroomed firmly
against the wall of the pipe, following the curve, providing a threaded port. I
chose 1/4"-20 NCT aluminium inserts for this example. Following this I inserted
an oxy-acetelene torch into the other end and adjusted it so flames were
shooting out the end past the insert and left it until the pipe started to glow a
dull red through most of it's length. The aluminium was unaffected, but I think I
would still choose steel or stainless inserts for the real installation to avoid
corrosion of dissimilar metals.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (5 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
The hole is sealed with a bolt when not in use. As can be seen from this picture,
the bolt may protrude into the pipe unless cut to length. Besides being a
potential for further restriction, the exposed threads could become clogged with
carbon deposits from the exhaust making future removal difficult or impossible. I
suggest trimming the bolt to avoid problems.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (6 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
When cutting a thread, it's a good idea to temporarily install a nut first. Cut the
thread off beyond the nut, then wind the thread past the end of the nut. If the
thread binds while removing the nut, make sure the thread is not protruding past
the nut and simply tap it against something solid to re-form the thread. In this
case, because the bolt is now so short, it was easier to set it on the anvil of the
vice and tap gently with a hammer.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (7 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
The trimmed bolt no longer protrudes into the pipe.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (8 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
In an effort to reduce any possible restriction, I tried cutting 1/2 the threaded
portion of a riv-nut off before installing it. The threads stripped out before it fully
mushroomed, resulting in this failed installation on the right. The insert is loose,
but cannot be removed and there are no threads left to seal it! The full threaded
length is required to properly install the insert.
Following Fastwally's description of the procedure given his Yamaha dealer, we
have all kind of been hung up on the riv-nut idea, myself included.
With all due respect to Yamaha, I offer this option which has no restriction to
exhaust flow. I drilled a 33/64" hole in the pipe, threaded a bolt through a nut,
inserted the protruding thread through the hole, and welded the nut to the pipe.
The bolt can then be withdrawn and cut to length. For the real thing, spring for a
stainless nut.
Caution: before arc welding on a motorcycle, unplug the ECU and disconnect the
battery!
Also visible in this picture is a bolt installed in the riv-nut.
(note: I also recommend remembering to turn on the argon before MIG welding!
The result will be much stronger and prettier that way. What can I say -- it was a
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (9 of 10) [15/05/2003 5:56:43 PM]
Installing Riv-Nut ports in the FJR's Headers
long night ;-)
-- torch
Copyright © 2003, by H. Marc Lewis and Dwayne Verhey.
All rights reserved.
http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (10 of 10) [15/05/2003 5:56:43 PM]
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement