Yamaha Automobile YZF-R6SR User manual

Yamaha Automobile YZF-R6SR User manual
EAS00010
YZF-R6R/YZF-R6SR
YZF-R6RC/YZF-R6SRC
SERVICE MANUAL
2002 by Yamaha Motor
Corporation, U.S.A.
First edition, December 2002
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-16-45
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
S This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
S Designs and specifications are subject to change without notice.
EAS00040
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.
2
1
3
4
5
8
6
7
EAS00008
1
2
GEN
INFO
SYMBOLS
SPEC
3
4
CHK
ADJ
CHAS
5
6
COOL
ENG
7
8
FI
ELEC
Symbols 10 to 17 indicate the following.
10
9
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
21
24
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
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
22
23
25
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
FI
7
ELEC
8
TRBL
SHTG
9
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE OF FI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-3
1-4
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS /PLATES AND COTTER PINS . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
1-7
1-7
1-7
1-8
1-8
1-8
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . 3-1
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-5
3-5
3-6
3-6
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . .
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR INTAKE SYSTEM SURGE TANKS . . . . . . . .
CHECKING THE THROTTLE BODY JOINTS . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10
3-10
3-16
3-18
3-19
3-21
3-22
3-24
3-25
3-27
3-29
3-30
3-31
3-31
3-32
3-32
3-33
3-33
3-34
3-35
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . .
3-39
3-39
3-40
3-41
3-42
3-43
3-43
3-44
3-45
3-46
3-47
3-48
3-50
3-51
3-53
3-55
3-57
3-58
3-58
3-58
3-58
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . .
3-59
3-59
3-64
3-66
3-67
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . .
4-1
4-3
4-3
4-5
4-6
4-7
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . .
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . .
4-9
4-9
4-10
4-12
4-13
4-13
4-13
4-14
4-15
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . .
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . .
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER .
4-16
4-16
4-17
4-18
4-21
4-23
4-26
4-28
4-28
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
4-45
4-45
4-48
4-49
4-50
4-51
4-56
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-58
4-59
4-59
4-60
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
4-63
4-63
4-65
4-65
4-66
4-29
4-30
4-32
4-34
4-36
4-38
4-39
4-40
4-41
4-43
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND GAS
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND GAS
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTING ROD AND RELAY ARMS . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . .
4-68
4-71
4-72
4-72
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-73
4-75
4-76
4-76
4-77
4-79
4-70
4-70
4-71
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-3
5-5
5-6
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
5-8
5-9
5-10
5-11
5-13
5-13
5-14
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5-19
5-19
5-20
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-21
5-23
5-24
5-26
5-28
5-29
5-29
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-31
5-31
5-33
5-34
5-35
5-35
5-36
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-38
5-38
5-40
5-40
5-40
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR . . . . . . . 5-41
REMOVING THE PICKUP ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
INSTALLING THE PICKUP ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . .
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-45
5-45
5-47
5-48
5-48
5-49
5-49
5-50
5-50
5-50
5-51
5-51
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE . . . . . . . . .
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-54
5-57
5-57
5-58
5-58
5-58
5-58
5-59
5-59
5-60
5-60
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-61
5-63
5-64
5-64
5-64
5-64
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . .
5-66
5-67
5-68
5-68
5-69
5-70
5-71
5-74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-78
5-79
5-79
5-82
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT
FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . .
5-83
5-83
5-89
5-89
5-90
5-90
5-91
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
6-12
6-13
6-13
6-15
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU’S SELF-DIAGNOSTIC FUNCTION . . . . . . . . . . . . . . . . . . . . . .
ALTERNATE INSTRUCTIONS OPERATION CONTROL
(FAIL-SAFE ACTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAIL-SAFE ACTIONS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2
7-3
THROTTLE BODIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE REGULATOR . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-27
7-31
7-31
7-32
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . .
7-35
7-35
7-35
7-36
7-37
7-4
7-4
7-5
7-6
7-12
7-32
7-33
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . .
TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . .
CHECKING THE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5
8-5
8-6
8-7
8-7
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14
8-14
8-15
8-16
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 8-22
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
8-26
8-26
8-28
8-30
SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
8-33
8-33
8-35
8-35
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-46
8-46
8-47
8-48
8-50
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-2
9-2
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . 9-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4
9-4
9-4
9-4
9-4
9-4
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
FAULTY LIGHTING OR SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL /BRAKE LIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . .
TAIL /BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT COME ON . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
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 LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare parts.
1-1
1
FEATURES
GEN
INFO
EAS00896
FEATURES
OUTLINE OF FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective 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
4
5
6
7
sensor
Fuel delivery hose
Fuel tank
Fuel pump
Fuel return hose
8 Intake
9
10
11
12
13
air pressure
sensor
Throttle position sensor
Fuel injector
Catalytic converter
Crankshaft position
sensor
Coolant temperature
sensor
14 Spark plug
15 Cylinder identification
16
17
18
19
20
1-2
sensor
Pressure regulator
Battery
ECU
Atmospheric pressure
sensor
Fuel injection system
relay
21 Engine trouble warn-
ing light
angle cut-off
switch
23 Air cut-off valve
22 Lean
FEATURES
GEN
INFO
EAS00897
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 284 kPa (2.84 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 and coolant temperature 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.
1
2
3
4
5
Fuel pump
Pressure regulator
Fuel injector
Throttle body
Intake
temperature
sensor
6 Throttle position sen-
sor
7 Intake air pressure
sensor
8 ECU
9 Atmospheric pressure
sensor
10 Coolant
temperature
sensor
11 Cylinder identification
sensor
12 Crankshaft
position
sensor
1-3
A Fuel system
B Air system
C Control system
FEATURES
1
2
3
4
GEN
INFO
INSTRUMENT FUNCTION
Multi-function display
The multi-function display is equipped with the
following:
S a speedometer (which shows the riding
speed)
S an odometer (which shows the total distance
traveled)
S two tripmeters (which show the distance
traveled since they were last set to zero)
S a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)
S a clock
S a self-diagnosis device
S a display brightness and engine speed warning light control mode
Multi-function display
“SELECT” button
“RESET” button
Engine trouble warning light
NOTE:
S Be sure to turn the key to “ON” before using the “SELECT” and ”RESET” buttons.
SFor the U.K. only: To switch the speedometer and odometer/tripmeter display between kilometers
and miles, press the “SELECT” button and “RESET” button together for at least two seconds.
Odometer and tripmeter modes
Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order:
ODO ! TRIP 1 ! TRIP 2 ! ODO
If the fuel level warning light comes on, the odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case,
pushing the “SELECT” button switches the display between the various tripmeter and odometer
modes in the following order:
F-TRIP ! TRIP 1 ! TRIP 2 ! ODO ! F-TRIP
To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at
least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically
and the display will return to the prior mode after refueling and traveling 5 km (3.1 mi).
Clock mode
Turn the key to “ON”.
To change the display to the clock mode, push the “SELECT” button for at least one second.
To change the display back to the prior mode, push the “SELECT” button.
To set the clock:
1. Push the “SELECT” button and “RESET” button together for at least two seconds.
2. When the hour digits start flashing, push the “RESET” button to set the hours.
3. Push the “SELECT” button, and the minute digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release it to start the clock.
1-4
FEATURES
1
2
3
4.
5.
GEN
INFO
Display brightness and shift timing indicator light control mode
This mode cycles through five control functions,
allowing you to make the following settings in
the order listed below.
1. Display brightness: This function allows you
to adjust the brightness of the multi-function
display to suit the outside lighting conditions.
2. Shift timing indicator light activity: This function allows you to choose whether or not the
indicator light should be activated and
Shift timing indicator light
whether it should blink or stay on when acti“SELECT” button
vated.
“RESET” button
3. Shift timing indicator light activation: This
function allows you to select the shift timing
at which the indicator light will be activated.
Shift timing indicator light deactivation: This function allows you to select the engine speed at which
the indicator light will be deactivated.
Shift timing indicator light brightness: This function allows you to adjust the brightness of the indicator light to suit your preference.
NOTE:
S To make any settings in this mode, you have to cycle through all of its functions. However, if the key is
turned to “OFF” or engine is started before completing the procedure, only the settings made before
the “SELECT” button was last pushed will be applied.
S In this mode, the multi-function display shows the current setting for each function (except the shift
timing indicator light activity function).
To adjust the display brightness
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then, after five seconds, release the “SELECT” button.
4. Push the “RESET” button to select the desired display brightness level.
5. Push the “SELECT” button to confirm the selected display brightness level. The control mode
changes to the shift timing indicator light activity function.
To set the shift timing indicator light activity function
1. Push the “RESET” button to select one of the following indicator light activity settings:
a. The indicator light will stay on when activated. (This setting is selected when the indicator light stays
on.)
b. The indicator light will flash when activated. (This setting is selected when the indicator light flashes
four times per second.)
c. The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected
when the indicator light flashes once every two seconds.)
2. Push the “SELECT” button to confirm the selected indicator light activity. The control mode changes
to the shift timing indicator light activation function.
1-5
FEATURES
GEN
INFO
To set the shift timing indicator light activation function
NOTE:
S The indicator light activation function can be set between 10,000 and 16,000 r/min.
S From 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min.
S From 12,000 r/min to 16,000 r/min, the indicatar light can be set in increments of 200 r/min.
1. Push the “RESET” button to select the desired engine speed for activating the indicator light.
2. Push the “SELECT” button to confirm the selected engine speed.
The control mode changes to the shift timing indicator light deactivation function.
To set the shift timing indicator light deactivation function
NOTE:
S The indicator light deactivation function can be set between 7,000 and 12,000 r/min in increments of
500 r/min.
S Be sure to set the deactivation function to a higher engine speed than for the activation function,
otherwise the shift timing indicator light will remain deactivated.
1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light.
2. Push the “SELECT” button to confirm the selected engine speed.
The control mode changes to the shift timing indicator light brightness function.
To adjust the shift timing indicator light brightness
1. Push the “RESET” button to select the desired indicator light brightness level.
2. Push the “SELECT” button to confirm the selected indicator light brightness level. The multi-function
display will return to the odometer, tripmeter or clock mode.
1-6
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
lip
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.
lip
spring
oil
grease
1-7
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-based
grease. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
1 Bearing
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
1-8
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
S lead
S coupler
S connector
2. Check:
S lead
S coupler
S connector
Moisture ! Dry with an air blower.
Rust/stains ! Connect and disconnect several times.
3. Check:
S all connections
Loose connection ! Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
S lead
S coupler
S connector
NOTE:
Make sure all connections are tight.
5. Check:
S continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112
NOTE:
S If there is no continuity, clean the terminals.
S When checking the wire harness, perform
steps (1) to (3).
S As a quick remedy, use a contact revitalizer
available at most part stores.
1-9
GEN
INFO
SPECIAL TOOLS
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.
NOTE:
S For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
S For others, use part number starting with “90890-”.
Tool No.
Flywheel puller
90890-01362
YU-33270-B
Adapter
90890-04089
YM-33282
Tool name/Function
Flywheel puller
Adapter
This tool is used to remove the generator rotor.
Sheave holder
90890-01701
YS-01880-A
This tool is used to hold the generator rotor
when removing or installing the generator rotor bolt or pickup coil rotor bolt.
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston pins.
Radiator cap
tester
90890-01325
YU-24460-01
Adapter
90890-01352
YU-33984
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
Steering nut wrench
90890-01403
YU-33975
This tool is used to loosen or tighten the steering stem ring nuts.
Damper rod holder
90890-01473
This tool is used to hold the damper rod assembly when loosening or tightening the
damper rod assembly bolt.
Pivot shaft
wrench
90890-01471
YM-01471
Pivot shaft wrench
adapter
90890-01476
Pivot shaft wrench
Pivot shaft wrench adapter
This tool is used to loosen or tighten the pivot
adjust bolt and engine mount adjust bolt.
1-10
Illustration
SPECIAL TOOLS
Tool No.
90890-01426
YU-38411
Rod puller
90890-01437
YM-01437
Rod puller
attachment
90890-01436
Fork seal driver
90890-01367
YM-33963
Fork seal driver
attachment
90890-01374
YM-8020-A
Vacuum gauge
90890-03094
YU-08030
Compression
gauge
90890-03081
YU-33223
Adapter
90890-04136
90890-03112
YU-3112
Oil pressure
gauge
90890-03153
YU-03153
Adapter
90890-03139
Tool name/Function
Oil filter wrench
This tool is needed to loosen or tighten the oil
filter cartridge.
Rod puller
Rod puller attachment
These tools are used to pull up the front fork
damper rod.
Fork seal driver weight
Fork seal driver attachment
This tool is used to install the front fork’s oil
seal and dust seal.
Vacuum gauge
This gauge is used to synchronize the carburetors.
Compression gauge
Adapter
These tools are used to measure engine
compression.
Pocket tester
This tool is used to check the electrical system.
Oil pressure gauge
Adapter
These tools are used to measure engine oil
pressure.
Digital circuit tester
90890-03174
This tool is used to check the electrical system.
Fuel pressure adapter
90890-03176
YM-03176
This tool is needed to measure fuel pressure.
Pressure gauge
90890-03153
YU-03153
This tool used is to measure fuel pressure.
1-11
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-04044
YM-04044
Tool name/Function
Piston ring compressor
This tool is used to compress piston rings
when installing the cylinder.
Carburetor angle driver
90890-03158
Valve spring
compressor
90890-04019
YM-04019
Attachment
90890-04108
YM-01253
Middle driven shaft
bearing driver
90890-04058
YM-4058
Mechanical seal
installer
90890-04078
YM-33221
This tool is used to turn the pilot screw when
adjusting the engine idling speed.
Valve spring compressor
Attachment
These tools are used to remove or install the
valve assemblies.
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water pump
seal.
Clutch holding tool
90890-04086
YM-91042
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
Valve lapper
90890-04101
This tool is needed to remove and install
the valve lifter.
Valve guide remover (φ4)
90890-04111
This tool is used to remove or install the valve
guides.
Valve guide installer (φ4)
90890-04112
This tool is used to install the valve guides.
Valve guide reamer (φ4)
90890-04113
YM-04113
90890-06754
YM-34487
This tool is used to rebore the new valve
guides.
Ignition checker
This tool is used to check the ignition system
components.
1-12
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-06756
YB-35956
90890-85505
ACC-1100105-01
Tool name/Function
Vacuum/pressure pump gauge set
This tool used to measure the vacuum pressure.
Yamaha bond No. 1215
This bond is used to seal two mating surfaces
(e.g., crankcase mating surfaces).
1-13
GEN
INFO
Illustration
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)
Maximum load (except motorcycle)
Standard
Limit
5SL3 (USA except for CAL)
5SL4 (CAL)
5SL7 (USA except for CAL)
5SL8 (CAL)
SSS
2,025 mm (79.7 in)
690 mm (27.2 in)
1,090 mm (42.9 in)
820 mm (32.3 in)
1,380 mm (54.3 in)
135 mm (5.3 in)
3,400 mm (133.9 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
182 kg (401 lb) (USA except for CAL)
183 kg (404 lb) (CAL)
193 kg (426 lb) (USA except for CAL)
192 kg (423 lb) (CAL)
SSS
SSS
SSS
SSS
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore
stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Liquid-cooled, 4-stroke, DOHC
600 cm3 (36.61 cu.in)
Forward-inclined parallel 4-cylinder
65.5
44.5 mm (2.58
1.75 in)
12.4 : 1
1,250 X 1,350 r/min
24 kPa (180 mmHg, 7.0872inHg)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1,550 kPa (15.50 kg/cm2,15.50 bar,
220.46 psi) at 400 r/min
SSS
Premium unleaded gasoline only
SSS
17 L (3.74 Imp gal, 4.49 US gal)
3.5 L (0.77 Imp gal, 0.92 US gal)
SSS
SSS
Wet sump
SSS
At 5_C (40_F) or higher
Yamalube 4 (20W40) or
SAE 20W40 type SE motor oil
At 15_C (60_F) or lower
Yamalube 4 (10W30) or
SAE 10W30 type SE motor oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Engine oil temperature
Relief valve opening pressure
Limit
SSS
SSS
SSS
SSS
3.4 L (2.99 Imp qt, 3.59 US qt)
2.4 L (2.11 Imp qt, 2.54 US qt)
SSS
SSS
2.6 L (2.29 Imp qt, 2.75 US qt)
240 kPa at 6,600 r/min
(2.4 kg/cm2 at 6,600 r/min)
(2.4 bar at 6,600 r/min)
(34.1 psi at 6,600 r/min)
96_C (205_F)
450 X 550 kPa (4.5 X 5.5 kg/cm2,
4.5 X 5.5 bar, 65.3 X 79.8 psi)
SSS
SSS
2-2
SSS
SSS
2
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
Limit
Formed
80 X 120 kPa (0.8 X 1.2 kg/cm2,
0.8 X 1.2 bar, 11.6 X 17.4 psi)
SSS
SSS
Trochoid
0.03 X 0.09 mm
(0.0012 X 0.0035 in)
0.03 X 0.08 mm
(0.0012 X 0.0031 in)
SSS
0.15 mm
(0.0059 in)
0.15 mm
(0.0059 in)
2.15 L (1.89 Imp qt, 2.27 US qt)
110 X 140 kPa (1.1 X 1.4 kg/cm2,
1.1 X 1.4 bar, 16.0 X 20.3 psi)
SSS
320 mm (12.6 in)
258 mm (10.2 in)
24 mm (0.94 in)
SSS
SSS
SSS
0.44 L (0.39 Imp qt, 0.47 US qt)
SSS
Single suction centrifugal pump
86/44
31/31 (1.955)
SSS
SSS
SSS
0.15 mm
(0.006 in)
Starting system type
Electric starter
Electric fuel injection
Type
Manufacturer
INP-250/4
NIPPON INJECTOR
SSS
SSS
CR9EK or CR10EK (NGK)
4
0.6 X 0.7 mm (0.0236 X 0.0276 in)
SSS
SSS
10.3 X 10.9 cm3 (0.63 X 0.67 cu.in)
SSS
SSS
0.05 mm
(0.002 in)
Spark plugs
Model (manufacturer)
Spark plug gap
Cylinder head
Volume
Max. warpage
quantity
2-3
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Chain drive (right)
23.008 X 23.029 mm (0.9058 X 0.9067 in)
22.967 X 22.980 mm (0.9042 X 0.9047 in)
0.028 X 0.062 mm (0.0011 X 0.0024 in)
SSS
SSS
SSS
0.08 mm
(0.0031 in)
Measurement A
33.45 X 33.55 mm (1.317 X 1.321 in)
Measurement B
25.12 X 25.22 mm (0.989 X 0.993 in)
33.40 mm
(1.315 in)
25.07 mm
(0.987 in)
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Intake camshaft lobe dimensions
Exhaust camshaft lobe dimensions
Measurement A
32.55 X 32.65 mm (1.282 X 1.285 in)
Measurement B
25.07 X 25.17 mm (0.987 X 0.991 in)
Max. camshaft runout
SSS
2-4
32.50 mm
(1.280 in)
25.02 mm
(0.985 in)
0.06 mm
(0.0024 in)
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Head Diameter
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Limit
RH2015 /120
Automatic
SSS
SSS
0.13 X 0.20 mm (0.0051 X 0.0079 in)
0.23 X 0.30 mm (0.0091 X 0.0118 in)
SSS
SSS
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
SPEC
Seat Width
Margin Thickness
24.9 X 25.1 mm (0.9803 X 0.9882 in)
21.9 X 22.1 mm (0.8622 X 0.8701 in)
SSS
SSS
1.14 X 1.98 mm (0.0449 X 0.0780 in)
1.14 X 1.98 mm (0.0449 X 0.0780 in)
SSS
SSS
0.9 X 1.1 mm (0.0354 X 0.0433 in)
0.9 X 1.1 mm (0.0354 X 0.0433 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
0.6 X 0.8 mm (0.0236 X 0.0315 in)
0.6 X 0.8 mm (0.0236 X 0.0315 in)
0.5 mm (0.02 in)
0.5 mm (0.02 in)
3.975 X 3.990 mm (0.1565 X 0.1571 in)
3.95 mm
(0.1555 in)
3.935 mm
(0.1549 in)
3.960 X 3.975 mm (0.1559 X 0.1565 in)
4.000 X 4.012 mm (0.1575 X 0.1580 in)
4.000 X 4.012 mm (0.1575 X 0.1580 in)
0.010 X 0.037 mm (0.0004 X 0.0015 in)
0.025 X 0.052 mm (0.0010 X 0.0020 in)
Valve stem runout
SSS
Valve seat width
Intake
Exhaust
0.9 X 1.1 mm (0.0354 X 0.0433 in)
0.9 X 1.1 mm (0.0354 X 0.0433 in)
2-5
4.042 mm
(0.1591 in)
4.042 mm
(0.1591 in)
0.08 mm
(0.0031 in)
0.10 mm
(0.0039 in)
0.04 mm
(0.0016 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake (inner)
Intake (outer)
Exhaust
Installed length (valve closed)
Intake (inner)
Intake (outer)
Exhaust
Compressed spring force
(installed)
Intake (inner)
SPEC
Standard
Limit
35.7 mm (1.41 in)
40.3 mm (1.59 in)
41.7 mm (1.64 in)
33.9 mm (1.33 in)
38.3 mm (1.50 in)
39.6 mm (1.56 in)
30 mm (1.18 in)
32.5 mm (1.28 in)
36.1 mm (1.42 in)
SSS
SSS
SSS
61.5 X 70.7 N (6.27 X 7.21 kg,
13.83 X 15.89 lb)
139.1 X 160.1 N (14.18 X 16.33 kg,
31.27 X 35.99 lb)
160 X 184 N (16.32 X 18.76 kg,
35.97 X 41.36 lb)
SSS
Intake (inner)
SSS
Intake (outer)
SSS
Exhaust
SSS
2.5_/1.6 mm
(0.06 in)
2.5_/1.8 mm
(0.07 in)
2.5_/1.8 mm
(0.07 in)
(outer)
Exhaust
SSS
SSS
Spring tilt
Winding direction (top view)
Intake (inner)
Intake (outer)
Exhaust
Cylinders
Cylinder arrangement
Bore
stroke
Compression ratio
Bore
Max. out-of-round
Counter clockwise
Clockwise
Clockwise
SSS
SSS
SSS
Forward-inclined, parallel 4-cylinder
65.5 mm
44.5 mm (2.58
1.75 in)
12.4 : 1
65.50 X 65.51 mm (2.5787 X 2.5791 in)
SSS
SSS
SSS
SSS
SSS
0.05 mm
(0.002 in)
2-6
ENGINE SPECIFICATIONS
Item
Piston
Piston-to-cylinder clearance
SPEC
Standard
0.010 X 0.035 mm (0.0004 X 0.0014 in)
Limit
Diameter D
65.475 X 65.490 mm (2.5778 X 2.5783 in)
0.055 mm
(0.0022 in)
SSS
Height H
Piston pin bore (in the piston)
Diameter
4 mm (0.16 in)
SSS
16.002 X 16.013 mm
(0.6300 X 0.6304 in)
0.5 mm (0.0197 in)
Intake side
16.043 mm
(0.6316 in)
SSS
SSS
15.991 X 16.000 mm
(0.6296 X 0.6299 in)
0.002 X 0.022 mm (0.0001 X 0.0009 in)
15.971 mm
(0.6288 in)
0.072 mm
(0.0028 in)
Ring type
Dimensions (B
T)
End gap (installed)
Barrel
0.90
2.45 mm (0.04
0.10 in)
0.25 X 0.35 mm (0.0098 X 0.0138 in)
Ring side clearance
0.030 X 0.065 mm (0.0012 X 0.0026 in)
SSS
SSS
0.60 mm
(0.0236 in)
0.115 mm
(0.0045 in)
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
2nd ring
Ring type
Dimensions (B
T)
End gap (installed)
Taper
0.8
2.5 mm (0.03
0.10 in)
0.7 X 0.8 mm (0.0276 X 0.0315 in)
Ring side clearance
0.030 X 0.065 mm (0.0012 X 0.0026 in)
SSS
SSS
1.15 mm
(0.0453 in)
0.125 mm
(0.0049 in)
Oil ring
Dimensions (B
T)
End gap (installed)
1.5
2.0 mm (0.06
0.08 in)
0.10 X 0.35 mm (0.0039 X 0.0138 in)
2-7
SSS
SSS
ENGINE SPECIFICATIONS
Item
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
SPEC
Standard
Limit
0.028 X 0.052 mm (0.0011 X 0.0020 in)
0.09 mm
(0.0035 in)
1 = Blue 2 = Black 3 = Brown 4 = Green SSS
Crankshaft
Width A
Width B
Max. runout C
51.85 X 52.55 mm (2.04 X 2.06 in)
268.8 X 270.0 mm (10.58 X 10.63 in)
SSS
Big end side clearance D
Big end radial clearance
Small end free play
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
0.160 X 0.262 mm (0.0063 X 0.0103 in)
0.028 X 0.052 mm (0.0011 X 0.0020 in)
0.32 X 0.50 mm (0.01 X 0.02 in)
0.034 X 0.058 mm (0.0013 X 0.0023 in)
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
0 = White 1 = Blue 2 = Black
3 = Brown 4 = Green
SSS
SSS
0.03 mm
(0.0012 in)
SSS
SSS
SSS
0.10 mm
(0.0039 in)
SSS
Wet, multiple disc
Outer pull, rack and pinion pull
Cable operation
Left-hand operation
10 X 15 mm (0.39 X 0.59 in)
SSS
SSS
SSS
SSS
SSS
Brown
2.9 X 3.1 mm (0.114 X 0.122 in)
SSS
2.8 mm
(0.110 in)
SSS
SSS
2.8 mm
(0.110 in)
SSS
6
Purple
2.9 X 3.1 mm (0.114 X 0.112 in)
2
1.9 X 2.1 mm (0.07 X 0.08 in)
7
SSS
2.2 X 2.4 mm (0.086 X 0.095 in)
1
SSS
50 mm (1.97 in)
6
2-8
SSS
SSS
0.1 mm
(0.0039 in)
SSS
SSS
0.1 mm
(0.0039 in)
49 mm
(1.93 in)
SSS
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
SPEC
Standard
Limit
Constant mesh, 6-speed
Spur gear
86/44 (1.955)
Chain drive
48/16 (3.000)
Left-foot operation
SSS
SSS
SSS
SSS
SSS
SSS
37/13 (2.846)
37/19 (1.947)
28/18 (1.556)
32/24 (1.333)
25/21 (1.190)
26/24 (1.083)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.02 mm
(0.0008 in)
0.02 mm
(0.0008 in)
SSS
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum/Guide bar
SSS
SSS
0.05 mm
(0.002 in)
Air filter type
Wet element
SSS
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
SSS
5PW (DENSO)
SSS
294 kPa (2.94 kg/cm2, 2.94 bar, 42.6 psi) SSS
2-9
ENGINE SPECIFICATIONS
Item
Throttle position sensor
Resistance
Output voltage (at idle)
Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play
lay (at the flange
of the throttle grip)
ID mark
Throttle valve size
Standard
SPEC
Limit
4.85 X 5.15 kΩ at 20_C (68_F)
0.63 X 0.73 V
SSS
38EIS (MIKUNI)
4
24 kPa (180 mmHg, 7.0872 inHg)
6 X 8 mm (0
(0.24
24 X 0
0.31
31 in)
SSS
SSS
SSS
5SL1 00 (5SL3/5SL7), 5SL4 10 (5SL4/5SL8) SSS
#100
SSS
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 X 90 kg (0 X 198 lb)
90 X 193 kg (198 X 426 lb)
(USA except for CAL)
90 X 192 kg (198 X 423 lb)
(CAL)
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
24_
86 mm (3.39 in)
SSS
SSS
SSS
Cast wheel
SSS
17 M/C
MT3.50
Aluminum
120 mm (4.72 in)
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Cast wheel
SSS
17 M/C
MT5.50
Aluminum
120 mm (4.72 in)
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Tubeless
120/60 ZR17 M/C (55W)
Pilot SPORT N (MICHELIN)
D208FL (DUNLOP)
SSS
SSS
SSS
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
SSS
SSS
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
SSS
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
SSS
SSS
1.6 mm
(0.06 in)
2-11
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X 90 kg (0 X 198 lb)
90 X 193 kg (198 X 426 lb)
(USA except for CAL)
90 X 192 kg (198 X 423 lb) (CAL)
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter
thickness
Min. thickness
Standard
SSS
SSS
SSS
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
SSS
SSS
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
SSS
SSS
SSS
1.6 mm
(0.06 in)
Dual disc brake
Right hand operation
DOT 4
2.3 X 11.5 mm (0.09 X 0.45 in)
SSS
SSS
SSS
SSS
298
SSS
SSS
4.5 mm
(0.18 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
5 mm (11.73
SSS
Brake pad lining thickness
4.5 mm (0.18 in)
Rear brake
Brake type
Operation
Brake pedal position (below the
bottom of the footrest bracket)
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter
thickness
Min. thickness
Limit
Tubeless
180/55 ZR17 M/C (73W)
Pilot SPORT B (MICHELIN)
D208L (DUNLOP)
Max. deflection
Master cylinder inside diameter
Caliper cylinder inside diameter
SPEC
0.20 in)
SSS
14 mm (0.55 in)
30.2 mm and 27 mm (1.19 in and 1.06 in) SSS
Single disc brake
Right foot operation
7 X 11 mm (0.28 X 0.43 in)
SSS
SSS
SSS
DOT 4
4.3 X 9.3 mm (0.17 X 0.37 in)
SSS
SSS
220
SSS
SSS
4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
5 mm (8.66
Max. deflection
SSS
Brake pad lining thickness
6.0 mm (0.24 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
12.7 mm (0.5 in)
38.1 mm (1.5 in)
2-12
0.20 in)
SSS
SSS
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)
Inner tube outer diameter
Inner tube bending limit
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)
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
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
120 mm (4.72 in)
SSS
SSS
SSS
249.3 mm (9.81 in)
No
244.3 mm
(9.62 in)
SSS
SSS
SSS
SSS
SSS
0.2 mm
(0.01 in)
SSS
Suspension oil “01”
0.49 L (0.43 Imp qt, 0.52 US qt)
106 mm (4.17 in)
SSS
SSS
SSS
8
7
1
SSS
SSS
SSS
10
9
1
SSS
SSS
SSS
9
7
1
SSS
SSS
SSS
100 mm (3.937 in)
240.3 mm (9.46 in)
8.3 N/mm (0.83 kg/mm, 46.49 lb/in)
0 X 120 mm (0 X 4.7244 in)
43 mm (1.69 in)
SSS
2-13
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm
Free play (at the end of the
swingarm)
Radial
Axial
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
SPEC
Standard
Limit
Angular bearing
SSS
Swingarm (link suspension)
Coil spring/gas-oil damper
SSS
SSS
60 mm (2.36 in)
SSS
168.5 mm (6.63 in)
157.5 mm (6.2 in)
98 N/mm (9.80 kg/mm, 548.87 lb/in)
0 X 60 mm (0.00 X 2.36 in)
No
1,200 kPa (12 kg/cm2, 12 bar, 174 psi)
SSS
SSS
SSS
SSS
SSS
SSS
1
4
9
SSS
SSS
SSS
20
10
5
SSS
SSS
SSS
20
10
1
SSS
SSS
SSS
SSS
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
SSS
532ZLV KAI (DAIDO)
116
35 X 45 mm (1.38 X 1.77 in)
SSS
2-14
SSS
SSS
SSS
150.1 mm
(5.91 in)
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
12 V
SSS
DC. CDI
10_ BTDC at 1,300 r/min
(USA except for CAL)
5_ BTDC at 1,300 r/min (CAL)
248 X 372 Ω at 20_C (68_F)/Gy-B
SSS
SSS
F8T926 (MITSUBISHI)
SSS
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
J0454 (DENSO)
6 mm (0.24 in)
0.17 X 0.23 Ω at 20_C (68_F)
4.8 X 7.2 kΩ at 20_C (68_F)
SSS
SSS
SSS
SSS
Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance/color
A.C. magneto
LLZ68 (DENSO)
14 V/300 W at 5,000 r/min
0.18 X 0.26 Ω at 20_C (68_F)/W-W
SSS
SSS
SSS
SSS
Rectifier/regulator
Regulator type
Model ((manufacture))
No-load regulated voltage
Rectifier capacity
Withstand voltage
Semi conductor short circuit
SH713AA (SHINDENGEN)
(
)
14.1 X 14.9 V
35 A
200 V
SSS
SSS
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity
Specific gravity
Manufacturer
Ten hour rate amperage
GT9B-4
12 V/8 Ah
1.320
GS
0.8A
SSS
SSS
SSS
SSS
SSS
Headlight type
Halogen bulb
Bulbs (voltage/wattage
quantity)
Headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
Licence light
Meter light
12 V 55 W
2
LED
1
12 V 21 W/5W
12 V 21 W
2
12 V 5 W
1
LED
1
System voltage
Ignition system
Ignition system type
Ignition timing
Crankshaft position sensor
resistance/color
CDI unit model (manufacturer)
2-15
2
SSS
SSS
SSS
SSS
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Indicator light
(voltage /wattage
quantity)
Neutral indicator light
High beam indicator light
Oil level indicator light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
LED
LED
LED
LED
LED
LED
LED
LED
1
1
1
2
1
1
1
1
Limit
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Constant mesh
SSS
SM-14 (MITSUBA)
0.6 kW
SSS
SSS
10 mm (0.39 in)
3.5 mm
(0.14 in)
SSS
Armature coil resistance
Commutator diameter
7.16 X 9.52 N (730 X 971 g,
25.77 X 34.27 oz)
0.0012 X 0.0022 Ω at 20_C (68_F)
28 mm (1.1 in)
Mica undercut
0.7 mm (0.03 in)
SSS
27 mm
(1.06 in)
SSS
Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768088-A (JIDECO)
180 A
4.18 X 4.62 Ω at 20_C (68_F)
SSS
SSS
SSS
Horn
Horn type
Model (manufacturer)
Max. amperage
Performance
Coil resistance
Plain
YF-12 (NIKKO)
1
3A
105 X 113 db/2 m
1.15 X 1.25 Ω at 20_C (68_F)
SSS
SSS
SSS
SSS
SSS
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE246BH (DENSO)
No
75 X 95 cycles/min.
21 W
2 + 3.4 W
SSS
SSS
SSS
SSS
SSS
Oil level switch
Model (manufacturer)
5SL (SOMIC ISHIKAWA)
SSS
Spring force
quantity
2-16
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Limit
Fuses (amperage
quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Backup fuse (odometer and clock)
Reserve fuse
40 A
1
15 A
1
20 A
1
15 A
1
15 A
1
15 A
1
10 A
1
40 A, 20 A, 15 A, 10 A
Fuel level sender
Model (manufacture)
Sender unit resistance-full
5PW (DENSO)
750 X 1,100 Ω
SSS
SSS
Starting circuit at-off relay
Model (manufacture)
Coil resistance
G8R-30Y-R (OMRON)
162 X 198 Ω
SSS
SSS
Headlight relay, Radiator fan motor
relay
Model (manufacture)
Coil resistance
ACA12115 (MATSUSHITA)
72 X 88 Ω
SSS
SSS
Fuel injection system relay
Model (manufacture)
Coil resistance
G8R-30Y-R (OMRON)
162 X 198 Ω
SSS
SSS
Water temperature sensor
Model (manufacture)
Resistance
K003T20191 (MITSUBISHI)
0.2898 X 0.3542 Ω at 80_C (176_F)
SSS
SSS
2-17
1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
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
** mm
0.03937
=
** in
2 mm
0.03937
=
0.08 in
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.
IMPERIAL
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Tightening
torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
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.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(_C)
55.997
14.2234
9 / 5+32
lb / in
psi (lb / in2)
Fahrenheit
(_F)
A: Distance between flats
B: Outside thread diameter
2-18
A
(nut)
B
(bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
6
15
30
55
85
130
mSkg
0.6
1.5
3.0
5.5
8.5
13.0
ftSlb
4.3
11
22
40
61
94
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Spark plugs
Cylinder head
Camshaft caps
Cylinder head cover
Camshaft cap oil check bolt
Reed valve cover
Air-cut valve stay
Camshaft sprockets
Connecting rod caps
Generator rotor
Timing chain tensioner
Timing chain tensioner cap bolt
Thermostat cover
Coolant hose joint
Water pump cover
Water pump
Radiator and frame
Radiator stay and crankcase
Oil pump cover
Oil pump
Oil pan
Oil pan (center)
Oil cooler
Engine oil drain bolt
Oil filter union bolt
Oil filter
Oil pump chain guide
Oil pipe
Throttle body joint
Air filter case cover
Air filter case and frame
Throttle body and throttle body
joint
Throttle body and air filter case
Exhaust pipe and cylinder head
Exhaust pipe and exhaust pipe
stay
Exhaust pipe and muffler
Exhaust pipe stay and frame
Crankcase (main journal)
Crankcase
Crankcase
Crankcase
Fastener
Thread
Q’ty
Q
ty
size
–
Nut
M10
M10
4
10
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
–
Bolt
Bolt
Bolt
Screw
Bolt
Clamp
M6
M6
M6
M8
M6
M6
M7
M7
M12
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M20
M14
M20
M20
M6
M6
M6
M5
M6
M4
2
20
6
1
4
1
4
8
1
2
1
2
2
2
2
2
1
3
3
12
1
1
1
1
1
2
2
8
6
1
4
Clamp
Nut
Bolt
M5
M8
M8
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M8
M8
M8
M6
M6
M8
2-19
Tightening torque
Nm
mSkg
ftSlb
13
1st 19
2nd 50
12
10
12
20
10
10
24
1.3
1.9
5.0
1.2
1.0
1.2
2.0
1.0
1.0
2.4
9.4
14
36
8.7
7.2
8.7
15
7.2
7.2
17
Remarks
Yamaha bond
No.1215
15 + 150_ 1.5 + 150_ 11 + 150_
75
12
7.0
12
10
10
12
7.0
10
12
12
12
12
63
43
70
17
12
12
10
3.0
10
3.0
7.5
1.2
0.7
1.2
1.0
1.0
1.2
0.7
1.0
1.2
1.2
1.2
1.2
6.3
4.3
7.0
1.7
1.2
1.2
1.0
0.3
1.0
0.3
54
8.7
5.1
8.7
7.2
7.2
8.7
5.1
7.2
8.7
8.7
8.7
8.7
46
31
51
12
8.7
8.7
7.2
2.2
7.2
2.2
4
8
1
3.0
20
20
0.3
2.0
2.0
2.2
15
15
1
1
10
2
13
2
20
34
2.0
3.4
See NOTE 2
14
1.4
12
1.2
24
2.4
15
25
1.0
8.7
17
See NOTE 1
TIGHTENING TORQUES
Item
Generator rotor cover
Clutch cover
Clutch cover
Pickup coil rotor cover
Clutch cable holder
Pickup coil rotor cover
Shift shaft cover
Breather plate
Stator coil
Pickup rotor cover and
clamp
Drive sprocket cover
Oil gallery bolt
Generator rotor cover and
stator coil lead clamp
Breather hose cover
Oil pipe
Crankshaft position sensor
Starter clutch
Clutch pressure plate
Clutch boss
Drive sprocket
Transmission bearing housing
Shift drum retainer
Shift shaft spring stopper
Shift rod
Shift rod
Shift rod joint
Shift arm
Pickup coil rotor
Starter motor
Neutral switch
Oil level switch
Speed sensor
Cylinder identification sensor
Fastener
Thread
Q’ty
Q
ty
size
SPEC
Tightening torque
Nm
mSkg
ftSlb
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Screw
M6
M6
M6
M6
M6
M8
M6
M6
M6
M6
9
9
1
5
2
1
6
3
3
1
12
12
12
12
12
15
12
12
10
7.0
1.2
1.2
1.2
1.2
1.2
1.5
1.2
1.2
1.0
0.7
8.7
8.7
8.7
8.7
8.7
11
8.7
8.7
7.2
5.1
Bolt
–
Screw
M6
M16
M6
3
2
1
10
8
10
1.0
0.8
1.0
7.2
5.8
7.2
Bolt
Bolt
Bolt
Screw
Bolt
Nut
M6
M6
M6
M8
M6
M20
4
2
2
3
6
1
12
12
10
32
8.0
70
1.2
1.2
1.0
3.2
0.8
7.0
8.7
8.7
7.2
23
5.8
51
Nut
M18
1
90
9.0
65
Screw
Bolt
Screw
Nut
Nut
Bolt
Bolt
Bolt
Bolt
–
Bolt
Bolt
Bolt
M6
M6
M8
M8
M6
M6
M6
M8
M6
M10
M6
M6
M6
3
2
1
1
1
1
1
1
2
1
2
1
1
12
10
22
10
6.5
10
10
35
10
20
10
10
10
1.2
1.0
2.2
1.0
0.65
1.0
1.0
3.5
1.0
2.0
1.0
1.0
1.0
8.7
7.2
16
7.2
4.7
7.2
7.2
25
7.2
14
7.2
7.2
7.2
Remarks
Yamaha bond
No.1215
Use a lock
washer
Use a lock
washer
Left thread
Yamaha bond
No.1215
NOTE 1:
Retighten the bolt at 1000 km (600 ml).
NOTE 2:
1. First, tighten the bolts to approximately 12 Nm (1.2 mSkg, 8.7 ftSlb) with a torque wrench.
2. Retighten the bolts 25 Nm (2.5 mSkg, 18 ftSlb) with a torque wrench.
3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7
mSkg, 20 ftSlb) again.
2-20
TIGHTENING TORQUES
Cylinder head tightening sequence:
Crankcase tightening sequence.
2-21
SPEC
SPEC
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Tightening
Item
Thread
size
Nm
mSkg
ftSlb
Upper bracket and front fork
Steering stem nut
Handlebar and front fork
Handlebar and upper bracket
Lower ring nut
Under bracket pinch bolt
Main switch and upper bracket
Front brake master cylinder cap stopper
Front brake hose union bolts
Front brake master cylinder and bracket
Windshield and front cowling
Front cowling and headlight assembly
Headlight and front cowling stay
Meter assembly and front cowling stay
Front cowling stay and frame
Front cowling stay and duct
Duct and joint
Surge tank joint (front)
Surge tank joint (rear)
Rear view mirror and front cowling
Cowling and inner panel
Cowlings and frame
Engine mount bolts (front)
Engine mount bolts (rear upper)
Engine mount bolts (rear lower)
Engine mount adjust bolt
Frame and rear frame
Inner panel and frame
Clutch cable lock nut (engine side)
Throttle cable adjust nut (handlebar side)
Pivot shaft and nut
Connecting rod and frame
Relay arm and connecting rod
Relay arm and swingarm
Rear shockabsorber and relay arm
Rear shockabsorber and bracket
Bracket and frame
Fuel pump and fuel tank
Fuel tank bracket and frame
Fuel tank bracket and fuel tank
Fuel tank and rear frame
Rider seat and frame
Coolant reservoir tank and generator rotor cover
Footrest bracket and frame
Rear footrest and frame
Rear footrest and muffler
Rear brake master cylinder and footrest bracket
M8
M28
M8
M6
M30
M8
M8
M4
M10
M6
M5
M5
M5
M5
M8
M5
M5
M4
M5
M6
M5
M6
M10
M10
M10
M16
M10
M5
M8
M6
M18
M10
M10
M10
M10
M10
M14
M5
M6
M6
M6
M6
M6
M8
M8
M8
M8
26
113
33
13
14
23
23
1.2
30
13
0.4
1.7
2.5
1.3
23
1.3
1.3
1.2
1.2
7
1.5
4.5
45
45
45
7
47
3.8
7
4.5
95
44
44
44
44
44
52
4
7
7
7
7
6.5
28
28
23
18
2.6
11.3
3.3
1.3
1.4
2.3
2.3
0.12
3.0
1.3
0.04
0.17
0.25
0.13
2.3
0.13
0.13
0.12
0.12
0.7
0.15
0.45
4.5
4.5
4.5
0.7
4.7
0.38
0.7
0.45
9.5
4.4
4.4
4.4
4.4
4.4
5.2
0.4
0.7
0.7
0.7
0.7
0.65
2.8
2.8
2.3
1.8
19
82
24
9.4
10
17
17
0.9
22
9.4
0.3
1.23
1.81
0.94
17
0.94
0.94
0.87
0.87
5.1
1.1
3.3
33
33
33
5.1
34
2.7
5.1
3.3
69
32
32
32
32
32
38
2.9
5.1
5.1
5.1
5.1
4.7
20
20
17
13
2-22
Remarks
See NOTE 1
TIGHTENING TORQUES
Item
Rear brake hose union bolt
Sidestand bracket and frame
Front wheel axle shaft and bolt
Rear wheel axle nut
Front brake caliper and front fork
Front brake disc and front wheel
Rear brake disc and rear wheel
Rear wheel sprocket and rear wheel drive hub
Brake caliper bleed screw
Pinch bolt (front wheel axle)
SPEC
Tightening
Thread
size
Nm
mSkg
ftSlb
M10
M10
M14
M24
M10
M6
M8
M10
M8
M8
30
61
91
110
40
18
30
100
6
18
3.0
6.1
9.1
11.0
4.0
1.8
3.0
10.0
0.6
1.8
22
44
66
80
29
13
22
72
4.3
13
Remarks
See NOTE 2
NOTE 1:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mSkg, 38 ftSlb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the lower ring nut to specification.
NOTE 2:
S Tighten wheel axle pinch bolts 2 and 1 to
specified torque.
S Retighten pinch bolt 2 to specified torque.
S Tap the outer side of the left fork leg with a rubber mallet to align it with the end of the wheel
axle.
S Tighten wheel axle pinch bolts 4 and 3 to
specified torque.
S Retighten pinch bolt 4 to specified torque.
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Connecting rod bolts and nuts
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Valve lifter surface
Piston cooler (O-ring)
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum bearing
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surface
Yamaha bond
No.1215
Crankcase mating surface
Yamaha bond
No.1215
Generator rotor cover (stator coil assembly lead grommet)
Yamaha bond
No.1215
Pickup rotor cover (crankshaft position sensor lead grommet)
Yamaha bond
No.1215
2-24
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Front wheel oil seal (right and left)
Rear wheel oil seal
Front axle shaft
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
Rear axle shaft
Rear brake pedal shaft
Sidestand pivoting point and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Rear frame thread
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Engine mount bolts (rear upper and lower)
Seat lock assembly
Shift pedal shaft
Shift shaft joint
2-25
COOLING SYSTEM DIAGRAMS
COOLING SYSTEM DIAGRAMS
1 Radiator
2 Oil cooler
2-26
SPEC
COOLING SYSTEM DIAGRAMS
1 Water pump
2 Oil cooler
3 Radiator
2-27
SPEC
COOLING SYSTEM DIAGRAMS
1 Oil cooler
2 Water pump
2-28
SPEC
COOLING SYSTEM DIAGRAMS
1 Radiator
2 Thermostat
2-29
SPEC
ENGINE OIL LUBRICATION CHART
ENGINE OIL LUBRICATION CHART
2-30
SPEC
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1 Oil level switch
2 Oil cooler
3 Relief valve
2-31
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Oil pump
Exhaust camshaft
Intake camshaft
Oil strainer
2-32
SPEC
LUBRICATION DIAGRAMS
1 Oil cooler
2 Oil strainer
3 Oil level switch
4 Oil pump
2-33
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Oil pump
3 Relief valve
2-34
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Cylinder head
Intake camshaft
Exhaust camshaft
Crankshaft
2-35
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Drive axle
2-36
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Right handlebar switch lead
Clutch cable
Main switch lead and left handlebar switch lead
Throttle cable (return side)
Throttle cable (pull side)
Front brake hoses
Throttle cables
Joint
Under bracket
A Pass the right handlebar switch lead inside the front
brake hoses and over the throttle cables.
B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward.
C Pass the clutch cable through the guide.
D Plastic locking tie shall be positioned at 10 mm
(0.39 in.) below from the upper bracket.
E Clamp the left handlebar switch lead to the front fork
with the plastic locking tie and cut the tip of the tie.
Clamp it to the protector section.
2-37
CABLE ROUTING
F Pass the horn lead by the outside of the throttle
cables and clamp it to the forefront of upper face of
the under bracket. And then route it under the front
brake hose and clamp it to the pawl of the under
cover.
G Clamp it at the position of 40 X 60 mm (1.57 X 2.36
in) from the upper face of the under bracket with the
plastic locking tie. Cut the surplus part of the clamp
tip leaving 2 X 4 mm (0.08 X 0.16 in). Point the tip
of the clamp to the outside of vehicle.
H Pass the throttle cables inside the front brake
hoses.
I Set in the coupler between the head light’s hollow
section and the duct.
SPEC
J Install the relay to the rib of the headlight.
(Location for the left and right relays is alternative.)
K To the wire harness
L To the front turn signal / position light (right)
M Set the sub wire harness in the joint.
N Do not catch the sub wire harness when the duct is
assembled.
O To the front turn signal / position light (left)
P Point the tip of the plastic locking tie to the front side
of the vehicle. Cut the tip leaving 2 X 10 mm (0.08
X 0.39 in).
Q Point the tip of the plastic locking tie under the under
bracket and rear side of the vehicle. Cut the tip leaving 2 X 10 mm (0.08 X 0.39 in).
2-38
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Throttle stop screw
Coolant reservoir tank hose
Crankshaft position sensor lead
Rear brake light switch lead
Water pump inlet hose
Clutch cable
Coolant hose protector
Hose clamp assembly
Hose clamp
A Pass the rear brake light switch lead outside of rear
engine mount bolt.
B Pass the ignition coil lead outside of the radiator
hose.
C Pass the coolant reservoir tank hose under the
frame and right side of the throttle body.
SPEC
D Pass the clutch cable inside of the coolant reservoir
tank hose and radiator return hoses.
E The punch mark starting point should be lower than
the clamp’s top end.
However, the aiming position of the punch mark
starting point should be 5 mm (0.20 in) below the
clamp’s bottom end.
F Pass the clutch cable inside of the radiator hose.
G Assemble as “ a ” shown below when clamping.
H Tip of the plastic locking tie shall be pointed to the
inner side at the rear part of the vehicle.
I Clamp the clutch cable so that it is positioned in this
range.
J Clamp the clutch cable by routing the upper end of
the clamp along with the bottom end of the hose
clamp assembly.
2-39
CABLE ROUTING
K Put and apply the hose clamp to it.
L Pass the crankshaft position sensor lead over the
throttle stop screw.
2-40
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Throttle cable (return side)
Throttle cable (pull side)
Starter motor lead
Canister hose (for CAL)
Balance hose (for CAL)
Canister (for CAL)
Coolant reservoir tank breather hose
Oil level switch lead
Sidestand switch lead
A.C. magneto lead
Radiator fan motor lead
Coolant reservoir tank
Coolant reservoir tank cover
Fuel tank drain hose
Fuel tank breather hose
Drive sprocket cover
SPEC
A Pass the main switch lead under the left handlebar
switch lead and then to the right side of the vehicle.
B Pass the throttle stop cable by the left side of the
sidestand switch lead, oil level switch lead, A.C.
magneto lead, fuel tank drain hose and fuel tank
breather hose, and then to the right side of the vehicle.
C Pass the fuel tank drain hose and fuel tank breather
hose inside of the reservoir tank breather hose and
reservoir tank hose, wire harness and throttle stop
cable and then route it by the out side of the starter
motor lead.
D To the throttle body.
E Route the coolant reservoir tank hose by the outside of the fuel tank drain hose and the fuel tank
breather hose.
2-41
CABLE ROUTING
F Pass the fuel tank drain hose and fuel tank breather
hose through the clamp of the coolant reservoir
tank.
G Projection allowance from the coolant reservoir
tank cover shall be 30 X 50 mm (1.18 X 1.97 in).
H 10 X 50 mm (0.39 X 1.97 in).
I Fasten the sidestand switch lead and oil level switch
lead with a clamp.
J Pass the coolant reservoir tank breather hose, oil
level switch lead and sidestand switch lead through
the clamp.
K Pass the sidestand switch lead, oil level switch lead
and A.C. magneto lead between the engine stay
and the engine.
L To the radiator fan motor relay and fuse box
SPEC
M Route it above the radiator hose.
N Pass the throttle cable between the guide of the
cover 2 and the frame.
O Pass the radiator fan motor lead through the hole of
the frame to the inner side of the vehicle.
P To the horn.
Q Route it below the coolant reservoir tank.
R Pass the coolant reservoir tank breather hose
through the hole of the coolant reservoir tank cover.
S Order of ups and downs means no object.
2-42
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Right handlebar switch lead
Sub wire harness
Cover 8
Ignition coil lead
Throttle position sensor coupler
Coolant reservoir tank hose
Throttle stop cable
Speed sensor lead coupler
Crankshaft position sensor lead
coupler
Fuel tank breather hose (except
for CAL)
Fuel tank drain hose
Fuel hose (return side)
Fuel pump 2 coupler
Fuel pump 1 coupler
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Starter motor lead
Fuel hose (feed side)
Canister hose (for CAL)
Crankcase breather hose
Air vent hose
Fuse box
Cover 7
Radiator fan motor relay
Radiator fan motor lead
Left handlebar switch lead
Main switch lead
Wire harness
Throttle cables
Throttle sub-lead 1 (white 6
poles)
2-43
SPEC
29 Throttle sub-lead 2 (black 6
poles)
30 Oil level switch lead coupler
(white 1 pole)
31 Sidestand switch lead coupler
(blue 2 poles)
magneto lead coupler
(white 3 poles)
33 Rear brake light switch lead coupler (brown 2 poles)
34 Neutral switch lead coupler
(connector 1 pole)
32 A.C.
CABLE ROUTING
A To the headlight
B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
C Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against the
plastic locking tie. Point the tip of the plastic locking
tie to the downward in the inner side of the vehicle.
D Route the head light and meter leads under the
frame’s lower part from the hollow section of the
cover 2.
E Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
F Connect the couplers (4 units) at the frame side
hole. Do not catch each lead and wire harness when
the cover 8 is attached.
SPEC
G From the radiator
H Pass the coolant reservoir tank hose through forward the starter motor lead and speed sensor lead.
I Pass the speed sensor lead coupler and crankshaft
position sensor lead coupler over the throttle stop
cable.
J Pass the fuel tank breather hose and fuel tank drain
hose under the fuel hose.
K To the rear brake light switch lead.
L To the neutral switch
M Insert the wire harness wrapping clamp to the frame
hole.
N Pass the battery negative lead over the wire harness.
O There should be no interference between the wire
harness and the tip of the rear frame attaching bolts.
2-44
CABLE ROUTING
P To the coolant reservoir tank
Q To the intake air temperature sensor (air filter case)
R To the oil level switch, sidestand switch and A.C.
magneto
S Install the wire harness wrapping clamp to the stay
of the throttle body.
T Pass the wire harness over the throttle air vent
hose.
U Pass the wire harness between frame and coolant
hose.
V Pass it through the frame hole.
W Do not catch the coupler when the air filter case is
assembled.
SPEC
X Clamp the wire harness, left and right handlebar
switch leads and main switch lead. Align the tapping
positions of three leads except the wire harness.
Point the tip of the clamp to the front side of the vehicle.
Y Sealing set of the cover can be either upper or lower
against the frame lower end. However, it should not
be caught.
Z Clamp the wire harness, main switch lead branch
section and radiator fan motor lead.
AA Branching leads to the fuse box and radiator fan
motor relay shall pass through the guide section
of the cover 2 under the wire harness and then to
the outside of the frame.
2-45
CABLE ROUTING
AB To the fuse box and fan motor relay
AC Pass the throttle cables over the cover 2.
AD Point the tip of the plastic locking tie to the rear
side of the vehicle.
AE To the main switch lead coupler
AF Tip of the plastic locking tie should point to the
downward outside of the vehicle.
AG Use the plastic locking tie to clamp the starter motor lead at the protector section.
AH Branching harness from the wire harness.
2-46
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
Battery
Battery positive lead
Starter relay
Turn signal relay
Pressure sensor
Tail/ brake light
Tool kit
Starting circuit cut-off relay
Battery box
ECU
Wire harness
Battery negative lead
Battery band
SPEC
A Push the starter motor lead in the clamping sections
(two points) or the battery box assembly and secure
it.
B Fit the plastic cover in the starter relay after the
flange bolts are installed.
C Make sure to clamp the wire harness. (Tighten it until the clamp latchet stops.)
D Install to the deepest position of the rib of the battery
box assembly.
E When installing the ECU, make sure to hook the
pawls of the battery box assembly (at four points).
F Hook of the battery box assembly shall hook on the
upper face of the fuse box. (It should not be put on
the side face.)
G Install the pin of the battery box assembly to its
base.
2-47
CABLE ROUTING
H The knob section should be positioned in this area.
I Pass the turn signal lead by the outside of the right
side attaching boss of the tail / brake light.
J Pass the turn signal light and license light leads between the rear side ribs of the battery box assembly
and to the rear part of the vehicle.
K Connect the turn signal lead couplers.
L Connect the license light leads.
M Route the branching lead to the license light behind
the tail / brake light left side attaching boss.
N Route the tail / brake light lead under the projection
part.
O Route the tail / brake light lead above the projection
part.
P There should be no significant difference between
right and left side of the tension rate on the band.
SPEC
Q Point the opening to the rear side of the vehicle.
R Connect the tail / brake light lead coupler.
S Install the starting circuit cut-off relay to the deepest
position after placing the tail / brake light lead and
turn signal lead in the guide.
T The hook of the battery box assembly should hook
on the surface.
U Route the fuse box lead under the ECU connection
coupler.
V Install the wrapping clamp of the wire harness to the
hole of the battery box assembly.
W Connect the negative lead and the wire harness.
2-48
CABLE ROUTING
SPEC
For California
1
2
3
4
5
6
Fuel pump assembly
Canister hose
Canister
Breather hose
Blance hose
Fuel tank drain hose
A Install the roll over valve until it contacts with the fuel
tank’s nipple.
B Install the O-ring with its lip pointed upward.
C Install the clip with its tab pointed in the upward
direction.
D Install the breather hose without projecting canister
nipple out of the breather hose.
E Install the clip with its tab pointed in the downward
direction.
2-49
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND
LUBRICATION CHART
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.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
INITIAL
NO.
ITEM
600 mi
(1,000 km)
or
1 month
REMARKS
ODOMETER READINGS
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
1
*
Valve clearance
(See page 3-10)
S Check and adjust valve clearance when
engine is cold.
2
*
Spark plugs
(See page 3-21)
S Check condition.
S Adjust gap and clean.
S Replace at 8,000 mi (13,000 km) or 12
months.
Ǹ
Replace.
Ǹ
Replace.
Ǹ
3
*
Crankcase ventilation
system
(See page 3-32)
S Check ventilation hose for cracks or damage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
4
*
Fuel line
(See page 3-32)
S Check fuel hoses for cracks or damage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
5
*
Exhaust system
(See page 3-33)
S Check for leakage.
S Tighten if necessary.
S Replace gasket(s) if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
6
*
Electronic fuel injection
(See page 3-16, 18)
S Check and adjust engine idle speed and
synchronization.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
7
*
Evaporative emission
control system**
S Check control system for damage.
S Replace if necessary.
8
*
Air induction system
(See page 7-35)
S Check the air cut-off valve, reed valve,
and hose for damage.
S Replace any damaged parts.
Every 26,600 mi (42,000 km)
Ǹ
Ǹ
Ǹ
Ǹ
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
** California only
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
NO.
1
ITEM
REMARKS
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Engine oil
(See page 3-24, 25)
S Replace (warm engine before draining).
Ǹ
Ǹ
2
*
Engine oil filter
cartridge
(See page 3-25)
S Replace at initial 600 mi (1,000 km) or 1
month, and thereafter every 8,000 mi
(13,000 km) or 12 months.
3
*
Air filter element
(See page 3-30)
S Check condition and damage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
S Check hoses for cracks or damage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
*
Cooling system
(See page 3-34, 35)
4
Ǹ
Ǹ
S Replace with ethylene glycol antifreeze
coolant every 24 months.
Replace.
5
*
Brake system
(See page 3-39, 40, 41,
43)
S Check operation, pad wear, and fluid
leakage.
S Correct if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
6
*
Clutch
(See page 3-29)
S Check operation.
S Adjust or replace cable.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
3-1
3
CHK
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
NO.
ITEM
REMARKS
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
7
*
Control cables
(See page 3-58)
S Apply Yamaha chain and cable lube or
engine oil 10W-30 thoroughly.
8
*
Swingarm pivot
bearing
(See page 4-75)
S Check bearing assembly for looseness.
S Moderately repack with lithium-soapbased grease every 16,000 mi (25,000
km) or 24 months.
Ǹ
Ǹ
Repack.
9
*
Rear suspension link
pivots
(See page 4-75)
S Check operation.
S Correct if necessary.
Ǹ
Ǹ
10
*
Shock absorber
assembly
(See page 4-71)
S Check operation and for oil leakage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
11
*
Front fork
(See page 3-50)
S Check operation and oil leakage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
12
*
Steering bearings
(See page 3-48)
S Check bearing assembly for looseness.
S Moderately repack with lithium-soapbased grease every 16,000 mi (25,000
km) or 24 months.
Ǹ
Ǹ
Ǹ
Ǹ
Repack.
Ǹ
13
Brake and clutch
lever pivot shafts
(See page 3-58)
S Apply lithium-soap-based grease (all-purpose grease) lightly.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
14
Brake and shift pedal
pivot shafts
(See page 3-58)
S Apply lithium-soap-based grease (all-purpose grease) lightly.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
15
Drive chain
(See page 3-46)
S Check chain slack/alignment and condition.
S Adjust and lubricate chain with a special
O-ring chain lubricant thoroughly.
Wheel bearings
(See page 4-3)
S Check bearing for smooth operation.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Sidestand pivot
(See page 3-58)
S Check operation and lubricate.
S Apply lithium-soap-based grease (all-purpose grease) lightly.
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
16
*
17
Ǹ
Every 500 mi (800 km) or after washing the
motorcycle or riding in the rain.
18
*
Sidestand switch
(See page 8-4)
S Check operation and replace if necessary.
19
*
Chassis fasteners
(See page 2-22)
S Check all chassis fitting and fasteners.
S Correct if necessary.
Ǹ
Ǹ
20
*
Brake hoses
(See page 3-43)
S Check for cracks or damage.
Ǹ
Ǹ
21
*
Wheels
(See page 4-3)
S Check runout and for damage.
S Replace if necessary.
Ǹ
Ǹ
Ǹ
Ǹ
22
*
Tires
(See page 3-55)
S
S
S
S
Ǹ
Ǹ
Ǹ
Ǹ
Ǹ
S Replace.
Every 4 years
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Ǹ
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
NOTE:
From 24,000 mi (37,000 km) 36 months, repeat the maintenance intervals starting from 4,000 mi
(7,000 km) or 6 months.
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
S Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
3-2
SEATS
CHK
ADJ
EAS00039
SEATS
7 Nm (0.7 mSkg, 5.1 ftSlb)
Order
1
2
Job/Part
Q’ty
Removing the seats
Passenger seat
Rider seat
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
7 Nm (0.7 mSkg, 5.1 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
Removing the fuel tank
Rider seat
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Fuel tank overflow hose
Fuel tank breather hose
Fuel tank
Fuel pump
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
3-4
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:
S fuel return hose
S 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:
S 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:
S fuel pump
CAUTION:
S Do not drop the fuel pump or give it a
strong shock.
S Do not touch the base section of the fuel
sender.
3-5
FUEL TANK
CHK
ADJ
INSTALLING THE FUEL PUMP
1. Install:
S fuel pump
4 Nm (0.4 mSkg, 2.9 ftSlb)
NOTE:
S Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
S Always use a new fuel pump gasket.
S Install the fuel pump as shown in the illustration.
S Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:
S fuel hose
S fuel return hose
S fuel hose connector cover
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.
2. Install:
S fuel sender coupler
S fuel pump coupler
S fuel tank breather hose
S fuel tank overflow hose
3-6
COWLINGS
CHK
ADJ
COWLINGS
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Removing the cowlings
Rider and passenger seats
Front cowling inner panel (left and right)
Front turn signal light lead couplers
Side cowlings (left and right)
Side cowlings inner panels
(left and right)
Bottom cowlings (left and right)
Bottom cowling front cover
Front cowling
Rear view mirrors (left and right)
Windshield
Rear cowling
Frame side cover
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
2
2
2
2
Disconnect.
2
1
1
2
1
1
2
For installation, reverse the removal
procedure.
3-7
COWLINGS
CHK
ADJ
REMOVAL
1. Remove:
S rear cowling
S side cowlings
NOTE:
To remove the quick fastener, push its center
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:
S side cowlings
S rear cowling
NOTE:
To install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin a
in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-8
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “FUEL TANK”.
Removing the air filter case
Rider seat
Fuel tank
Air intake duct
Intake temperature sensor coupler
Throttle body hose
Air induction system hose
Clamp
Air filter case
Crankcase breather hose
2
1
2
1
4
1
1
3-9
Disconnect.
Disconnect.
Disconnect.
Loosen.
Disconnect.
For installation, reverse the removal
procedure.
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
S Valve clearance adjustment should be made
on a cold engine, at room temperature.
S When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
S air filter case
Refer to “AIR FILTER CASE”.
S bottom cowling
S side cowlings
Refer to “COWLINGS”.
S throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.
S air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
S radiator
S radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove
S ignition coils
S spark plugs
S cylinder head cover
S cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove
S pickup rotor cover 1
3-10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
4. Measure:
S valve clearance
Out of specification ! Adjust.
Valve clearance (cold)
Intake valve
0.13 X 0.20 mm
(0.0051 X 0.0079 in)
Exhaust valve
0.23 X 0.30 mm
(0.0091 X 0.0118 in)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
pickup 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:
S If the valve clearance is incorrect, record the
measured reading.
S Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 ! #2 ! #4 ! #3
A 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.
B Degrees that the crankshaft is turned counterclockwise
C Cylinder
D Combustion cycle
3-11
Cylinder #2
180_
Cylinder #4
360_
Cylinder #3
540_
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
5. Remove:
S camshafts
NOTE:
S Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chapter 5.
S When removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.
6. Adjust:
S valve clearance
a. Remove the valve lifter 1 and the valve pad
2 with a valve lapper 3 .
Valve lapper
90890-04101
NOTE:
S Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
S Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
b. Select the proper valve pad from the following table.
Valve pad
thickness range
Nos.
120 X
240
1.20
(0.0472) X
2.40 mm
(0.0945 in)
Available valve
pads
25 thicknesses in
0.05 mm (0.002 in)
increments
NOTE:
S The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
S Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
3-12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
c. Round off the original valve pad number according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number
= 148 (thickness =1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
e. Install the new valve pad 1 and the valve lifter 2 .
NOTE:
S Lubricate the valve pad with molybdenum disulfide grease.
S Lubricate the valve lifter with molybdenum disulfide oil.
S The valve lifter must turn smoothly when rotated by hand.
S Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 mSkg, 7.2 ftSlb)
3-13
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
S Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAMSHAFT” in chapter 5.
S Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
S First, install the exhaust camshaft.
S Align the camshaft marks with the camshaft
cap marks.
S Turn the crankshaft counterclockwise 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.
3-14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
INTAKE
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.12
0.13 X 0.20
0.21 X 0.25
0.26 X 0.30
0.31 X 0.35
0.36 X 0.40
0.41 X 0.45
0.46 X 0.50
0.51 X 0.55
0.56 X 0.60
0.61 X 0.65
0.66 X 0.70
0.71 X 0.75
0.76 X 0.80
0.81 X 0.85
0.86 X 0.90
0.91 X 0.95
0.96 X 1.00
1.01 X 1.05
1.06 X 1.10
1.11 X 1.15
1.16 X 1.20
1.21 X 1.25
1.26 X 1.30
1.31 X 1.35
1.36 X 1.40
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
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
235 240
VALVE CLEARANCE (cold):
240
220
205
210
215
225
210
215
220
230
215
220
225
235 240
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
0.13 X 0.20 mm (0.0051 X 0.0079 in)
Example: Installed is 175
Measured clearance is 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
EXHAUST
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.12
0.13 X 0.17
0.18 X 0.22
0.23 X 0.30
0.31 X 0.35
0.36 X 0.40
0.41 X 0.45
0.46 X 0.50
0.51 X 0.55
0.56 X 0.60
0.61 X 0.65
0.66 X 0.70
0.71 X 0.75
0.76 X 0.80
0.81 X 0.85
0.86 X 0.90
0.91 X 0.95
0.96 X 1.00
1.01 X 1.05
1.06 X 1.10
1.11 X 1.15
1.16 X 1.20
1.21 X 1.25
1.26 X 1.30
1.31 X 1.35
1.36 X 1.40
1.41 X 1.45
1.46 X 1.50
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
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
235 240
VALVE CLEARANCE (cold):
240
220
195
200
205
210
215
225
200
205
210
215
220
230
205
210
215
220
225
235 240
210 215
215 220
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
0.23 X 0.30 mm (0.0091 X 0.0118 in)
Example: Installed is 175
Measured clearance is 0.35 mm (0.0138 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
3-15
ADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
7. Install:
S all removed parts
NOTE:
For installation, reverse the removal procedure.
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:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
S air filter case
Refer to “AIR FILTER CASE”.
3. Remove:
S synchronizing hose 1
4. Install:
S vacuum gauge 1
(onto the synchronizing hose)
S digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
3-16
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
5. Install:
S air filter case
Refer to “AIR FILTER CASE”.
S fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:
S engine idling speed
Out of specification ! Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,250 X 1,350 r/min
8. Adjust:
S throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws 1 .
NOTE:
S After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
S 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
24 kPa
(180 mmHg, 7.0872 inHg)
NOTE:
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
3-17
SYNCHRONIZING THE THROTTLE BODIES/
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
9. Measure:
S 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.
11. Adjust:
S throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
12. Remove:
S digital tachometer
S vacuum gauge
13. Install:
S air filter case
Refer to “AIR FILTER CASE”.
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
EAS00052
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
throttle bodies synchronization should be adjusted properly, and the engine should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:
S digital tachometer
(to the ignition of cylinder #1)
3. Check:
S engine idling speed
Out of specification ! Adjust.
Engine idling speed
1,250 X 1,350 r/min
3-18
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
4. Adjust:
S 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.
5. Adjust:
S throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted properly.
1. Check:
S throttle cable free play a
Out of specification ! Adjust.
Throttle cable free play (at the
flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
2. Remove:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
S air filter case
Refer to “AIR FILTER CASE”.
S left frame side cover
Refer to “COWLINGS”.
3-19
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
3. Adjust:
S 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.
Direction a
Throttle cable free play is
increased.
Direction b
Throttle cable free play is
decreased.
c. 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 a
Throttle cable free play is
increased.
Direction b
Throttle cable free play is
decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
3-20
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
CHK
ADJ
4. Install:
S left frame side cover
Refer to “COWLINGS”.
S air filter case
Refer to “AIR FILTER CASE”.
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
S air filter case
Refer to “AIR FILTER CASE”.
2. Remove:
S heat protector plate
S ignition coils
S spark plugs
CAUTION:
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from falling into the cylinders.
3. Check:
S spark plug type
Incorrect ! Change.
Spark plug type (manufacturer)
CR9EK or CR10EK (NGK)
4. Check:
S electrode 1
Damage/wear ! Replace the spark plug.
S insulator 2
Abnormal color ! Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
S spark plug
(with a spark plug cleaner or wire brush)
3-21
CHECKING THE SPARK PLUGS/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
6. Measure:
S spark plug gap a
(with a wire Thickness gauge)
Out of specification ! Regap.
Spark plug gap
0.6 X 0.7 mm
(0.0236 X 0.0276 in)
7. Install:
S spark plug
13 Nm (1.3 mSkg, 9.4 ftSlb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Install:
S air filter case
Refer to “AIR FILTER CASE”.
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
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:
S 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:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
S air filter case
Refer to “AIR FILTER CASE”.
4. Remove:
S cover
S ignition coils
S spark plugs
3-22
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
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.
5. Install:
S compression gauge 1
S adapter
Compression gauge
90890-03081, YU-33223
Adapter
90890-04136
6. Measure:
S compression pressure
Out of specification ! Refer to steps (c) and
(d).
Compression pressure
(at sea level)
Minimum
1,350 kPa (13.50 kg/cm2,
13.50 bar, 191.87 psi)
Standard
1,550 kPa (15.50 kg/cm2,
15.50 bar, 220.46 psi)
Maximum
1,736 kPa (17.36 kg/cm2,
17.36 bar, 246.92 psi)
a. Turn 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, 14.22 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits ! Eliminate.
3-23
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
d. If the compression pressure is below the
minimum specification, pour a teaspoonful of
engine oil into the spark plug bore and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston ring(s) wear
or damage !
Repair.
Same as without
oil
Piston, valves,
cylinder head
gasket or piston
possibly defective
! Repair.
7. Install:
S spark plug
13 Nm (1.3 mSkg, 9.4 ftSlb)
8. Install:
S ignition coils
9. Install:
S heat protector plate
S air filter case
Refer to “AIR FILTER CASE”.
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
S Place the motorcycle on a suitable stand.
S Make sure the motorcycle is upright.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Check:
S 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.
3-24
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
Recommended oil
At 5_C (40_F) or higher A
Yamalube 4 (20W40) or
SAE 20W40 type SE motor
oil
At 15_C (60_F) or lower B
Yamalube 4 (10W30) or
SAE 10W30 type SE motor
oil
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.
EAS00074
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:
S bottom cowling
Refer to “COWLINGS”.
S coolant reservoir tank
Refer to “CHANGING THE COOLANT”.
4. Remove:
S engine oil filler cap 1
S engine oil drain bolt 2
(along with the gasket)
5. Drain:
S engine oil
(completely from the crankcase)
3-25
CHANGING THE ENGINE OIL
CHK
ADJ
6. If the oil filter cartridge is also to be replaced,
perform the following procedure.
a. Remove the oil filter cartridge 1 with an oil
filter wrench 2 .
Oil filter wrench
90890-01426, YU-38411
b. 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.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge
17 Nm (1.7 mSkg, 12 ftSlb)
7. Replace:
S engine oil drain bolt gasket New
8. Install:
S engine oil drain bolt
(along with the new gasket)
43 Nm (4.3 mSkg, 31 ftSlb)
9. Fill:
S crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
3.4 L (2.99 Imp qt, 3.59 US qt)
Without oil filter cartridge
replacement
2.4 L (2.11 Imp qt, 2.54 US qt)
With oil filter cartridge
replacement
2.6 L (2.29 Imp qt, 2.75 US qt)
3-26
CHANGING THE ENGINE OIL/
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
10. Install:
S engine oil filler cap
S coolant reservoir tank
Refer to “CHANGING THE COOLANT”.
S bottom cowling
Refer to “COWLINGS”.
11. Start the engine, warm it up for several minutes, and then turn it off.
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
S engine oil level
Below the minimum level mark ! Add the
recommended engine oil to the proper level.
2. 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. Remove:
S bottom cowling
Refer to “COWLINGS”.
4. Remove:
S oil gallery bolt 1
WARNING
The engine, muffler and engine oil are extremely hot.
5. Install:
S oil pressure gauge 1
S adapter 2
Pressure gauge
90890-03153, YU-03153
Oil pressure adapter
90890-03139
3-27
CHK
ADJ
MEASURING THE ENGINE OIL PRESSURE
6. Measure:
S engine oil pressure
(at the following conditions)
Engine oil pressure
240 kPa
(2.4 kg/cm2, 2.4 bar, 34.1 psi)
Engine speed
Approx. 6,600 r/min
Engine oil temperature
96_C (205_F)
NOTE:
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
only as a reference when measuring the engine
oil pressure.
Engine oil pressure
Below
specification
ifi i
Possible causes
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:
S oil gallery bolt 1
8 Nm (0.8 mSkg, 5.8 ftSlb)
8. Install:
S bottom cowling
Refer to “COWLINGS”.
3-28
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
S clutch cable free play a
Out of specification ! Adjust.
Clutch cable free play (at the
end of the clutch lever)
10 X 15 mm (0.39 X 0.59 in)
2. Adjust:
S clutch cable free play
Handlebar side
a. Turn the adjusting dial 1 in direction b or c
until the specified clutch cable free play is obtained.
Direction b
Clutch cable free play is
increased.
Direction c
Clutch cable free play is
decreased.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Remove the bottom cowling. Refer to
“COWLINGS”.
b. Loosen the locknuts 1 .
c. Turn the adjusting nut 2 in direction a or b
until the specified clutch cable free play is obtained.
Direction a
Clutch cable free play is
increased.
Direction b
Clutch cable free play is
decreased.
d. Tighten the locknuts.
e. Install the bottom cowling. Refer to “COWLINGS”.
3-29
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
2. Remove:
S air filter case cover 1
S air filter element
3. Clean:
S air filter element 1
Use solvent to clean the air filter element. After cleaning the air filter element, remove the
solvent from the air filter element.
4. Apply the engine oil to the entire surface of
the filter and remove the excess oil. The air
filter should be wet but not dripping.
5. Check:
S air filter element
Damage ! Replace.
6. Install:
S air filter element
S 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 bodies 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. Install:
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
3-30
CLEANING THE AIR INTAKE SYSTEM SURGE TANKS/
CHECKING THE THROTTLE BODY JOINTS
CHK
ADJ
EAS00092
CLEANING THE AIR INTAKE SYSTEM
SURGE TANKS
The following procedure applies to both air intake system surge tanks.
1. Remove:
S front cowling
Refer to “COWLINGS”.
2. Remove:
S air intake system surge tank 1
3. Clean:
S air intake system surge tank
a. Thoroughly flush out the air intake system
surge tank with clean water.
b. Hold the air intake system surge tank upside
down to allow the water to drain out.
c. Repeat the flushing steps until the excess
water is clear and free of debris.
d. Place the air intake system surge tank in an
upright position to allow any remaining water
to drain out of the lower drain tube.
e. Keep the air intake system surge tank upright
to allow it to dry sufficiently.
4. Install:
S air intake system surge tank
5. front cowling
Refer to “COWLINGS”.
EAS00095
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the
throttle body joints and intake manifolds.
1. Remove:
S throttle bodies
Refer to “THROTTLE BODIES” in chapter 7.
2. Check:
S throttle body joints 1
Cracks/damage ! Replace.
3. Install:
S throttle bodies
Refer to “THROTTLE BODIES” in chapter 7.
3-31
CHECKING THE FUEL AND BREATHER HOSES/
CHECKING THE CRANKCASE BREATHER HOSE
CHK
ADJ
EAS00096
CHECKING THE FUEL AND BREATHER
HOSES
The following procedure applies to all of the fuel
and breather hoses.
1. Remove:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
2. Check:
S breather hoses 1
S fuel hoses 2
Cracks/damage ! Replace.
Loose connection ! Connect properly.
NOTE:
Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
3. Install:
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
S rider seat
Refer to “SEATS”.
S fuel tank
Refer to “FUEL TANK”.
2. Check:
S crankcase breather hose 1
Cracks/damage ! Replace.
Loose connection ! Connect properly.
CAUTION:
Make sure the crankcase breather hose is
routed correctly.
3. Install:
S fuel tank
Refer to “FUEL TANK”.
S rider seat
Refer to “SEATS”.
3-32
CHECKING THE EXHAUST SYSTEM/
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes and gaskets.
1. Remove:
S bottom cowling
Refer to “COWLINGS”.
S radiator
Refer to “RADIATOR” in chapter 6.
2. Check:
S exhaust pipe 1
S muffler 2
Cracks/damage ! Replace.
S gasket 3
Exhaust gas leaks ! Replace.
3. Check:
S tightening torque
Exhaust pipe nut 4
20 Nm (2.0 mSkg, 15 ftSlb)
Exhaust pipe and muffler bolt 5
20 Nm (2.0 mSkg, 15 ftSlb)
Muffler and rear footrest nut 6
23 Nm (2.3 mSkg, 17 ftSlb)
Exhaust pipe and exhaust pipe
stay 7
20 Nm (2.0 mSkg, 15 ftSlb)
4. Install:
S radiator
Refer to “RADIATOR” in chapter 6.
S bottom cowling
Refer to “COWLINGS”.
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
S Place the motorcycle on a suitable stand.
S Make sure the motorcycle is upright.
3-33
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
2. Check:
S 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:
S 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.
S Use only distilled water. However, if distilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
S coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
S bottom cowling
S side cowlings
Refer to “COWLINGS”.
3-34
CHECKING THE COOLING SYSTEM/
CHANGING THE COOLANT
CHK
ADJ
2. Check:
S radiator 1
S radiator inlet hose 2
S radiator outlet hose 3
S oil cooler 4
S oil cooler inlet hose 5
S oil cooler outlet hose 6
S water jacket outlet joint 7
S water jacket hose 8
S water pump outlet pipe 9
S water pump outlet hose 10
Cracks/damage ! Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
S side cowlings
S bottom cowling
Refer to “COWLINGS”.
EAS00105
CHANGING THE COOLANT
1. Remove:
S bottom cowlings
S left side cowling
Refer to “COWLINGS”.
S coolant reservoir tank cover
2. Remove:
S coolant reservoir tank
3-35
CHANGING THE COOLANT
CHK
ADJ
3. Disconnect:
S coolant reservoir cap 1
4. Drain:
S coolant
(from the coolant reservoir tank)
5. Remove:
S radiator cap 1
CAUTION:
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:
S coolant drain bolt (water pump) 1
(along with the copper washer)
7. Drain:
S coolant
(from the engine and radiator)
8. Check:
S copper washer 1 New
(coolant drain bolt-water pump 2 )
9. Install:
S coolant drain bolt (water pump)
(with copper washer)
10 Nm (1.0 mSkg, 7.2 ftSlb)
3-36
CHANGING THE COOLANT
CHK
ADJ
10. Install:
S coolant reservoir tank
11. Connect:
S coolant reservoir hose
12. Fill:
S cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
2.15 L (1.89 Imp qt,
2.27 US qt)
Coolant reservoir capacity
0.44 L (0.39 Imp qt,
0.47 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
S If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
S If coolant splashes on your clothes, quickly wash it away with water and then with
soap and water.
S If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
S 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.
3-37
CHANGING THE COOLANT
CHK
ADJ
S Use only distilled water. However, if distilled water is not available, soft water may
be used.
S If coolant comes into contact with painted
surfaces, immediately wash them with water.
S Do not mix different types of antifreeze.
13. Install:
S radiator cap
14. Fill:
S coolant reservoir tank
(with the recommended coolant to the maximum level mark a )
15. Install:
S coolant reservoir cap
16. Start the engine, warm it up for several minutes, and then stop it.
17. Check:
S 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:
S coolant reservoir tank cover
S bottom cowling
S left side cowling
Refer to “COWLINGS”.
3-38
ADJUSTING THE FRONT BRAKE
CHK
ADJ
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
S brake lever position
(distance a from the throttle grip to the brake
lever)
NOTE:
S While pushing the brake lever forward, turn the
adjusting dial 1 until the brake lever is in the
desired position.
S Be sure to align the setting on the adjusting dial
with the arrow mark 2 on the brake lever holder.
Position #1
Position #5
Distance a is the
largest.
Distance a is the
smallest.
WARNING
S 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.
S A soft or spongy feeling in the brake 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 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.
3-39
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00110
ADJUSTING THE REAR BRAKE
1. Check:
S brake pedal position
(distance a bottom of the footrest bracket)
Out of specification ! Adjust.
Brake pedal position (below the
bottom of the footrest bracket)
7 X 11 mm (0.28 X 0.43 in)
2. Adjust:
S 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.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)
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.
3-40
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
3. Adjust:
S rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
S Place the motorcycle on a suitable stand.
S Make sure the motorcycle is upright.
2. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
A
Recommended brake fluid
DOT 4
A Front brake
B Rear brake
WARNING
B
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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.
3-41
CHECKING THE BRAKE FLUID LEVEL/
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.
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.
1. Check:
S rear brake light operation timing
Incorrect ! Adjust.
2. Adjust:
S rear brake light operation timing
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.
3-42
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
CHECKING THE FRONT AND REAR BRAKE PADSā/
CHECKING THE FRONT AND REAR BRAKE HOSES
CHK
ADJ
EAS00122
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
S front brake pad
S rear brake pad
Brake pad wear limit a , b
Wear limit reached ! Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
A
Brake pad wear limit
a 0.5 mm (0.02 in.)
b 1.0 mm (0.04 in.)
B
A Front brake
B Rear brake
EAS00131
A
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
S brake hose
Cracks/damage/wear ! Replace.
A Front
B Rear
2. Check:
S brake hose clamp
Loose ! Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
S brake hose
Brake fluid leakage ! Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
B
3-43
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00135
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system whenever:
S the system is disassembled.
S a brake hose is loosened, disconnected or
replaced.
S the brake fluid level is very low.
S brake operation is faulty.
NOTE:
S Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
S 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.
S 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.
1. Bleed:
S hydraulic brake system
a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
A Front
B Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
A
B
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.
3-44
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SHIFT PEDAL
CHK
ADJ
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.
Bleed screw
6 Nm (0.6 mSkg, 4.3 ftSlb)
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:
S shift rod length a
Out of specification ! Adjust.
Shift rod length
290 mm (11.42 in)
2. Adjust:
S shift pedal position
a. Loosen both locknuts 1 .
b. Turn the shift rod 2 in direction b or c to
obtain the correct shift pedal position.
Direction b
Direction c
Shift pedal is raised.
Shift pedal is lowered.
c. Tighten both locknuts.
3-45
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swingarm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
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. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:
S drive chain slack a
Out of specification ! Adjust.
Drive chain slack
35 X 45 mm (1.38 X 1.77 in)
4. Adjust:
S drive chain slack
a. Loosen the wheel axle nut 1 .
b. Loosen both locknuts 2 .
c. Turn both adjusting bolts 3 in direction a or
b until the specified drive chain slack is obtained.
3-46
ADJUSTING THE DRIVE CHAIN SLACK/
LUBRICATING THE DRIVE CHAIN
CHK
ADJ
Direction a
Drive chain is tightened.
Direction b
Drive chain is loosened.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)
e. Tighten the wheel axle nut to specification.
Wheel axle nut
110 Nm (11 mSkg, 80 ftSlb)
EAS00142
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with engine
oil or chain lubricant that is suitable for O-ring
chains. Do not use any other lubricants on the
drive chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
3-47
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00146
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:
S steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness ! Adjust the steering
head.
3. Remove:
S upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:
S steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
b. Loosen the lower ring nut 4 and then tighten
it to specification with a steering nut wrench
5.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403, YU-33975
Lower ring nut (initial tightening
torque)
52 Nm (5.2 mSkg, 38 ftSlb)
3-48
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
c. Loosen the lower ring nut 4 completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
14 Nm (1.4 mSkg, 10 ftSlb)
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 under bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer 3 .
f. Install the upper ring nut 2 .
g. Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 1 .
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b .
5. Install:
S upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
6. Measure:
S steering head tension
NOTE:
Make sure all of the cables and wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge 2 onto the plastic locking tie.
d. Hold the spring gauge at a 90_ angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handlebar starts to run.
3-49
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
Steering head tension
200 X 500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specification (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steering head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness ! Adjust the steering
head.
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:
S inner tube 1
Damage/scratches ! Replace.
S oil seal 2
Oil leakage ! Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
S 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.
3-50
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
S Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
S Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
S Grooves are provided to indicate the adjustment position.
S Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
S 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: 8
Standard: 7
Maximum: 1
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-51
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
1. Adjust:
S rebound damping
a. Turn the adjusting screw 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: 10 clicks in direction b *
Standard: 9 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S 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: 9 clicks in direction b *
Standard: 7 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
3-52
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
EAS00158
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S spring preload
a. Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
b. Turn the adjusting ring 1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper 2 .
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-53
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
1. Adjust:
S rebound damping
a. Turn the adjusting screw 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: 20 clicks in direction b *
Standard: 10 clicks in direction b *
Maximum: 5 clicks in direction b *
*: with the adjusting knob fully
turned-in direction a
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S 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: 20 clicks in direction b *
Standard: 10 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
3-54
CHECKING THE TIRES
CHK
ADJ
EAS00162
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
S tire pressure
Out of specification ! Regulate.
WARNING
S The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
S 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.
S Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic
weight
(with oil
and a full
fuel tank)
182 kg (401 lb)
(USA except for CAL)
183 kg (404 lb) (CAL)
Maximum
load*
193 kg (426 lb)
(USA except for CAL)
192 kg (423 lb) (CAL)
Cold tire
pressure
Front
Rear
Up to
90 kg
load*
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar,
2.5 bar,
35.6 psi)
35.6 psi)
90 kg X
maximum
load*
2.5 kPa
(2.5 kgf/cm2,
2.5 bar,
35.6 psi)
Highspeed
riding
2.5 kPa
2.5 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar,
2.5 bar,
35.6 psi)
35.6 psi)
290 kPa
(29 kgf/cm2,
2.9 bar,
41.3 psi)
* Total weight of rider, passenger, cargo and accessories
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-55
CHECKING THE TIRES
CHK
ADJ
2. Check:
S tire surfaces
Damage/wear ! Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
WARNING
S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
S When using a tube tire, be sure to install the
correct tube.
S Always replace a new tube tire and a new
tube as a set.
S To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
S 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.
A
A Tire
B Wheel
B
Tube wheel
Tube tire only
T beless wheel
Tubeless
Tube or tubeless
tire
WARNING
S 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.
3-56
CHECKING THE TIRES/CHECKING THE WHEELS
CHK
ADJ
Front tire
Manufacturer
Size
Model
DUNLOP
120/60ZR 17
M/C (55W)
D208FL
MICHELIN
120/60ZR 17
M/C (55W)
Pilot
SPORTS N
Manufacturer
Size
Model
DUNLOP
180/55ZR 17
M/C (73W)
D208L
MICHELIN
180/55ZR 17
M/C (73W)
Pilot
SPORTS B
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 1 :
S Install the tire with the mark pointing in the
direction of wheel rotation.
S Align the mark 2 with the valve installation
point.
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
S 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.
3-57
CHECKING AND LUBRICATING THE CABLES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Replace damaged outer cable and inner cables
as soon as possible.
1. Check:
S outer cable
Damage ! Replace.
2. Check:
S 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-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum-disulfide grease
3-58
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:
S Wear protective eye gear when handling or
working near batteries.
S Charge batteries in a well-ventilated area.
S Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
S DO NOT SMOKE when charging or handling batteries.
S KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
S Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
S Skin – Wash with water.
S Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
S Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
CAUTION:
S This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery performance will deteriorate.
S 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.
3-59
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:
S rider seat
Refer to “SEATS”.
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead
1 , and then the positive battery lead 2 .
3. Remove:
S battery
4. Check:
S battery charge
a. Connect a pocket tester to the battery terminals.
Open-circuit voltage (V)
Positive tester probe !
positive battery terminal
Negative tester probe !
negative battery terminal
13.0
Relationship between the open-circuit voltage
and the charging time at 20_C
NOTE:
S 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).
S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
12.5
12.0
11.5
5 6.5
10
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 X 30%
Open-circuit voltage (V)
Ambient
temperature
20_C
Charging condition of the battery (%)
3-60
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
5. Charge:
S battery
(refer to the appropriate charging method illustration)
Charging
Open-circuit voltage (V)
Ambient temperature 20_C
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
S Never remove the MF battery sealing caps.
S 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.
S If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
S 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.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S 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.
S 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!
S 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.
3-61
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Measure the open-circuit
voltage prior to charging.
Connect a charged and
AMP meter to the battery
and start charging.
YES
Make sure that the current
is higher than the standard
charging current written on
the battery.
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 X 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
NO
By turning the charging
voltage adjust dial, set the
charging voltage at 20 X 24 V.
Adjust the voltage so that the
current is at the standard
charging level.
YES
Monitor the amperage for
3 X 5 minutes to check if the
standard charging current is
reached.
NO
Set the time according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.
If the current does not
exceed the standard
charging current after 5
minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the
charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
Connect a charger and
AMP meter to the battery
and start charging.
YES
Make sure that the current
is higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.
NO
This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
NOTE:
Set the charging time at 20 hours
(maximum).
Measure the battery open-circuit
voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
3-63
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Install:
S battery
7. Connect:
S battery leads
(to the battery terminals)
CAUTION:
First, connect the positive battery lead 1 ,
and then the negative battery lead 2 .
8. Check:
S battery terminals
Dirt ! Clean with a wire brush.
Loose connection ! Connect properly.
9. Lubricate:
S battery terminals
Recommended lubricant
Dielectric grease
10. Install:
S rider seat
Refer to “SEATS”.
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:
S front cowling inner panel (left)
Refer to “COWLINGS”.
S rider seat
Refer to “SEATS”.
2. Check:
S fuse
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω
3-64
1”.
CHECKING THE FUSES
CHK
ADJ
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:
S blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
rating
Q’ty
Main
40 A
1
Fuel injection
system
15 A
1
Headlight
20 A
1
Signaling
system
15 A
1
Ignition
15 A
1
Backup fuse
(odometer
and clock)
10 A
1
Radiator
fan motor
15 A
1
Reserve
40 A, 20 A,
15 A, 10 A
1
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:
S front cowling inner panel (left)
Refer to “COWLINGS”.
S rider seat
Refer to “SEATS”.
3-65
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Remove:
S front cowling inner panels
Refer to “COWLINGS”.
2. Disconnect:
S headlight bulb cover
S headlight coupler 1
3. Remove:
S headlight bulb holder 1
4. Remove:
S headlight bulb
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
5. Install:
S 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. Install:
S headlight bulb holder
7. Install:
S headlight bulb cover
8. Connect:
S headlight coupler
9. Install:
S front cowling inner panels
Refer to “COWLINGS”.
3-66
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Remove:
S front cowling inner panels
Refer to “COWLINGS”.
2. Adjust:
S 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. Adjust:
S headlight beam (horizontally)
a. Turn the adjusting screw 2 in direction a or
b.
Direction a
Headlight beam moves to
the left.
Direction b
Headlight beam moves to
the right.
4. Install:
S front cowling inner panels
Refer to “COWLINGS”.
3-67
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
7 Nm (0.7 mSkg, 5.1 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
91 Nm (9.1 mSkg, 66 ftSlb)
18 Nm (1.8 mSkg, 13 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
18 Nm (1.8 mSkg, 13 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
Removing the front wheel and brake
discs
1
2
3
4
5
6
7
8
9
2
2
4
1
1
2
2
2
2
Brake hose holder (left and right)
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle bolt
Front wheel axle
Collar (left and right)
Oil seal cover (left and right)
Front wheel
Front brake disc (left and right)
Remarks
Loosen.
For installation, reverse the removal
procedure.
4-1
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00518
4
Order
1
2
3
Job/Part
Q’ty
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
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:
S left brake caliper
S right brake caliper
Refer to “FRONT BRAKE CALIPERS”.
NOTE:
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:
S front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Remove:
S front wheel axle
S front wheel axle bolt
S front wheel
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
S wheel axle
Roll the wheel axle on a flat surface.
Bends ! Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
S tire
S 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:
S radial wheel runout 1
S lateral wheel runout 2
Over the specified limits ! Replace.
Radial wheel runout limit
1 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:
S wheel bearings
Front wheel turns roughly or is loose ! Replace the wheel bearings.
S oil seals
Damage/wear ! Replace.
5. Replace:
S wheel bearings New
S 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
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
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:
S brake discs
Damage/galling ! Replace.
2. Measure:
S brake disc deflection
Out of specification ! Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front: 0.1 mm (0.004 in)
Rear: 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflection, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 X 3 mm (0.08 X
0.12 in) below the edge of the brake disc.
3. Measure:
S 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 (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
S 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.
4-5
FRONT WHEEL AND BRAKE DISCS
CHAS
Brake disc bolt
Front: 18 Nm (1.8 mSkg, 13 ftSlb)
Rear: 30 Nm (3.0 mSg, 22 ftSlb)
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:
S wheel axle
S oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
NOTE:
Install the tire with the mark 1 pointing in the
direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Install the brake calipers by installing the
bolts, and then tightening them to the specified torque.
NOTE:
Make sure that there is enough space between
the brake pads before installing the brake calipers onto the brake discs.
Brake caliper bolt:
40 Nm (4.0 mSkg, 29 ftSlb)
6. Install the brake hose holders by installing
the bolts and nuts.
7. Secure the wheel axle by installing the axle
bolt, and then tightening it to the specified
torque.
Axle bolt:
91 Nm (9.1 mSkg, 66 ftSlb)
4-6
FRONT WHEEL AND BRAKE DISCS
CHAS
8. Tighten wheel axle pinch bolt 2 , and then
pinch bolt 1 to specified torque.
9. Retighten pinch bolt 2 to the specified
torque.
Wheel axle pinch bolt:
18 Nm (1.8 mSkg, 13 ftSlb)
10. Tap the outer side of the left fork leg with a
rubber mallet to align it with the end of the
wheel axle.
11. Tighten wheel axle pinch bolt 4 , and then
pinch bolt 3 to specified torque.
12. Retighten pinch bolt 4 to the specified
torque.
Wheel axle pinch bolt:
18 Nm (1.8 mSkg, 13 ftSlb)
13. While applying the front brake, push down
hard on the handlebar several times to
check for proper fork operation.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
S After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
S Adjust the front wheel static balance with the
brake discs installed.
1. Remove:
S balancing weight(s)
2. Find:
S front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
4-7
FRONT WHEEL AND BRAKE DISCS
CHAS
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
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”.
3. Adjust:
S 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:
S 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
REAR WHEEL
23 Nm (2.3 mSkg, 17 ftSlb)
28 Nm (2.8 mSkg, 20 ftSlb)
110 Nm (11 mSkg, 80 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Removing the rear wheel
1
2
3
4
5
6
7
8
9
10
Remarks
1
2
2
1
1
1
1
1
1
1
Rear brake caliper
Locknut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Washer
Rear wheel axle
Left adjusting block
Right adjusting block
Rear wheel
Rear brake caliper bracket
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-9
REAR WHEEL AND BRAKE DISC
CHAS
EAS00556
REAR BRAKE DISC AND REAR WHEEL SPROCKET
30 Nm (3.0 mSkg, 22 ftSlb)
100 Nm (10 mSkg, 72 ftSlb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
Removing the rear brake disc and
rear wheel sprocket
Rear brake disc
Rear wheel sprocket
Collar
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Collar
Rear wheel
Remarks
Remove the parts in the order listed.
1
1
1
1
2
1
6
1
1
For installation, reverse the removal
procedure.
4-10
REAR WHEEL AND BRAKE DISC
CHAS
EAS00560
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear wheel
Collar
Bearing
Spacer
Oil seal
Circlip
Bearing
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
For installation, reverse the disassembly
procedure.
4-11
REAR WHEEL AND BRAKE DISC
CHAS
EAS00561
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:
S brake caliper 1
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:
S locknuts 1 (left and right)
S adjusting bolts 2 (left and right)
4. Remove:
S wheel axle nut 3
S wheel axle 4
S rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
S left collar 1
S rear wheel drive hub 2
S rear wheel drive hub damper
S right collar
4-12
REAR WHEEL AND BRAKE DISC
CHAS
EAS00565
CHECKING THE REAR WHEEL
1. Check:
S wheel axle
S rear wheel
S wheel bearings
S oil seals
Refer to “CHECKING THE FRONT
WHEEL”.
2. Check:
S tire
S rear wheel
Damage/wear ! Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
S radial wheel runout
S lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
S rear wheel drive hub 1
Cracks/damage ! Replace.
S rear wheel drive hub dampers 2
Damage/wear ! Replace.
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
S rear wheel sprocket
More than 1/4 tooth a wear ! Replace the
rear wheel sprocket.
Bent teeth ! Replace the rear wheel sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
4-13
CHAS
REAR WHEEL AND BRAKE DISC
2. Replace:
S rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
100 Nm (10 mSkg, 72 ftSlb)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Install:
S rear brake caliper bracket
S rear wheel
S adjusting blocks
S rear wheel axle
3. Adjust:
S drive chain slack
Drive drain slack
35 X 45 mm (1.38 X 1.77 in)
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
4. Tighten:
110 Nm (11 mSkg, 80 ftSlb)
S wheel axle nut
S brake caliper bolt (front)
28 Nm (2.8 mSkg, 20 ftSlb)
(rear)
23 Nm (2.3 mSkg, 17 ftSlb)
4-14
REAR WHEEL AND BRAKE DISC
CHAS
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
S After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
S Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
S rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE”.
4-15
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
6 Nm (0.6 mSkg, 4.3 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
The following procedure applies to both of
the front brake calipers.
Removing the front brake pads
1
2
3
4
5
6
Front brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw
Remarks
1
2
1
1
2
1
For installation, reverse the removal
procedure.
4-16
FRONT AND REAR BRAKES
CHAS
REAR BRAKE PADS
6 Nm (0.6 mSkg, 4.3 ftSlb)
28 Nm (2.8 mSkg, 20 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
18 Nm (1.8 mSkg, 13 ftSlb)
2.5 Nm (0.25 mSkg, 1.8 ftSlb)
Order
1
2
3
4
5
6
Job/Part
Removing the rear brake pads
Screw plug
Brake pad pin
Rear brake caliper
Brake pad shim
Brake pad
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
1
2
1
4
2
1
For installation, reverse the removal
procedure.
4-17
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
WARNING
S Never disassemble brake components unless absolutely necessary.
S 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.
S Never use solvents on internal brake components.
S Use only clean or new brake fluid for cleaning brake components.
S Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
S Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
S 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:
S brake hose holder 1
S brake caliper 2
4-18
FRONT AND REAR BRAKES
CHAS
2. Remove:
S brake pad clips 1
S brake pad pin 2
S brake pad spring 3
3. Remove:
S brake pads 1
4. Measure:
S brake pad wear limit a
Out of specification ! Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
5. Install:
S brake pads
S brake pad spring
NOTE:
Always install new brake pads, and a brake pad
spring as a set.
4-19
FRONT AND REAR BRAKES
CHAS
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.
Bleed screw
6 Nm (0.6 mSkg, 4.3 ftSlb)
NOTE:
The arrow mark a on the brake pad spring must
point in the direction of disc rotation.
d. Install new brake pads and a new brake pad
spring.
6. Install:
S brake pad pins
S brake pad clips
S brake caliper
40 Nm (4.0 mSkg, 29 ftSlb)
7. Check:
S 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.
8. Check:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-20
FRONT AND REAR BRAKES
CHAS
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:
S screw plug 1
S brake pad pin
S brake caliper 2
2. Remove:
S brake pad spring
3. Remove:
S brake pads 1
(along with the brake pad shims 2 )
4. Measure:
S brake pad wear limit a
Out of specification ! Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
5. Install:
S brake pad shims
(onto the brake pads)
S brake pads
S brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
4-21
CHAS
FRONT AND REAR BRAKES
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.
Bleed screw
6 Nm (0.6 mSkg, 4.3 ftSlb)
d. Install a new brake pad shim 3 onto each
new brake pad 4 .
6. Install:
S rear brake caliper (front)
28 Nm (2.8 mSkg, 20 ftSlb)
rear brake caliper (rear)
23 Nm (2.3 mSkg, 17 ftSlb)
S brake pad pin
S screw plug
7. Check:
S 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.
8. Check:
S brake pedal operation
Soft or spongy feeling !Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-22
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
30 Nm (3.0 mSkg, 22 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Removing the front brake master
cylinder
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Remarks
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Dust cover
Circlip
Hose joint
Brake lever
Front brake switch connector
Union bolt
Copper washer
Brake hose
1
1
1
1
1
1
1
1
1
1
2
1
3
2
4-23
Disconnect.
FRONT AND REAR BRAKES
CHAS
30 Nm (3.0 mSkg, 22 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
Order
15
16
17
Job/Part
Brake master cylinder bracket
Brake master cylinder
Front brake switch
Q’ty
Remarks
1
1
1
For installation, reverse the removal
procedure.
4-24
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-25
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
18 Nm (1.8 mSkg, 13 ftSlb)
30 Nm (3.0 mSkg, 22 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the rear brake master
cylinder
Brake fluid
1
2
3
4
5
6
7
8
9
10
Remarks
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Union bolt
Copper washer
Brake hose
Brake master cylinder
1
1
1
1
1
1
1
2
1
1
For installation, reverse the removal
procedure.
4-26
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
Job/Part
Q’ty
1
2
Disassembling the rear brake master
cylinder
Brake master cylinder kit
Brake master cylinder body
Remarks
Disassemble the parts in the order listed.
1
1
For assembly, reverse the disassembly
procedure.
4-27
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. Disconnect:
brake light switch connector 1
(from the brake light switch)
2. Remove:
S union bolt 2
S copper washers 3
S brake hoses 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove:
S brake master cylinder bracket
S brake master cylinder assembly
4. Remove:
S dust boot
S circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove:
S brake master cylinder assembly
3. Remove:
S dust boot
S circlip
4-28
FRONT AND REAR BRAKES
CHAS
EAS00593
A
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:
S brake master cylinder
Damage/scratches/wear ! Replace.
S brake fluid delivery passages
(brake master cylinder body)
Obstruction ! Blow out with compressed air.
A Front
B Rear
B
2. Check:
S brake master cylinder kit
Damage/scratches/wear ! Replace.
A Front
B Rear
A
B
A
3. Check:
S brake fluid reservoir 1
Cracks/damage ! Replace.
S brake fluid reservoir diaphragm 2
Cracks/damage ! Replace.
4. Check:
S brake hoses
Cracks/damage/wear ! Replace.
B
4-29
FRONT AND REAR BRAKES
CHAS
EAS00607
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
1. Install:
S brake master cylinder kit
S circlip New
S dust boot
2. Install:
S brake master cylinder 1
13 Nm (1.3 mSkg, 9.4 ftSlb)
NOTE:
S Install the brake master cylinder holder with
the “UP” mark a facing up.
S Align the mating surfaces of the brake master
cylinder holder with the punch mark b on the
right handlebar.
S First, tighten the upper bolt, then the lower bolt.
There should be 8.2 mm (0.32 in.) for clearance between the right handlebar switch and
the brake master cylinder holder.
3. Install:
S copper washers New
S brake hose
S union bolt
30 Nm (3.0 mSkg, 22 ftSlb)
S brake light switch coupler
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
4-30
FRONT AND REAR BRAKES
CHAS
NOTE:
S While holding the brake hose, tighten the
union bolt as shown.
S Turn the handlebars to the left and right to
make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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.
5. Bleed:
S brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-31
FRONT AND REAR BRAKES
CHAS
6. Check:
S 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:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00610
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
S brake master cylinder kit
S circlip
S dust boot
2. Install:
S copper washers New
S brake hose
30 Nm (3.0 mSkg, 22 ftSlb)
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a on the
brake master cylinder.
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
3. Fill:
S brake fluid reservoir
(to the maximum level mark)
Recommended brake fluid
DOT 4
4-32
FRONT AND REAR BRAKES
CHAS
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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.
4. Bleed:
S brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
S 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. Adjust:
S brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position
Brake pedal position (below the
bottom of the footrest bracket)
7 X 11 mm (0.28 X 0.43 in)
7. Adjust:
S rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4-33
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPERS
7 Nm (0.7 mSkg, 5.1 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
30 Nm (3.0 mSkg, 22 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
The following procedure applies to both
of the front brake calipers.
Removing the front brake calipers
1
2
3
4
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Remarks
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-34
FRONT AND REAR BRAKES
CHAS
EAS00615
6 Nm (0.6 mSkg, 4.3 ftSlb)
Order
Job/Part
Q’ty
Disassemble the parts in the order listed.
NOTE:
The following procedure applies to both
of the front brake calipers.
Disassembling the front brake
calipers
1
2
3
4
5
6
7
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
Remarks
2
1
1
2
4
8
1
For assembly, reverse the disassembly
procedure.
4-35
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
30 Nm (3.0 mSkg, 22 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
28 Nm (2.8 mSkg, 20 ftSlb)
Order
1
2
3
4
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-36
FRONT AND REAR BRAKES
CHAS
EAS00617
2.5 Nm (0.25 mSkg, 1.8 ftSlb)
18 Nm (1.8 mSkg, 13 ftSlb)
6 Nm (0.6 mSkg, 4.3 ftSlb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
Disassembling the rear brake caliper
Screw plug
Brake pad pin
Brake pad
Brake pad shim
Brake pad spring
Brake caliper piston
Brake caliper piston seal
Bleed screw
1
1
2
4
1
1
2
1
Remarks
Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
4-37
FRONT AND REAR BRAKES
CHAS
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
S brake caliper pistons 1
S 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
S Never try to pry out the brake caliper pistons.
S 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.
4-38
FRONT AND REAR BRAKES
CHAS
EAS00627
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
S brake caliper 4
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
S brake caliper piston 1
S brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the pistons from
the brake caliper.
WARNING
S Cover the brake caliper piston with a rag.
Be careful not to get injured when the pistons are expelled from the brake caliper.
S Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
4-39
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 four years
Brake fluid
Every two years
and whenever the
brake is disassembled
1. Check:
S brake caliper pistons 1
Rust/scratches/wear ! Replace the brake
caliper pistons.
S brake caliper cylinders 2
Scratches/wear ! Replace the brake caliper assembly.
S brake caliper body 3
Cracks/damage ! Replace the brake caliper assembly.
S brake fluid delivery passages
(brake caliper body)
Obstruction ! Blow out with compressed air.
A
B
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
S rear brake caliper bracket 1
Cracks/damage ! Replace.
4-40
FRONT AND REAR BRAKES
CHAS
EAS00640
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
S Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
S brake pads
S brake pad spring
S brake pad pin
2. Install:
S brake caliper 1
40 Nm (4.0 mSkg, 29 ftSlb)
S copper washers New
S brake hose 2
S union bolt 3
30 Nm (3.0 mSkg, 22 ftSlb)
S brake hose holder
7 Nm (0.7 mSkg, 5.1 ftSlb)
Refer to “REPLACING THE BRAKE PADS”.
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.
4-41
FRONT AND REAR BRAKES
CHAS
3. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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.
4. Bleed:
S brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
S 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:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-42
CHAS
FRONT AND REAR BRAKES
ASSEMBLING AND INSTALLING THE
REAR BRAKE CALIPER
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
S Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
S brake caliper 1
(front)
28 Nm (2.8 mSkg, 20 ftSlb)
(rear)
23 Nm (2.3 mSkg, 17 ftSlb)
S brake pad pin
S screw plug
S copper washers New
S brake hose 2
S union bolt 3
30 Nm (3.0 mSkg, 22 ftSlb)
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 that the brake pipe
a touches the projection b on the brake
caliper.
2. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
4-43
FRONT AND REAR BRAKES
CHAS
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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:
S brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
S 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. Check:
S brake pedal operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-44
FRONT FORK
CHAS
EAS00647
FRONT FORK
FRONT FORK LEGS
33 Nm (3.3 mSkg, 24 ftSlb)
26 Nm (2.6 mSkg, 19 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
6 Nm (0.6 mSkg, 4.3 ftSlb)
Order
1
2
3
4
5
6
Job/Part
Removing the front fork legs
Front wheel
Front brake calipers
Front cowling inner panels
Front fender
Cap bolt
Handlebar pinch bolt
Upper bracket pinch bolt
Under bracket pinch bolt
Front fork leg
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT AND REAR BRAKES”.
Refer to “COWLINGS” in chapter 3.
1
1
1
1
2
1
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-45
FRONT FORK
CHAS
EAS00648
23 Nm (2.3 mSkg, 17 ftSlb)
15 Nm (1.5 mSkg, 11 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
Order
Job/Part
Q’ty
Disassemble the parts in the order listed.
NOTE:
The following the procedure applies to
both of the front fork legs.
Disassembling the front fork legs
1
2
3
4
5
6
7
8
9
10
11
12
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Washer
Fork spring
Dust seal
Oil seal clip
Damper rod assembly bolt
Copper washer
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
4-46
FRONT FORK
CHAS
23 Nm (2.3 mSkg, 17 ftSlb)
15 Nm (1.5 mSkg, 11 ftSlb)
40 Nm (4.0 mSkg, 29 ftSlb)
Order
13
14
15
16
17
18
19
Job/Part
Damper rod assembly
Inner tube
Oil seal
Washer
Outer tube bushing
Inner tube bushing
Oil lock piece
Q’ty
Remarks
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-47
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. Remove
S front wheel
S front brake caliper
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
3. Remove:
S front cowling inner panels
Refer to “COWLINGS” in chapter 3.
S handlebar
4. Loosen:
S handlebar pinch bolt 1
S upper bracket pinch bolt 2
S cap bolt 3
S under bracket pinch bolt 4
WARNING
Before loosening the upper and under
bracket pinch bolts, support the front fork
leg.
5. Remove:
S front fork leg
4-48
FRONT FORK
CHAS
EAS00655
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Loosen:
S nut 1
2. Remove:
S cap bolt 2
(from the damper rod assembly)
3. Remove:
S damper adjusting rod 1
S washer 2
S spacer 3
S fork spring
4. Drain:
S fork oil
NOTE:
Stroke the damper rod 1 several times while
draining the fork oil.
5. Remove:
S dust seal
S oil seal clip 1 (with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
6. Remove:
S damper rod assembly bolt
S copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 , loosen the damper rod assembly
bolt.
4-49
FRONT FORK
CHAS
Damper rod holder
90890-01473
7. Remove:
S damper rod assembly
8. Remove:
S inner tube
S oil seal
S inner tube bushing
a. Hold the front fork leg horizontally.
b. Slowly push A the inner tube into the outer
tube and just before it bottoms out, pull B the
inner tube back quickly.
c. Repeat this step until the inner tube separates from the outer tube.
EAS00657
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
S inner tube 1
S 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:
S spring free length a
Out of specification ! Replace.
Spring free length
249.3 mm (9.81 in)
<Limit> :
244.3 mm (9.62 in)
3. Check:
S damper rod 1
Damage/wear ! Replace.
Obstruction ! Blow out all of the oil passages with compressed air.
S oil lock piece 2
S damper rod adjusting rod 3
Bends/damage ! Replace.
4-50
FRONT FORK
CHAS
CAUTION:
S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly
sensitive to foreign material.
S When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
4. Check:
S 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
S Make sure the oil levels in both front fork
legs are equal.
S Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
S When assembling the front fork leg, be sure to
replace the following parts:
– inner tube bushing
– outer tube bushing
– oil seal
– dust seal
S Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
S inner tube bushing
S oil lock piece
S inner tube 1
S damper rod assembly 2
S damper rod assembly bolt
S copper washer New
4-51
FRONT FORK
CHAS
WARNING
Always use new copper washers.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube 1 until it protrudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:
S inner tube’s outer surface
Recommended lubricant
Suspension oil “01” or
equivalent
3. Tighten:
S damper rod assembly bolt 1
40 Nm (4.0 mSkg, 29 ftSlb)
LOCTITE
NOTE:
While holding the damper rod assembly with the
damper rod holder 2 , tighten the damper rod
assembly bolt.
Damper rod holder
90890-01473
4. Install:
S outer tube bushing 1
(with the fork seal driver weight 2 and fork
seal driver attachment 3 )
Fork seal driver weight
90890-01367, YM-33963
Fork seal driver attachment
90890-01374, YM-8020-A
4-52
FRONT FORK
CHAS
5. Install:
S washer
S oil seal 1
(with the fork seal driver weight and fork seal
driver attachment)
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
S Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
S Lubricate the outer surface of the inner tube
with fork oil.
S 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.
6. Install:
S oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7. Install:
S dust seal 1
(with the fork seal driver weight)
8. Install:
S rod puller 1
S adapter 2
(onto the damper rod 3 )
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436
4-53
FRONT FORK
CHAS
9. Fully compress the front fork leg.
10. Fill:
S front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.49 L (0.43 Imp qt, 0.52 US qt)
Recommended oil
Suspension oil “01”
CAUTION:
S Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
S When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
11. 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.
12. Slowly stroke the inner tube 1 up and down
to distribute the fork oil once more (1 stroke
= about 100 mm (3.94 in)).
NOTE:
Be careful not to stroke the inner tube over 100
mm (3.94 in) as this will cause air to enter. If the
inner tube is stroked more than 100 mm (3.94
in), repeat steps (12) and (13).
13. 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.
4-54
FRONT FORK
CHAS
14. Measure:
S 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)
106 mm (4.17 in)
15. Install:
S nut 1
S fork spring 2
S washer 3
S spacer 4
S washer 5
S damper adjusting rod 6
S cap bolt 7
a. Remove the rod puller and rod puller attachment.
b. Install the damper adjusting rod locknut 1
and position it as specified a .
Damper adjusting rod nut position
(from the top of the rod to the top
of the nut) a
11 mm (0.43 in)
c. Set the cap bolt distance b to specification.
Distance b
25 mm (0.98 in)
d. Install the damper adjusting rod, fork spring,
washer (lower), spacer and washer (upper).
NOTE:
Install the fork spring with the smaller pinch a
facing up.
b Larger pitch
4-55
FRONT FORK
CHAS
e. Install the cap bolt and finger tighten it.
WARNING
S Before installing the cap bolt, apply grease
onto the O-ring.
S Always use a new cap bolt O-ring.
f. Hold the cap bolt and tighten the nut to specification.
Nut
15 Nm (1.5 mSkg, 11 ftSlb)
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
S handlebar (temporarily)
2. Install:
S front fork leg
Temporarily tighten the upper and under
bracket pinch bolts.
NOTE:
Make sure the inner fork tube is flush with the
top of the handlebar.
3. Remove:
S handlebar
4. Tighten:
S under bracket pinch bolt
23 Nm (2.3 mSkg, 17 ftSlb)
S upper bracket pinch bolt 1
S cap bolt 2
4-56
26 Nm (2.6 mSkg, 19 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
CHAS
FRONT FORK
5. Install:
S handlebar
S handlebar pinch bolt 1
33 Nm (3.3 mSkg, 24 ftSlb)
S handlebar bolt 2
13 Nm (1.3 mSkg, 9.4 ftSlb)
WARNING
Make sure the brake hoses are routed properly.
6. Adjust:
S spring preload
S rebound damping
S compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
4-57
HANDLEBARS
CHAS
EAS00665
HANDLEBARS
33 Nm (3.3 mSkg, 24 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
11 Nm (1.1 mSkg, 8.0 ftSlb)
33 Nm (3.3 mSkg, 24 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Removing the handlebars
Grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right handlebar switch
Throttle grip
Throttle cables
Front brake light switch connector
Front brake master cylinder holder
Front brake master cylinder
Reservoir tank bracket
Handlebar
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
1
1
1
1
1
2
2
1
1
1
2
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4-58
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:
S grip end
S handlebar grip
NOTE:
Blow compressed air between the left handlebar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:
S left handlebar switch 1
S clutch lever holder 2
4. Remove:
S grip end
S right handlebar switch 1
S throttle grip 2
S front brake master cylinder 3
EAS00669
CHECKING THE HANDLEBARS
1. Check:
S left handlebar
S right handlebar
Bends/cracks/damage ! Replace.
WARNING
Do not attempt to straighten bent handlebars as this may dangerously weaken them.
4-59
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:
S throttle cables
S throttle grip 1
S right handlebar switch 2
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the right handlebar.
3. Install:
S right handlebar 1
S right handlebar pinch bolt 2
33 Nm (3.3 mSkg, 24 ftSlb)
S right handlebar bolt 3
13 Nm (1.3 mSkg, 9.4 ftSlb)
4. Install:
S front brake master cylinder 1
S master cylinder holder 2
13 Nm (1.3 mSkg, 9.4 ftSlb)
CAUTION:
S Install the brake master cylinder holder
with the “UP” mark facing up.
S First, tighten the upper bolt, and then the
lower bolt.
NOTE:
S Align the mating surfaces of the brake master
cylinder holder with the punch mark a on the
right handlebar.
S There should be 8.2 mm (0.32 in) of clearance
between the right handlebar switch and the
brake master cylinder holder.
4-60
CHAS
HANDLEBARS
5. Install:
S clutch lever holder 1
11 Nm (1.1 mSkg, 8.0 ftSlb)
NOTE:
Align the slit on the clutch lever holder with the
punch mark a on the left handlebar.
6. Install:
S left handlebar
S left handlebar pinch bolt 1
33 Nm (3.3 mSkg, 24 ftSlb)
S left handlebar bolt 2
13 Nm (1.3 mSkg, 9.4 ftSlb)
7. Install:
S left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b on the left handlebar.
8. Install:
S handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
9. Install:
S grip ends
4-61
23 Nm (2.3 mSkg, 17 ftSlb)
HANDLEBARS
CHAS
10. Adjust:
S clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10 X 15 mm (0.39 X 0.59 in)
11. Adjust:
S 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)
6 X 8 mm (0.24 X 0.31 in)
4-62
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
UNDER BRACKET
26 Nm (2.6 mSkg, 19 ftSlb)
113 Nm (11.3 mSkg, 82 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
1st 52 Nm (5.2 mSkg, 38 ftSlb)
2nd 14 Nm (1.4 mSkg, 10 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Removing the under bracket
Front wheel
Front brake calipers
Front fork legs
Front fender
Handlebars
Fuel tank
Air filter case
1
2
3
4
5
6
7
Main switch coupler
Steering stem nut
Washer
Upper bracket
Under bracket panel
Lock washer
Upper ring nut
Remarks
Refer to “FRONT FORK”.
2
1
1
1
1
1
1
4-63
Refer to “HANDLEBARS”.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Disconnect
STEERING HEAD
CHAS
26 Nm (2.6 mSkg, 19 ftSlb)
113 Nm (11.3 mSkg, 82 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
1st 52 Nm (5.2 mSkg, 38 ftSlb)
2nd 14 Nm (1.4 mSkg, 10 ftSlb)
Order
8
9
10
11
12
13
14
15
16
Job/Part
Rubber washer
Lower ring nut
Under bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race
Q’ty
Remarks
1
1
1
1
2
1
1
1
2
For installation, reverse the removal
procedure.
4-64
STEERING HEAD
CHAS
EAS00679
REMOVING THE UNDER 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:
S steering stem nut
S washer
S upper bracket
S lock washer
S rubber washer
S ring nut 1
(with the steering nut wrench 2 )
NOTE:
Hold the lower ring nut with the exhaust and
steering nut wrench, and then remove the upper
ring nut with the ring nut wrench.
Steering nut wrench
90890-01403, YU-33975
WARNING
Securely support the under bracket so that
there is no danger of it falling over.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
S bearings
S bearing races
Recommended cleaning solvent
Kerosene
2. Check:
S bearings 1
S bearing races 2
Damage/pitting ! Replace.
4-65
STEERING HEAD
CHAS
3. Replace:
S bearings
S bearing races
a. Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer.
b. Remove the bearing race 3 from the under
bracket with a floor chisel 4 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:
S Always replace the bearings and bearing
races as a set.
S Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
S upper bracket
S under bracket
(along with the steering stem)
Bends/cracks/damage ! Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
S upper bearing
S lower bearing
S bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
S lower ring nut 1
S rubber washer 2
S upper ring nut 3
S lock washer 4
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
4-66
STEERING HEAD
3. Install:
S upper bracket
S washer
S steering stem nut
CHAS
113 Nm (11.3 mSkg, 82 ftSlb)
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
S front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
NOTE:
Temporarily tighten the upper and under bracket pinch bolts.
5. Install:
S front wheel
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
4-67
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
52 Nm (5.2 mSkg, 38 ftSlb)
44 Nm (4.4 mSkg, 32 ftSlb)
44 Nm (4.4 mSkg, 32 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the rear shock absorber
assembly
Rear wheel
1
2
3
4
5
6
7
8
Self-locking nut/bolt
(Relay arm – rear shock absorber)
Self-locking nut/bolt
(Rear shock absorber upper)
Rear shock absorber
Self-locking nut/bolt
(Relay arm – swingarm)
Self-locking nut/bolt
(Relay arm – connecting rod)
Relay arm
Self-locking nut/nut
(Connecting rod – frame)
Connecting rod
Remarks
Refer to “REAR WHEEL AND BRAKE
DISC”.
1/1
1/1
1
1/1
1/1
2
1/1
1
4-68
REAR SHOCK ABSORBER ASSEMBLY
CHAS
52 Nm (5.2 mSkg, 38 ftSlb)
44 Nm (4.4 mSkg, 32 ftSlb)
44 Nm (4.4 mSkg, 32 ftSlb)
Order
9
10
11
Job/Part
Oil seal/bearing/collar
Oil seal/bearing/collar
Bracket
Q’ty
Remarks
6/3/3
2/1/1
1
For installation, reverse the removal
procedure.
4-69
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
S Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
S Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.
S Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. To
release the gas pressure, drill a 2 X 3 mm (0.08
X 0.12 in) hole through the gas cylinder at a
point 15 X 20 mm (0.59 X 0.79 in) from its end
as shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
4-70
REAR SHOCK ABSORBER ASSEMBLY
CHAS
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.
2. Remove:
S rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
3. Remove:
S rear shock absorber assembly lower bolt 1
NOTE:
While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:
S rear shock absorber assembly upper bolt 1
S rear shock absorber assembly
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
S rear shock absorber rod
Bends/damage ! Replace the rear shock
absorber assembly.
S rear shock absorber
Gas leaks/oil leaks ! Replace the rear
shock absorber assembly.
4-71
REAR SHOCK ABSORBER ASSEMBLY
CHAS
S spring
Damage/wear ! Replace the rear shock absorber assembly.
S gas cylinder
Damage/gas leaks ! Replace.
S bushings
Damage/wear ! Replace.
S dust seals
Damage/wear ! Replace.
S bolts
Bends/damage/wear ! Replace.
CHECKING THE CONNECTING ROD AND
RELAY ARMS
1. Check:
S connecting rod 1
S relay arms 2
Damage/wear ! Replace.
2. Check:
S bearings 3
S oil seals 4
Damage/pitting ! Replace.
3. Check:
S collars 5
Damage/scratches ! Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
S spacers
S bearings
Recommended lubricant
Lithium-soap-based grease
2. Install:
S rear shock absorber assembly
NOTE:
When installing the rear shock absorber assembly, lift up the swingarm.
3. Tighten:
S rear shock absorber assembly upper nut 1
44 Nm (4.4 mSkg, 32 ftSlb)
S rear shock absorber assembly lower nut 2
44 Nm (4.4 mSkg, 32 ftSlb)
4-72
SWINGARM AND DRIVE CHAIN
CHAS
EAS00700
SWINGARM AND DRIVE CHAIN
16 Nm (1.6 mSkg, 12 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
95 Nm (9.5 mSkg, 69 ftSlb)
Order
6 Nm (0.6 mSkg, 4.3 ftSlb)
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the swingarm and drive
chain
Rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE” in chapter 5.
Rear shock absorber assembly
Relay arms and connecting rod
1
2
3
4
5
6
7
8
9
Drive sprocket cover
Adjusting bolt
Locknut
Rear fender
Pivot shaft nut/washer
Pivot shaft
Swingarm
Drive chain
Drive chain guide
Dust cover
Remarks
2
2
1
1/1
1
1
1
1
2
4-73
SWINGARM AND DRIVE CHAIN
CHAS
16 Nm (1.6 mSkg, 12 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
95 Nm (9.5 mSkg, 69 ftSlb)
Order
10
11
12
13
Job/Part
Bearing
Spacer
Pivot shaft adjust bolt
Drive chain case
6 Nm (0.6 mSkg, 4.3 ftSlb)
Q’ty
Remarks
2
1
1
1
For installation, reverse the removal
procedure.
4-74
SWINGARM AND DRIVE CHAIN
CHAS
EAS00703
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. Remove:
S rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
S rear shock absorber assembly, relay arm
and connecting rod
Refer to “REAR SHOCK ABSORBER ASSEMBLY”.
3. Measure:
S swingarm side play
S swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
95 Nm (9.5 mSkg, 69 ftSlb)
b. Measure the swingarm side play A by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
4-75
SWINGARM AND DRIVE CHAIN
CHAS
EAS00704
REMOVING THE DRIVE CHAIN
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:
S drive chain (with the drive chain cutter)
EAS00707
CHECKING THE SWINGARM
1. Check:
S swingarm
Bends/cracks/damage ! Replace.
2. Check:
S pivot shaft
Roll the pivot shaft on a flat surface.
Bends ! Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
S pivot shaft
S dust covers
S spacer
S washers
S bearings
Recommended cleaning solvent
Kerosene
4-76
SWINGARM AND DRIVE CHAIN
CHAS
4. Check:
S dust covers 1
S spacer 2
Damage/wear ! Replace.
S bearings
Damage/pitting ! Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:
S ten-link section a of the drive chain
Out of specification ! Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm (5.91 in)
NOTE:
S While measuring the ten-link section, push
down on the drive chain to increase its tension.
S Measure the length between drive chain roller
1 and 11 as shown.
S Perform this measurement at two or three different places.
2. Check:
S drive chain
Stiffness ! Clean and lubricate or replace.
3. Clean:
S drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
4-77
SWINGARM AND DRIVE CHAIN
CHAS
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s internals, and solvents will deteriorate the Orings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more then ten minutes. O-ring is
damage by kerosine.
4. Check:
S O-rings 1
Damage ! Replace the drive chain.
S drive chain rollers 2
Damage/wear ! Replace the drive chain.
S drive chain side plates 3
Damage/wear ! Replace the drive chain.
Cracks ! Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:
S drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
S drive sprocket
S rear wheel sprocket
More than 1/4 tooth a wear ! Replace the
drive chain sprockets as a set.
Bent teeth ! Replace the drive chain sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
4-78
CHAS
SWINGARM AND DRIVE CHAIN
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
S bearings
S spacers
S dust covers
S pivot shaft
Recommended lubricant
Lithium-soap-based grease
2. Install:
S pivot shaft adjust bolt 1
6 Nm (0.6 mSkg, 4.3 ftSlb)
S swingarm
S pivot shaft
95 Nm (9.5 mSkg, 69 ftSlb)
NOTE:
Use the pivot shaft wrench 2 and adapter 3 to
tighten the pivot adjust bolt to specification
torque.
Pivot shaft wrench:
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
3. Install:
S relay arms 1
S connecting rod 2
44 Nm (4.4 mSkg, 32 ftSlb)
44 Nm (4.4 mSkg, 32 ftSlb)
NOTE:
Install the connecting rod front bolt 3 from the
left.
4. Install:
S rear shock absorber assembly
S rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “INSTALLING THE REAR WHEEL”.
5. Adjust:
S drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
35 X 45 mm (1.38 X 1.77 in)
4-79
ENGINE
ENG
OVERHAULING THE ENGINE
ENGINE
DRIVE SPROCKET
10 Nm (1.0 mSkg, 7.2 ftSlb)
6.5 Nm (0.65 mSkg, 4.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
5
90 Nm (9.0 mSkg, 65 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the drive sprocket
Bottom cowling
Side cowlings
Drive chain
1
2
3
4
5
6
7
8
Remarks
Refer to “COWLINGS” in chapter 3.
2
1
1
1
1
1
1
1
Lock nut
Shift rod
Shift arm
Drive sprocket cover
Nut
Lock washer
Chain guide
Drive sprocket
Loosen.
Refer to “ADJUSTING THE DRIVE
CHAIN” in chapter 3.
Loosen.
For installation, reverse the removal
procedure.
5-1
ENGINE
ENG
EAS00189
EXHAUST PIPE
20 Nm (2.0 mSkg, 15 ftSlb)
20 Nm (2.0 mSkg, 15 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
20 Nm (2.0 mSkg, 15 ftSlb)
Order
1
2
3
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the exhaust pipe
Bottom cowling
Side cowlings
Muffler
Exhaust pipe assembly
Exhaust pipe gasket
Refer to “COWLINGS” in chapter 3.
1
1
4
For installation, reverse the removal
procedure.
5-2
ENGINE
ENG
EAS00188
LEADS AND HOSES
20 Nm (2.0 mSkg, 15 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
Job/Part
Q’ty
Disconnecting the leads and hoses
Air filter case
Throttle body assembly
Disconnect the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in chapter
8.
Engine oil
Oil filter cartridge
Oil cooler
Air cut-off valve
Starter motor
1
2
Battery negative lead
Battery positive lead
Remarks
1
1
CAUTION:
First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnection procedure.
5-3
ENGINE
ENG
20 Nm (2.0 mSkg, 15 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
3
4
5
6
7
8
9
10
Job/Part
Q’ty
1
1
1
1
1
1
1
1
Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler
5-4
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For connecting reverse the disconnection
procedure.
ENGINE
ENG
EAS00191
ENGINE
45 Nm (4.5 mSkg, 33 ftSlb)
45 Nm (4.5 mSkg, 33 ftSlb)
45 Nm (4.5 mSkg, 33 ftSlb)
45 Nm (4.5 mSkg, 33 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
Order
Job/Part
Q’ty
Removing the parts in the order listed.
NOTE:
Place a suitable stand under the frame and
engine.
Removing the engine
1
2
3
4
5
6
7
8
9
Remarks
1
2
2
2
2
2
1
2
1
Drive chain guide
Right front engine mounting bolt
Left front engine mounting bolt
Self-locking nut
Rear engine mounting bolt
Engine bracket bolt
Engine bracket
Engine mounting adjust bolt
Engine
Refer to “INSTALLING THE ENGINE”.
NOTE:
Use the pivot shaft wrench and adapter to
loosen the engine mounting adjust bolts.
For installation, reverse the removal
procedure.
5-5
ENGINE
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
S engine bracket 1 (to the engine)
45 Nm (4.5 mSkg, 33 ftSlb)
S engine mounting adjust bolts
(temporary tighten)
2. Install:
S rear engine mounting bolts 1
NOTE:
S Lubricate the rear engine mounting bolt
threads with lithium-soap-based grease.
3. Install:
S right front engine mounting bolts 1
(temporary tighten)
S left front engine mounting bolts 2
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the rear side engine mounting bolt.
4. Tighten:
S engine mounting adjust bolts
7 Nm (0.7 mSkg, 5.1 ftSlb)
NOTE:
S First tighten the lower engine mounting adjust
bolt.
S Use the pivot shaft wrench 1 and pivot shaft
wrench adapter 2 to tighten the engine
mounting adjust bolts.
5-6
ENGINE
ENG
Pivot shaft wrench
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
5. Tighten:
S nuts 1 (rear engine mounting bolts)
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the lower self-locking nut.
6. Tighten:
S right front engine mounting bolts 1
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the rear side engine mounting bolt.
7. Install:
S shift arm 1
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
S Align the punch mark a in the shift shaft with
the slot in the shift arm.
S Align the bottom edge of the shift pedal with the
mark on the frame-to-swingarm bracket.
8. Install:
S drive chain guide 1
7 Nm (0.7 mSkg, 5.1 ftSlb)
5-7
CAMSHAFTS
ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
10 Nm (1.0 mSkg, 7.2 ftSlb)
13 Nm (1.3 mSkg, 9.4 ftSlb)
Order
Job/Part
12 Nm (1.2 mSkg, 8.7 ftSlb)
Q’ty
Remove the parts in the order listed.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Removing the cylinder head cover
Throttle body assembly
Radiator assembly
Air cut-off valve
1
2
3
4
5
6
Remarks
4
4
1
1
1
1
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
Cylinder identification sensor
For installation, reverse the removal
procedure.
5-8
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
10 Nm (1.0 mSkg, 7.2 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
24 Nm (2.4 mSkg, 17 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
Job/Part
Q’ty
Removing the camshafts
Pickup rotor cover
1
2
3
4
5
6
7
8
9
10
11
12
4
1
1
1
3
6
3
6
1
1
1
1
Camshaft sprocket bolt
Timing chain tensioner
Timing chain tensioner gasket
Timing chain guide (exhaust side)
Intake camshaft cap
Dowel pin
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Pin
Timing chain guide (intake side)
Remarks
Remove the parts in the order listed.
Refer to “CRANKSHAFT POSITION
SENSOR AND PICKUP ROTOR”.
Loosen.
NOTE:
During removal, the dowel pins may still
be connected to the camshaft caps.
For installation, reverse the removal
procedure.
5-9
CAMSHAFTS
ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:
S pickup rotor cover
Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”.
2. Align:
S “T” mark a on the pickup rotor
(with the crankcase mating surface b )
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the pickup 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.
3. Loosen:
S camshaft sprocket bolts 1
4. Loosen:
S cap bolt 1
5. Remove:
S timing chain tensioner 2
S gasket
6. Remove:
S timing chain guide (exhaust side)
S camshaft caps 1
S 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.
5-10
CAMSHAFTS
ENG
7. Remove:
S intake camshaft 1
S exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire a .
8. Remove:
S camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
S camshaft lobes
Blue discoloration/pitting/scratches ! Replace the camshaft.
2. Measure:
S camshaft lobe dimensions a and b
Out of specification ! Replace the camshaft.
Camshaft lobe dimension limit
Intake camshaft
a 33.45 X 33.55 mm
(1.317 X 1.321 in)
<Limit>: 33.40 mm (1.315 in)
b 25.12 X 25.22 mm
(0.989 X 0.993 in)
<Limit>: 25.07 mm (0.987 in)
Exhaust camshaft
a 32.55 X 32.65 mm
(1.282 X 1.285 in)
<Limit>: 32.50 mm (1.280 in)
b 25.07 X 25.17 mm
(0.987 X 0.991 in)
<Limit>: 25.02 mm (0.985 in)
5-11
CAMSHAFTS
ENG
3. Measure:
S camshaft runout
Out of specification ! Replace.
Camshaft runout limit
0.06 mm (0.0024 in)
4. Measure:
S camshaft-journal-to-camshaft-cap
clearance
Out of specification ! Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.028 X 0.062 mm
(0.0011 X 0.0024 in)
<Limit>: 0.08 mm (0.0031 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
S Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
S Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge.
Camshaft cap bolt
10 Nm (1.0 mSkg, 7.2 ftSlb)
d. Remove the camshaft caps and then measure the width of the Plastigauge 1 .
5. Measure:
S 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
22.967 X 22.980 mm
(0.9042 X 0.9047 in)
5-12
CAMSHAFTS
ENG
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
S timing chain 1
Damage/stiffness ! Replace the timing
chain and camshaft sprockets as a set.
2. Check:
S camshaft sprocket
More than 1/4 tooth wear a ! Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
S timing chain guide (exhaust side) 1
S timing chain guide (intake side) 2
S timing chain guide (top side) 3
Damage/wear ! Replace the defective
part(s).
EAS00210
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
S timing chain tensioner
Cracks/damage ! Replace.
2. Check:
S one-way cam operation
Rough movement ! Replace the timing
chain tensioner assembly.
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.
5-13
CAMSHAFTS
ENG
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.
3. Check:
S cap bolt
S copper washer New
S gasket New
Damage/wear ! Replace the defective
part(s).
EAS00215
INSTALLING THE CAMSHAFTS
1. Align:
S “T” mark a on the pickup rotor
(with the crankcase mating surface b )
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC, align the “T” mark
a with the crankcase mating surface b .
2. Install:
S exhaust camshaft 1
S intake camshaft 2
(with the camshaft sprocket temporarily
tightened)
NOTE:
Make sure the match mark a on the camshaft
sprocket is aligned with the cylinder head edge
b.
5-14
ENG
CAMSHAFTS
3. Install:
S dowel pins
S exhaust camshaft caps
S intake cmashaft caps
NOTE:
S Make sure each camshaft cap is installed in its
original place.
S Make sure the arrow mark a on each camshaft cap points towards the right side of the
engine.
4. Install:
S camshaft cap bolts
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
I1, 12: Intake side camshaft cap mark
E1, E2: Exhaust side camshaft cap mark
CAUTION:
S Lubricate the camshaft cap bolts with the
engine oil.
S The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
S Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
5. Install:
S timing chain guide (exhaust side)
NOTE:
When installing the timing chain guide, be sure
to keep the timing chain as tight as possible on
the exhaust side.
5-15
ENG
CAMSHAFTS
6. Install:
S 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 .
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.
Timing chain tensioner bolt
12 Nm (1.2 mSkg, 8.7 ftSlb)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.
Cap bolt
7 Nm (0.7 mSkg, 5.1 ftSlb)
7. Turn:
S crankshaft
(several full turns clockwise)
8. Check:
S “T” mark a
Make sure the “T” mark on the pickup rotor is
aligned with the crankcase mating sure face
b.
S camshaft sprocket match mark c
Make sure the match marks on the camshaft
sprockets are aligned with the crankcase
mating surface d .
Out of alignment ! Adjust.
Refer to the installation steps above.
9. Tighten:
S camshaft sprocket bolts 1
24 Nm (2.4 mSkg, 17 ftSlb)
CAUTION:
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
5-16
CAMSHAFTS
ENG
10. Measure:
S valve clearance
Out of specification ! Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
5-17
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
1st 19 Nm (1.9 mSkg, 14 ftSlb)
2nd 50 Nm (5.0 mSkg, 36 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
1
2
3
Job/Part
Removing the cylinder head
Intake and exhaust camshaft
Engine bracket
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CAMSHAFTS”.
Refer to “ENGINE”.
1
1
2
For installation, reverse the removal
procedure.
5-18
CYLINDER HEAD
ENG
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
S cylinder head bolts
NOTE:
S Loosen the bolts in the proper sequence as
shown.
S Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
S combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
S spark plug bore threads
S valve seats
2. Check:
S cylinder head
Damage/scratches ! Replace.
S cylinder head water jacket
Mineral deposits/rust ! Eliminate.
3. Measure:
S cylinder head warpage
Out of specification ! Resurface the cylinder head.
Maximum cylinder head warpage
0.05 mm (0.002 in)
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400 X 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.
5-19
CYLINDER HEAD
ENG
EAS00233
INSTALLING THE CYLINDER HEAD
1. Install:
S gasket New 1
S dowel pins 2
2. Install:
S cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
S cylinder head bolts
1st
2nd
S cylinder head bolts
1 X 10
19 Nm (1.9 mSkg, 14 ftSlb)
50 Nm (5.0 mSkg, 36 ftSlb)
11 , 12
12 Nm (1.2 mSkg, 8.7 ftSlb)
NOTE:
S First, tighten the bolts 1 X 10 to approximately 19 Nm (1.9 mSkg, 14 ftSlb) with a torque
wrench and then tighten the 50 Nm (5.0 mSkg,
36 ftSlb).
S Lubricate the cylinder head bolts with engine
oil.
S Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
S exhaust camshaft
S intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
5-20
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
13
Remove the valves and valve springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring outer
Intake valve spring inner
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
8
8
16
8
8
8
8
8
8
8
8
8
16
5-21
Refer to “REMOVING/INSTALLING
THE VALVES”.
VALVES AND VALVE SPRINGS
Order
14
15
16
17
18
19
Job/Part
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Q’ty
8
8
8
8
8
8
ENG
Remarks
Refer to “REMOVING/INSTALLING
THE VALVES”.
For installation, reverse the removal
procedure.
5-22
VALVES AND VALVE SPRINGS
ENG
EAS00238
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:
S valve lifter 1
S 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:
S valve sealing
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 .
3. Remove:
S valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
2 and the valve spring compressor attachment
3.
5-23
VALVES AND VALVE SPRINGS
ENG
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
90890-04108, YM-01253
4. Remove:
S upper spring seat 1
S valve spring outer 2
S valve spring inner (intake only) 3
S valve 4
S oil seal 5
S lower spring seat 6
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.
1. Measure:
S 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 X 0.037 mm
(0.0004 X 0.0015 in)
<Limit>: 0.08 mm (0.0031 in)
Exhaust
0.025 X 0.052 mm
(0.0010 X 0.0020 in)
<Limit>: 0.10 mm
(0.0039 in)
5-24
VALVES AND VALVE SPRINGS
ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C (212_F) in an oven.
a. Remove the valve guide with the valve guide
remover 1 .
b. Install the new valve guide with the valve
guide 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-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover
(4 mm, 0.16 in)
90890-04111,
Valve guide installer
(4 mm, 0.16 in)
90890-04112,
Valve guide reamer (4 mm, 0.16 in)
90890-04113, YM-04113
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear ! Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem ! Replace the valve.
5-25
VALVES AND VALVE SPRINGS
ENG
5. Measure:
S valve margin thickness a
Out of specification ! Replace the valve.
Valve margin thickness
0.6 X 0.8 mm
(0.0236 X 0.0315 in)
<Limit>: 0.5 mm (0.02 in)
6. Measure:
S valve stem runout
Out of specification ! Replace the valve.
NOTE:
S When installing a new valve, always replace
the valve guide.
S If the valve is removed or replaced, always replace the oil seal.
Valve stem runout
<Limit>: 0.04 mm (0.0016 in)
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
S carbon deposits
(from the valve face and valve seat)
2. Check:
S valve seat
Pitting/wear ! Replace the cylinder head.
3. Measure:
S valve seat width a
Out of specification ! Replace the cylinder
head.
Valve seat width
0.9 X 1.1 mm
(0.0354 X 0.0433 in)
<Limit>: 1.6 mm (0.06 in)
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.
5-26
VALVES AND VALVE SPRINGS
ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
4. Lap:
S valve face
S 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.
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.
5-27
VALVES AND VALVE SPRINGS
ENG
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:
S valve spring free length a
Out of specification ! Replace the valve
spring.
Valve spring free length
Intake valve spring (inner)
35.7 mm (1.41 in)
<Limit>: 33.9 mm (1.33 in)
Intake valve spring (outer)
40.3 mm (1.59 in)
<Limit>: 38.3 mm (1.50 in)
Exhaust valve spring
41.7 mm (1.64 in)
<Limit>: 39.6 mm (1.56 in)
2. Measure:
S compressed valve spring force a
Out of specification ! Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
Intake valve spring (inner)
61.5 X 70.7 N
(6.27 X 7.21 kg,
13.83 X 15.89 lb)
Intake valve spring (outer)
139.1 X 160.1 N
(14.18 X 16.33 kg,
31.27 X 35.99 lb)
Exhaust valve spring
160 X 184 N
(16.32 X 18.76 kg,
35.97 X 41.36 lb)
5-28
VALVES AND VALVE SPRINGS
ENG
3. Measure:
S valve spring tilt a
Out of specification ! Replace the valve
spring.
Spring tilt limit
Intake valve spring (inner)
2.5_/1.6 mm (0.06 in)
(outer)
2.5_/1.8 mm (0.07 in)
Exhaust valve spring
2.5_/1.8 mm (0.07 in)
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
S valve lifter
Damage/scratches ! Replace the valve lifters and cylinder head.
EAS00246
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
S valve stem end
(with an oil stone)
2. Lubricate:
S valve stem 1
S valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
S valve 1
S lower spring seat 2
S valve stem seal 3
S valve spring inner (intake only) 4
S valve spring outer 5
S upper spring seat 6
(into the cylinder head)
5-29
VALVES AND VALVE SPRINGS
ENG
NOTE:
S Make sure that each valve is installed in its
original place.
S Install the valve springs with the larger pitch a
facing up.
b Smaller pitch
4. Install:
S valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
90890-04108, YM-01253
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. Install:
S valve pad 1
S valve lifter 2
NOTE:
S Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.
S The valve lifter must move smoothly when rotated with a finger.
S Each valve lifter and valve pad must be reinstalled in its original position.
5-30
STARTER CLUTCH AND GENERATOR
ENG
EAS00341
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
10 Nm (1.0 mSkg, 7.2 ftSlb)
32 Nm (3.2 mSkg, 23 ftSlb)
75 Nm (7.5 mSkg, 54 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Removing the stator coil assembly
Rider seat and fuel tank
Buttom cowling
Left side cowling
Coolant
Coolant reservoir tank
Refer to “COWLINGS” in chapter 3.
Engine oil
1
2
3
4
5
Stator coil assembly coupler
Generator rotor cover
Generator rotor cover gasket
Dowel pin
Stator coil assembly lead holder
Remarks
1
1
1
2
1
5-31
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
STARTER CLUTCH AND GENERATOR
ENG
10 Nm (1.0 mSkg, 7.2 ftSlb)
32 Nm (3.2 mSkg, 23 ftSlb)
75 Nm (7.5 mSkg, 54 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
6
7
8
9
10
11
12
13
Job/Part
Stator coil assembly
Generator rotor bolt
Washer
Generator rotor
Starter clutch assembly
Idler gear shaft
Idler gear
Starter clutch drive gear
Q’ty
1
1
1
1
1
1
1
1
Remarks
Refer to “REMOVING/INSTALLING
THE GENERATOR”.
For installation, reverse the removal
procedure.
5-32
STARTER CLUTCH AND GENERATOR
ENG
EAS00347
REMOVING THE GENERATOR
1. Remove:
S rider seat and fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter 3.
S buttom cowling
S left side cowling
Refer to “COWLINGS” in chapter 3.
2. Drain:
S coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.
S engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
3. Remove:
S generator rotor cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
4. Remove:
S generator rotor bolt 1
S washer
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , loosen the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
5-33
STARTER CLUTCH AND GENERATOR
ENG
5. Remove:
S generator rotor 1
(with the flywheel puller 2 and flywheel puller attachment)
S woodruff key
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the flywheel puller set’s center bolt and the crankshaft.
NOTE:
Make sure the flywheel puller is centered over
the generator rotor.
Flywheel puller
90890-01362, YU-33270
Flywheel puller attachment
90890-04089, YM-33282
REMOVING THE STARTER CLUTCH
1. Remove:
S starter clutch bolt 1
NOTE:
S While holding the generator rotor with the
sheave holder, remove the starter clutch bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
5-34
STARTER CLUTCH AND GENERATOR
ENG
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
S starter clutch rollers 1
Damage/wear ! Replace.
2. Check:
S starter clutch idle gear 1
S starter clutch drive gear 2
Burrs/chips/roughness/wear ! Replace
the defective part(s).
3. Check:
S starter clutch gear’s contacting surfaces a
Damage/pitting/wear ! Replace the starter
clutch gear.
4. Check:
S starter clutch operation
a. Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise A , 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 B , it should turn freely,
otherwise the starter clutch is faulty and must
be replaced.
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
S starter clutch
32 Nm (3.2 mSkg, 23 ftSlb)
LOCTITIER
NOTE:
S While holding the generator rotor 1 with the
sheave holder 2 , tighten the starter clutch
bolt.
5-35
ENG
STARTER CLUTCH AND GENERATOR
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
EAS00354
INSTALLING THE GENERATOR
1. Install:
S generator rotor
S washer New
S generator rotor bolt
NOTE:
S Clean the tapered portion of the crankshaft
and the generator rotor hub.
S Replace the washer with new one.
2. Tighten:
S generator rotor bolt 1
75 Nm (7.5 mSkg, 54 ftSlb)
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
3. Apply:
S sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-05-01
4. Install:
S stator coil
5. Install:
S generator rotor cover
12 Nm (1.2 mSkg, 8.7 ftSlb)
5-36
STARTER CLUTCH AND GENERATOR
ENG
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
6. Fill:
S engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
S coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.
7. Install:
S left side cowling
S buttom cowling
Refer to “COWLINGS” in chapter 3.
S rider seat and fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter 3.
5-37
SHIFT SHAFT
ENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
22 Nm (2.2 mSkg, 16 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the shift shaft and stopper
lever
Coolant reservoir tank
Coolant
1
2
3
4
5
6
7
8
9
10
Drive sprocket cover
Shift shaft cover
Shift shaft cover gasket
Dowel pin
Oil seal
Shift shaft
Shift shaft spring
Collar
Stopper lever spring
Circlip
Washer
Remarks
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Refer to “ENGINE”.
1
1
1
1
1
1
1
1
1
1
5-38
SHIFT SHAFT
ENG
22 Nm (2.2 mSkg, 16 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
11
12
13
14
Job/Part
Stopper lever
Collar
Washer
Shift shaft spring stopper
Q’ty
Remarks
1
1
1
1
For installation, reverse the removal
procedure.
5-39
SHIFT SHAFT
ENG
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
S shift shaft 1
Bends/damage/wear ! Replace.
S shift shaft spring 2
Damage/wear ! Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
S stopper lever 1
Bends/damage ! Replace.
Roller turns roughly ! Replace the stopper
lever.
EAS00332
INSTALLING THE SHIFT SHAFT
1. Install:
S shift shaft spring stopper 1
22 Nm (2.2 mSkg, 16 ftSlb)
S washers
S shift shaft 2
NOTE:
S Apply LOCTITE to the threads of the shift
shaft spring stopper.
S Hook the ends 3 of the stopper lever spring
onto the stopper lever 4 and the crankcase
boss.
S Mesh the stopper lever with the shift drum segment assembly.
2. Install:
S shift shaft cover
NOTE:
Lubricate the oil seal lips with lithium-soapbased grease.
5-40
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
ENG
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
10 Nm (1.0 mSkg, 7.2 ftSlb)
15 Nm (1.5 mSkg, 11 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
35 Nm (3.5 mSkg, 25 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the crankshaft position
sensor and pickup rotor
Rider seat
Fuel tank
Right side cowling
Bottom cowling
Engine oil
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Generator cover
1
2
3
4
5
Remarks
Clutch cable
Crankshaft position sensor lead coupler
Pickup rotor cover
Pickup rotor cover gasket
Dowel pin
1
1
1
1
2
5-41
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Disconnect.
Disconnect.
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
ENG
10 Nm (1.0 mSkg, 7.2 ftSlb)
15 Nm (1.5 mSkg, 11 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
35 Nm (3.5 mSkg, 25 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
6
7
8
Job/Part
Crankshaft position sensor
Pickup rotor
Plug screw
Q’ty
Remarks
1
1
1
For installation, reverse the removal
procedure.
5-42
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
ENG
REMOVING THE PICKUP ROTOR
1. Remove:
S clutch cable holder 1
S pickup rotor cover 2
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:
S pickup rotor bolt 1
S washer 2
S pickup rotor 3
NOTE:
While holding the generator rotor 4 with the rotor holding tool 5 , loosen the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
INSTALLING THE PICKUP ROTOR
1. Install:
S pickup rotor 1
S washer
S pickup rotor bolt
NOTE:
When installing the pickup rotor, align the
groove 2 in the crankshaft sprocket with the
point a in the pickup rotor.
5-43
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
ENG
2. Tighten:
S pickup rotor bolt 1
35 Nm (3.5 mSkg, 25 ftSlb)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
3. Apply:
S sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-5-01
4. Install:
S pickup rotor cover
S clutch cable holder
NOTE:
S When installing the pickup rotor cover, align
the timing chain guide (intake side) pin 1 of
the with the hole 2 in the pickup rotor cover.
S Tighten the pickup rotor cover bolts in stages
and in a crisscross pattern.
5-44
CLUTCH
ENG
EAS00273
CLUTCH
CLUTCH COVER
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Removing the parts in the order listed.
Removing the clutch cover
Bottom cowling
Right side cowling
Engine oil
Refer to “COWLINGS” in chapter 3.
Coolant
1
2
3
4
5
Coolant hose
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Remarks
1
1
1
1
2
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
5-45
CLUTCH
Order
1
2
3
4
5
6
Job/Part
Disassembling the clutch cover
Circlip
Washer
Pull lever
Pull lever spring
Oil seal
Bearing
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
2
2
1
1
1
2
For assembly, reverse the disassembly
procedure.
5-46
CLUTCH
ENG
EAS00274
CLUTCH
70 Nm (7.0 mSkg, 51 ftSlb)
8 Nm (0.8 mSkg, 5.8 ftSlb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the clutch
Compression spring
Pressure plate
Pull rod
Bearing
Friction plate (Brown)
Clutch plate (t=2.0 mm, 0.08 in)
Friction plate (Purple)
Clutch plate (t=2.3 mm, 0.09 in)
Clutch boss nut
Lock plate
Clutch boss
Thrust plate
Q’ty
Remarks
Remove the parts in the order listed.
6
1
1
1
6
7
2
1
1
1
1
1
For installation, reverse the removal
procedure.
5-47
CLUTCH
ENG
EAS00276
REMOVING THE CLUTCH
1. Remove:
S clutch cover 1
S gasket
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:
S compression spring bolts 1
S compression springs
S pressure plate 2
S pull rod 3
S friction plates
S clutch plates
3. Straighten the lock washer tab.
4. Loosen:
S clutch bass nut 1
NOTE:
While holding the clutch boss 2 with the universal clutch holder, loosen the clutch boss nut.
Universal clutch holder
90890-04086, YM-91042
5. Remove:
S clutch boss nut 1
S lock washer 2
S clutch boss 3
S thrust plate 4
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
S friction plate
Damage/wear ! Replace the friction plates
as a set.
5-48
CLUTCH
ENG
2. Measure:
S 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 X 3.1 mm (0.114 X 0.122 in)
<Limit>: 2.8 mm (0.110 in)
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
S clutch plate
Damage ! Replace the clutch plates as a
set.
2. Measure:
S clutch plate warpage
(with a surface plate and thickness gauge 1 )
Out of specification ! Replace the clutch
plates as a set.
Clutch plate warpage limit
0.1 mm (0.0039 in)
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
S clutch spring
Damage ! Replace the clutch springs as a
set.
5-49
CLUTCH
ENG
2. Measure:
S clutch spring free length a
Out of specification ! Replace the clutch
springs as a set.
Clutch spring free length
50 mm (1.97 in)
<Limit>: 49 mm (1.93 in)
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
S 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:
S bearing
Damage/wear ! Replace the bearing and
clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
S 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:
S pressure plate 1
Cracks/damage ! Replace.
S bearing 2
Damage/wear ! Replace.
5-50
CLUTCH
ENG
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
S pull lever shaft pinion gear teeth a
S pull rod teeth b
Damage/wear ! Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:
S pull rod bearing
Damage/wear ! Replace.
EAS00299
INSTALLING THE CLUTCH
1. Install:
S thrust plate 1
S clutch boss 2
S lock washer 3 New
S clutch boss nut 4
70 Nm (7.0 mSkg, 51 ftSlb)
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 5 , tighten the clutch boss nut.
Universal clutch holder
90890-04089, YM-91042
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
S friction plates
S clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-51
CLUTCH
ENG
5. Install:
S friction plates
S clutch plates
NOTE:
First, install a clutch plate and then alternate between a friction plate and a friction plate.
a. Install the clutch plate and friction plate at following the illustrated.
Clutch plate 1 : t=2.3 mm (0.09 in)
Clutch plate 2 : t=2.0 mm (0.08 in)
Friction plate 3 : Color code/Purple
Friction plate 4 : Color code/Brown
6. Install:
S pressure plate 1
NOTE:
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.
7. Install:
S bearing 1
S pull rod 2
S pressure plate 3
S clutch springs
S clutch spring bolts
8 Nm (0.8 mSkg, 5.8 ftSlb)
NOTE:
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
8. Install:
S pull lever
NOTE:
In stall the pull lever with the “UP” mark facing
toward lower side.
5-52
CLUTCH
ENG
9. Install:
S clutch cover
S gasket New
NOTE:
S Install the pull rod so that the teeth a face towards the rear of the motorcycle. Then, install
the clutch cover.
S Apply oil onto the bearing.
S Apply molybdenum disulfide grease onto the
pull rod.
S When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.
S Tighten the clutch cover bolts in stages and in
a crisscross pattern.
10. Adjust:
S clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
5-53
OIL PAN AND OIL PUMP
ENG
EAS00356
OIL PAN AND OIL PUMP
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
Job/Part
Q’ty
Removing the oil pan and oil pump
Engine oil
Coolant
1
2
3
4
5
6
7
8
Exhaust pipe assembly
Water pump
Oil level switch coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Oil strainer
Oil strainer gasket
1
1
1
1
1
2
1
1
5-54
43 Nm (4.3 mSkg, 31 ftSlb)
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “ENGINE”.
Refer to “WATER PUMP” in chapter 6.
Disconnect.
OIL PAN AND OIL PUMP
12 Nm (1.2 mSkg, 8.7 ftSlb)
ENG
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
9
10
11
12
13
Job/Part
Oil pipe
Oil delivery pipe
Oil pump assembly
Dowel pin
Relief valve assembly
Q’ty
43 Nm (4.3 mSkg, 31 ftSlb)
Remarks
1
1
1
2
1
For installation, reverse the removal
procedure.
5-55
OIL PAN AND OIL PUMP
ENG
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the oil pump
assembly
Oil pump cover
Pin
Oil pump inner rotor
Oil pump outer rotor
Pin
Washer
Oil pump rotor housing
Oil pump driver sprocket
Q’ty
Remarks
Disassemble the parts in the order listed.
1
2
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-56
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
S oil level switch 1
S oil pan 2
S oil pan gasket
S 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.
EAS00364
CHECKING THE OIL PUMP
1. Check:
S oil pump driven gear 1
S oil pump rotor housing 2
S oil pump cover
Cracks/damage/wear ! Replace the defective part(s).
2. Measure:
S inner-rotor-to-outer-rotor-tip clearance a
S outer-rotor-to-oil-pump-housing clearance
b
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.03 X 0.09 mm
(0.0012 X 0.0035 in)
<Limit>: 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing
clearance
0.03 X 0.08 mm
(0.0012 X 0.0031 in)
<Limit>: 0.15 mm (0.0059 in)
5-57
OIL PAN AND OIL PUMP
ENG
3. Check:
S oil pump operation
Rough movement ! Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
S relief valve body 1
S relief valve 2
S spring 3
S O-ring 4
Damage/wear ! Replace the defective
part(s).
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
S oil delivery pipe 1
S oil pipe 2
Damage ! Replace.
Obstruction ! Wash and blow out with compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
S oil strainer 1
Damage ! Replace.
Contaminants ! Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:
S oil nozzle 1
Damage/wear ! Replace the oil nozzle.
S O-ring 2
Damage/wear ! Replace.
S oil nozzle passage
Obstruction ! Blow out with compressed air.
5-58
OIL PAN AND OIL PUMP
ENG
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:
S inner rotor
S outer rotor
S oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
S oil pump housing 1
S oil pump shaft 2
S washer 3
S pin 4
S inner rotor 5
S outer rotor 6
S dowel pins 7
S oil pump cover 8
12 Nm (1.2 mSkg, 8.7 ftSlb)
NOTE:
When installing the inner rotor, align the pin 4 in
the oil pump shaft with the groove in the inner rotor 5 .
3. Check:
S oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
S oil pump drive chain
S gear cover
S oil pump
12 Nm (1.2 mSkg, 8.7 ftSlb)
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
5-59
OIL PAN AND OIL PUMP
ENG
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
S oil strainer 1
S relief valve 2
NOTE:
Make sure to check the arrow mark a located
on the oil strainer housing for the front and rear
direction of the engine and then install the oil
strainer so that its arrow mark points to the front
side of the engine.
EAS00380
INSTALLING THE OIL PAN
1. Install:
S oil pipe
S oil delivery pipe
2. Install:
S dowel pins
S gasket New
12 Nm (1.2 mSkg, 8.7 ftSlb)
S oil pan 1
S oil level switch 2
10 Nm (1.0 mSkg, 7.2 ftSlb)
S engine oil drain bolt
43 Nm (4.3 mSkg, 31 ftSlb)
WARNING
Always use new copper washers.
NOTE:
S Tighten the oil pan bolts in stages and in a
crisscross pattern.
S Lubricate the oil level switch O-ring with engine oil.
5-60
CRANKCASE
ENG
CRANKCASE
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION
SENSOR AND PICKUP ROTOR”.
Refer to “CLUTCH”.
Refer to “WATER PUMP” in chapter 6.
Refer to “OIL PAN AND OIL PUMP”.
Removing the crankcase
Engine
Cylinder head
Starter clutch and generator
1
2
3
4
5
Shift shaft
Crankshaft position sensor and pickup
rotor
Clutch
Water pump assembly
Oil pan and oil pump
Timing chain
Oil pump drive chain
Oil pump drive chain guide
Lower crankcase
Dowel pin
Remarks
1
1
1
1
3
5-61
CRANKCASE
ENG
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
6
7
8
Job/Part
Thrust plate
Washer
Plate
Q’ty
Remarks
1
1
1
For installation, reverse the removal
procedure.
5-62
CRANKCASE
ENG
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
S crankcase bolts
NOTE:
S 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.
S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).
S The numbers embossed on the crankcase indicate the crankcase tightening sequence.
M8
85 mm (3.3 in) bolts: 1 X 7 , 10
M8
115 mm (4.5 in) bolts: 8 , 9
M8
65 mm (2.6 in) bolts: 11 , 12
M6
65 mm (2.6 in) bolts: 13 , 14
M6
55 mm (2.2 in) bolts: 15 , 22 X 26
M6
45 mm (1.8 in) bolts: 16 , 19 , 20
M6
65 mm (2.6 in) bolts: 17 , 27
M6
75 mm (3.0 in) bolt: 18
M6
100 mm (3.9 in) bolts: 21
3. Remove:
S lower crankcase
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves separate evenly.
4. Remove:
S dowel pins
5. Remove:
S crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
5-63
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:
S crankcase
Cracks/damage ! Replace.
S oil delivery passages
Obstruction ! Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
S bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement ! Replace.
2. Check:
S oil seals
Damage/wear ! Replace.
CHECKING THE TIMING CHAIN
1 Check:
S timing chain 2
Damage/stiffness ! Replace the timing
chain and crankshaft sprocket as a set.
S oil/water pump assembly drive chain 1
Damage/stiffness ! Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
ASSEMBLING THE CRANKCASE
1. Lubricate:
S crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
S sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
5-64
CRANKCASE
ENG
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 X 3 mm of
the crankshaft journal bearings.
3. Install:
S dowel pin
4. Set the shift drum assembly and transmission gears in the neutral position.
5. Install:
S lower crankcase 1
(onto the upper crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift correctly when the shift drum assembly is
turned by hand.
6. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Install a washer on bolts 1 X 10 .
S Seal bolt 18
S Tighten the bolts in the tightening sequence
cast on the crankcase.
M8
M8
M8
M6
M6
M6
M6
M6
M6
85 mm (3.3 in) bolts: 1 X 7 , 10
115 mm (4.5 in) bolts: 8 , 9
65 mm (2.6 in) bolts: 11 , 12
65 mm (2.6 in) bolts: 13 , 14
55 mm (2.2 in) bolts: 15 , 22 X 26
45 mm (1.8 in) bolts: 16 , 19 , 20
65 mm (2.6 in) bolts: 17 , 27
75 mm (3.0 in) bolt: 18
100 mm (3.9 in) bolt: 21
Crankcase bolt
Bolt 1 X 10
1st: 12 Nm (1.2 mSkg, 8.7 ftSlb)
2nd: 25 Nm (2.5 mSkg, 18 ftSlb)
*3rd: 27 Nm (2.7 mSkg, 20 ftSlb)
Bolt 11 , 12
24 Nm (2.4 mSkg, 17 ftSlb)
Bolt 13 X 27
12 Nm (1.2 mSkg, 8.7 ftSlb)
* Loosen the all bolts following the tightening order and then tighten to specification torque.
5-65
CONNECTING RODS AND PISTONS
ENG
EAS00252
CONNECTING RODS AND PISTONS
15 Nm (1.5 mSkg, 11 ftSlb) +150_
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the connecting rods and
pistons
Lower crankcase
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE”.
4
4
4
8
4
4
4
4
4
4
For installation, reverse the removal
procedure.
5-66
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:
S connecting rod cap 1
S big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
S piston pin clips 1
S piston pin 2
S piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
S For reference during installation, put identification marks on the piston crown.
S Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore
area. If both areas are debarred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set 4 .
Piston pin puller set
90890-01304, YU-01304
3. Remove:
S top ring
S 2nd ring
S 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.
5-67
CONNECTING RODS AND PISTONS
ENG
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
S crankshaft assembly
S crankshaft journal upper bearings
(from the upper crankcase)
Refer to “CRANKSHAFT”.
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
EAS00261
CHECKING THE CYLINDER AND PISTON
1. Check:
S piston wall
S cylinder wall
Vertical scratches ! Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:
S 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.
5-68
ENG
CONNECTING RODS AND PISTONS
Cylinder bore “C”
65.50 X 65.51 mm
(2.5787 X 2.5791 in)
Wear limit
65.56 mm
(2.5811 in)
Taper limit “T”
0.05 mm (0.002 in)
Out of round “R”
0.05 mm (0.002 in)
“C” = maximum of D1 X 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 pistons and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 4 mm (0.16 in) from the bottom edge of the piston
Piston size “P”
65.475 X 65.490 mm
(2.5778 X 2.5783 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.010 X 0.035 mm
(0.0004 X 0.0014 in)
<Limit>: 0.055 mm (0.0022 in)
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
S 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.
5-69
CONNECTING RODS AND PISTONS
ENG
Piston ring side clearance
Top ring
0.030 X 0.065 mm
(0.0012 X 0.0026 in)
<Limit>: 0.115 mm (0.0045 in)
2nd ring
0.030 X 0.065 mm
(0.0012 X 0.0026 in)
<Limit>: 0.125 mm (0.0049 in)
2. Install:
S piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
a 5 mm (0.20 in)
3. Measure:
S 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
0.25 X 0.35 mm
(0.0098 X 0.0138 in)
<Limit>: 0.60 mm (0.0236 in)
2nd ring
0.7 X 0.8 mm
(0.0276 X 0.0315 in)
<Limit>: 1.15 mm (0.0453 in)
Oil ring
0.10 X 0.35 mm
(0.0039 X 0.0138 in)
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
1. Check:
S piston pin
Blue discoloration/grooves ! Replace the
piston pin and then check the lubrication system.
5-70
CONNECTING RODS AND PISTONS
ENG
2. Measure:
S piston pin outside diameter a
Out of specification ! Replace the piston
pin.
Piston pin outside diameter
15.991 X 16.000 mm
(0.6296 X 0.6299 in)
<Limit>: 15.971 mm (0.6288 in)
3. Measure:
S piston pin bore inside diameter b
Out of specification ! Replace the piston.
Piston pin bore inside diameter
16.002 X 16.013 mm
(0.6300 X 0.6304 in)
<Limit>: 16.043 mm (0.6316 in)
4. Calculate:
S piston-pin-to-piston clearance
Out of specification ! Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 X 0.022 mm
(0.0001 X 0.0009 in)
<Limit>: 0.072 mm (0.0028 in)
CHECKING THE BIG END BEARINGS
1. Measure:
S crankshaft-pin-to-big-end-bearing
clearance
Out of specification ! Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing
clearance
0.028 X 0.052 mm
(0.0011 X 0.0020 in)
The following procedure applies to all of the
connecting rods.
5-71
CONNECTING RODS AND PISTONS
ENG
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 rods 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:
S Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
S Lubricate the bolt threads and nut seats with
molybdenum disulfide grease.
S Make sure that the “Y” mark c on the connecting rod faces towards the left side of the crankshaft.
S Make sure that the characters d on both the
connecting rod and connecting rod cap are
aligned.
5-72
CONNECTING RODS AND PISTONS
ENG
e. Tighten the connecting rod nuts.
Connecting rod nut
15 Nm (1.5 mSkg, 11 ftSlb) + 150_
f. Replace the connecting rod bolts and nuts
with new ones.
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
g. Clean the connecting rod bolts and nuts.
h. Tighten the connecting rod nuts.
i. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
j. Tighten the nut further to reach the specified
angle (150_).
WARNING
When the nut is tightened more than the specified angle, do not loosen the nut and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_
k. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS”.
l. Measure the compressed Plastigauge
width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select replacement big end bearings.
5-73
CONNECTING RODS AND PISTONS
ENG
2. Select:
S big end bearings (P1 X P4)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 on the connecting
rods are used to determine the replacement
big end bearing sizes.
S “P1” X “P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and the
crankshaft web “P1” numbers are “5” and “2” respectively, then the bearing size for “P1” is:
“P1” (connecting rod) – “P1”
(crankshaft) =
5 – 2 = 3 (brown)
BIG END BEARING COLOR CODE
1
Blue
2
Black
3
Brown
4
Green
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:
S top ring 1
S 2nd ring 2
S upper oil ring rail 3
S oil ring expander 4
S lower oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers a face up.
5-74
CONNECTING RODS AND PISTONS
ENG
2. Install:
S piston 1
(onto the respective connecting rod 2 )
S piston pin 3
S piston pin clip New 4
NOTE:
S Apply engine oil onto the piston pin.
S Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
S Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:
S piston
S piston rings
S cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
S piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
e Oil ring expander
5. Lubricate:
S crankshaft pins
S big end bearings
S connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-75
CONNECTING RODS AND PISTONS
ENG
6. Install:
S big end bearings
S connecting rod assembly
(into the cylinder and onto the crankshaft pin)
S connecting rod cap
(onto the connecting rod)
NOTE:
S Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
S Be sure to reinstall each big end bearing in its
original place.
S While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
S Make sure that the “Y” marks a on the connecting rods face towards the left side of the
crankshaft.
S Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
7. Align:
S bolt heads
(with the connecting rod caps)
8. Tighten:
S connecting rod nuts
15 Nm (1.5 mSkg, 11 ftSlb) + 150_
a. Replace the connecting rod bolts and nuts
with new ones.
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts.
d. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
5-76
CONNECTING RODS AND PISTONS
ENG
e. Tighten the nut further to reach the specified
angle (150_).
WARNING
When the nut is tightened more than the specified angle, do not loosen the nut and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
5-77
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
Removing the crankshaft
Crankcase
Connecting rod caps
1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Remarks
1
5
5
For installation, reverse the removal
procedure.
5-78
CRANKSHAFT
ENG
EAS00395
CHECKING THE CRANKSHAFT
1. Measure:
S crankshaft runout
Out of specification ! Replace the crankshaft.
Crankshaft runout
Less than 0.03 mm (0.0012 in)
2. Check:
S crankshaft journal surfaces
S crankshaft pin surfaces
S bearing surfaces
Scratches/wear ! Replace the crankshaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
S crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification ! Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.034 X 0.058 mm
(0.0013 X 0.0023 in)
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.
5-79
CRANKSHAFT
ENG
c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crankcase.
NOTE:
Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.
d. Put a piece of Plastigauge 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole in
the crankshaft journal.
e. Install the crankshaft journal lower bearings
1 into the lower crankcase and assemble
the crankcase halves.
NOTE:
S Align the projections a of the crankshaft journal lower bearings with the notches b in the
lower crankcase.
S 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.
Crankcase bolt
Bolt 1 X 10
1st: 12 Nm (1.2 mSkg, 8.7 ftSlb)
2nd: 25 Nm (2.5 mSkg, 18 ftSlb)
*3rd: 27 Nm (2.7 mSkg, 20 ftSlb)
Bolt 11 , 12
24 Nm (2.4 mSkg, 17 ftSlb)
Bolt 13 X 27
12 Nm (1.2 mSkg, 8.7 ftSlb)
* Loosen the all bolts following the tightening order and then tighten to specification torque.
NOTE:
Lubricate the crankcase bolt threads with engine oil.
Refer to “CRANKCASE”.
5-80
CRANKSHAFT
ENG
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge
width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification,
select replacement crankshaft journal bearings.
2. Select:
S crankshaft journal bearings (J1 X J5)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes.
S “J1 X J5” refer to the bearings shown in the
crankshaft illustration.
S If “J1 X J5” are the same, use the same size
for all of the bearings.
S If the size is the same for all “J1 to J5” one digit
for that size is indicated. (Crankcase side only)
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
“J1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
5-81
0
White
1
Blue
2
Black
3
Brown
4
Green
CRANKSHAFT
ENG
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
S crankshaft journal upper bearings 1
(into the upper crankcase)
NOTE:
S Align the projections a on the crankshaft journal upper bearings with the notches b in the
upper crankcase.
S Be sure to install each crankshaft journal upper bearing in its original place.
2. Install:
S crankshaft
3. Install:
S crankcase (lower)
Refer to “CRANKCASE”.
5-82
TRANSMISSION
ENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
Job/Part
Q’ty
Drive axle assembly
Circlip
Oil seal
Bearing
Shift drum retainer
Shift fork guide bar
Spring
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”
Remarks
Remove the part in the order listed.
Removing the transmission, shift
drum assembly, and shift forks
Crankcase lower
1
2
3
4
5
6
7
8
9
10
11
10 Nm (1.0 mSkg, 7.2 ftSlb)
Separate.
Refer to “CRANKCASE”.
1
1
1
1
1
2
4
1
1
1
1
5-83
TRANSMISSION
ENG
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
12
13
14
15
16
Job/Part
Main axle assembly
Oil pipe
Oil baffle plate
Thrust plate
Washer
Q’ty
10 Nm (1.0 mSkg, 7.2 ftSlb)
Remarks
1
1
1
1
1
For installation, reverse the removal
procedure.
5-84
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Disassembling the main axle
assembly
Bearing
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-85
TRANSMISSION
Order
15
16
Job/Part
Bearing housing
Bearing
Q’ty
ENG
Remarks
1
1
For installation, reverse the removal
procedure.
5-86
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
Collar
3rd wheel gear
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-87
TRANSMISSION
Order
15
16
17
18
19
20
21
22
23
24
Job/Part
6th wheel gear
Circlip
Washer
2nd wheel gear
Collar
Collar
Oil seal
Bearing
Circlip
Drive axle
Q’ty
ENG
Remarks
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-88
TRANSMISSION
ENG
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
S main axle assembly 1
(with the Torx wrench T30)
a. Insert two bolts 2 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:
S shift fork cam follower 1
S shift fork pawl 2
Bends/damage/scoring/wear ! Replace
the shift fork.
2. Check:
S 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:
S shift fork movement
(along the shift fork guide bar)
Rough movement ! Replace the shift forks
and shift fork guide bar as a set.
5-89
TRANSMISSION
ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
S shift drum grooves
Damage/scratches/wear ! Replace the
shift drum assembly.
S shift drum segment 1
Damage/wear ! Replace the shift drum assembly.
S shift drum bearing 2
Damage/pitting ! Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
S main axle runout
(with a centering device and dial gauge 1 )
Out of specification ! Replace the main
axle.
Main axle runout limit
0.02 mm (0.0008 in)
2. Measure:
S drive axle runout
(with a centering device and dial gauge 1 )
Out of specification ! Replace the drive
axle.
Drive axle runout limit
0.02 mm (0.0008 in)
3. Check:
S transmission gears
Blue discoloration/pitting/wear ! Replace
the defective gear(s).
S transmission gear dogs
Cracks/damage/rounded edges ! Replace
the defective gear(s).
5-90
TRANSMISSION
ENG
4. Check:
S transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect ! Reassemble the transmission
axle assemblies.
5. Check:
S transmission gear movement
Rough movement ! Replace the defective
part(s).
6. Check:
S circlips
Bends/damage/looseness ! Replace.
EAS00430
INSTALLING THE TRANSMISSION
1. Install:
S oil pipe 1
S main axle assembly 2
(with the Torx wrench T30)
NOTE:
Make sure to caulk the bolts at three positions
after installing the bearing housing.
2. Install:
S shift fork “C” 3
S shift drum assembly 4
S shift fork guide bar
NOTE:
S 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”.
S Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
S Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
5-91
TRANSMISSION
ENG
3. Install:
S shift fork “R” 1 and “L” 2
S drive axle 3
S shift fork guide bar
S shift drum retainer
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
S Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
S Make sure that the drive axle bearing circlip a
is inserted into the grooves in the upper crankcase.
9. Check:
S transmission
Rough movement ! Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
5-92
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
Job/Part
7 Nm (0.7 mSkg, 5.1 ftSlb)
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings and bottom cowling
Coolant
1
2
3
4
5
6
7
8
Remarks
1
2
1
1
1
1
1
1
Coolant reservoir hose
Throttle body hose
Radiator outlet hose
Coolant pipe
Radiator inlet hose
Oil cooler outlet hose
Radiator
Radiator fan
6-1
6
RADIATOR
COOL
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
9
Job/Part
7 Nm (0.7 mSkg, 5.1 ftSlb)
Q’ty
Radiator cap
Remarks
1
For installation, reverse the removal
procedure.
6-2
RADIATOR
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
S 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:
S radiator hoses
S radiator pipes
Cracks/damage ! Replace.
3. Measure:
S radiator cap opening pressure
Below the specified pressure ! Replace the
radiator cap.
Radiator cap opening pressure
110 X 140 kPa
(1.1 X 1.4 kg/cm2, 1.1 X 1.4 bar,
16.0 X 20.3 psi)
a. Install the radiator cap tester 1 and radiator
cap tester adapter 2 to the radiator cap 3 .
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
4. Check:
S 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:
S cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
S cooling system
Leaks ! Repair or replace any faulty part.
3. Measure:
S 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
10 Nm (1.0 mSkg, 7.2 ftSlb)
63 Nm (6.3 mSkg, 46 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “RADIATOR”.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Removing the oil cooler
Radiator assembly
Engine oil
1
2
3
4
5
6
7
8
9
10
11
Remarks
1
1
1
1
1
1
1
1
1
1
2
Oil cooler outlet hose
Union bolt
Washer
Oil cooler
Oil cooler inlet hose
Oil cooler inlet pipe
Water jacket joint hose
Water jacket joint
O-ring
O-ring
Water pump hose
For installation, reverse the removal
procedure.
6-5
OIL COOLER
COOL
EAS00458
CHECKING THE OIL COOLER
1. Check:
S oil cooler
Cracks/damage ! Replace.
2. Check:
S oil cooler inlet hose
S oil cooler outlet hose
Cracks/damage/wear ! Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:
S mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
S O-ring New
S oil cooler 1
S washer 2 New
S bolt 3
63 Nm (6.3 mSkg, 46 ftSlb)
NOTE:
S Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.
S Make sure that the O-ring is positioned properly.
S Align the projection a on the oil cooler with the
slot b in the crankcase.
3. Fill:
S cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
S crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Check:
S cooling system
Leaks ! Repair or replace any faulty part.
5. Measure:
S radiator cap opening pressure
Below the specified pressure ! Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-6
THERMOSTAT
COOL
EAS00461
THERMOSTAT
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in chapter
7.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Removing the thermostat
Rider seat
Air filter case
Throttle body assembly
Coolant
1
2
3
Remarks
Radiator inlet hose
Thermostat cover
Thermostat
1
1
1
For installation, reverse the removal
procedure.
6-7
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
S thermostat 1
Does not open at 71 X 85_C (160 X 185_F)
! Replace.
1
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
2
3
4
A
B
Thermostat
Thermometer
Water
Container
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover
Cracks/damage ! Replace.
INSTALLING THE THERMOSTAT
1. Install:
S thermostat
NOTE:
Install the thermostat with its breather hole a
facing up.
2. Install
S thermostat cover
12 Nm (1.2 mSkg, 8.7 ftSlb)
NOTE:
Before installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat
of lithium soap based grease.
6-8
THERMOSTAT
COOL
3. Fill:
S cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:
S cooling system
Leaks ! Repair or replace any faulty part.
5. Measure:
S radiator cap opening pressure
Below the specified pressure ! Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-9
WATER PUMP
COOL
EAS00408
WATER PUMP
12 Nm (1.2 mSkg, 8.7 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
10 Nm (1.0 mSkg, 7.2 ftSlb)
12 Nm (1.2 mSkg, 8.7 ftSlb)
Order
Job/Part
Q’ty
Removing the water pump
Bottom cowling
Coolant
1
2
3
4
5
Water pump inlet hose
Water pump outlet hose
Water pump hose
Clutch cable/holder
Water pump
Remarks
Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
1
1
1
1/1
1
NOTE:
It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
For installation, reverse the removal
procedure.
6-10
WATER PUMP
COOL
10 Nm (1.0 mSkg, 7.2 ftSlb)
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the water pump
Water pump cover
O-ring
Impeller shaft
Circlip
Water pump seal
Oil seal
Bearing
Water pump housing
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
6-11
WATER PUMP
COOL
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:
S circlip
S impeller shaft
2. Remove:
S water pump seal 1
NOTE:
Remove the water pump seal from the outside
of the water pump housing.
2 Water pump housing
3. Remove:
S oil seal 1
(with a thin, flat-head screwdriver)
NOTE:
Remove the oil seal from the outside of the water pump housing.
4. Remove:
S bearing 1
NOTE:
Remove the bearing from inside of the water
pump housing.
5. Remove:
S rubber damper holder 1
S rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
6-12
WATER PUMP
COOL
EAS00473
CHECKING THE WATER PUMP
1. Check:
S water pump housing 1
S water pump cover 2
S impeller 3
S rubber damper 4
S rubber damper holder 5
S water pump seals
S oil seal
Cracks/damage/wear ! Replace.
2. Check:
S bearing
Rough movement ! Replace.
3. Check:
S water pump outlet pipe
S radiator outlet hose
Cracks/damage/wear ! Replace.
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
S oil seal New 1
(into the water pump housing 2 )
NOTE:
S Before installing the oil seal, apply tap water or
coolant onto its out surface.
S Install the oil seal with a socket that matches its
outside diameter.
2. Install:
S water pump seal New 1
CAUTION:
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
S Install the water pump seal with the special
tools.
S Before installing the water pump seal, apply
Yamaha bond No.1215 or Quick Gasket 2 to
the water pump housing 3 .
6-13
WATER PUMP
COOL
Mechanical seal installer
90890-04078, YM-33221 4
Middle driven shaft bearing driver
90890-04058, YM-04058 5
Quick Gasket
ACC-11001-05-01
Yamaha bond #1215
90890-85505
A Push down.
3. Install:
S rubber damper New 1
S rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
4. Measure:
S 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.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1 Straightedge
2 Impeller
6-14
WATER PUMP
COOL
INSTALLING THE WATER PUMP
1. Install:
S water pump assembly
12 Nm (1.2 mSkg, 8.7 ftSlb)
NOTE:
Align the projection a at the oil pump shaft and
water pump shaft groove b .
2. Install:
S water pump outlet hose 1
S water pump inlet hose 2
NOTE:
S Install the inlet hose with yellow a mark positioned outside.
S Install the hose clamp with its screw head
pointed to the inner side not to contact with the
cowling.
3. Fill:
S coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.
6-15
FI
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 Ignition coil
2 Air filter case
3 Intake
temperature
4
5
6
7
sensor
Fuel delivery hose
Fuel tank
Fuel pump
Fuel return hose
8 Intake
13 Coolant
19 Atmospheric pressure
9
14
15
20 Fuel injection system
10
11
12
air pressure
sensor
Throttle position sensor
Fuel injector
Catalytic converter
Crankshaft
position
sensor
16
17
18
7-1
temperature
sensor
Spark plug
Cylinder identification
sensor
Pressure regulator
Battery
ECU
sensor
relay
21 Engine trouble warning
light
22 Lean
switch
angle
cut-off
FUEL INJECTION SYSTEM
FI
WIRING DIAGRAM
1 Main switch
5 Battery
6 Fuse (main)
9 Fuse (fuel injection)
10 Fuse (ignition)
11 Starting circuit cut-off relay
12 Sidestand switch
13 Fuel pump
14 ECU
15 Ignition coil
16 Spark plug
17 Fuel injector
19 Neutral switch
20 Crankshaft position sensor
21 Intake air temperature sensor
22 Coolant temperature sensor
23 Throttle position sensor
24 Intake air pressure sensor
25 Atmospheric pressure sensor
26 Cylinder identification sensor
27 Speed sensor
28 Lean angle cut-off switch
35 Multi-function meter
44 Engine stop switch
7-2
7
FI
FUEL INJECTION SYSTEM
EAS00899
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is
operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
S To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
S If a malfunction is detected in the system by the self-diagnostic function, this mode provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating a engine trouble warning light.
S After the engine has been stopped, the lowest fault code number appears on the clock LCD. Once a
fault code has been displayed, it remains stored in the memory of the ECU until it is deleted.
EAS00900
Engine trouble warning light indication and FI system operating condition
Warning light
indication
ECU’s operation
FI operation
Vehicle operation
Flashing*
Warning provided
when unable to start
engine
Operation stopped
Can not be operated
Remains ON
Malfunction detected
Operated with
substitute
characteristics
in accordance with the
description of the
malfunction.
Can or cannot be operated depending on
the fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch is
pushed.
11:
Cylinder identification sensor
30:
12:
Crankshaft position sensor
41:
19:
Sidestand switch
(open circuit in wire to ECU)
50:
Lean angle cut-off switch
(latch up detected)
Lean angle cut-off switch
(open or short circuit)
ECU internal malfunction
(memory check error)
EAS00901
Checking for a detective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON”
and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be detective.
7-3
FUEL INJECTION SYSTEM
FI
EAS00902
ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
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.
FAIL-SAFE ACTIONS TABLE
Fault
Code No.
Symptom
Fail-safe action
Engine
startability
Vehicle
drivability
Cylinder identification
sensor
No normal signals from the cylinder
identification sensor are received when
the engine is started or while the motor
cycle travels.
Continues to operate the engine based
on the results of the cylinder
identification that existed up to that
point.
Unable
Able
Crankshaft position
sensor
No normal signals are received from
the crankshaft position sensor.
S Stops the engine (by stopping the
injection and ignition).
Unable
Unable
Intake air pressure
sensor (open or short
circuit) (pipe system)
Intake air pressure sensor-open or
short circuit detected.
Faulty intake air pressure sensor
system.
S Fixes the intake air pressure to
760 mmHg.
Able
Able
Throttle position sensor
(open or short circuit)
(stuck)
Throttle position sensor-open or short
circuit detected.
S Fixes the throttle position sensor to
fully open.
Able
Able
Sidestand switch (open
circuit in wire to ECU)
Open circuit is detected in the input
line from the sidestand switch to the
ECU.
-- (No start)
19
Unable
Unable
20
Intake air pressure sensor or Atmospheric pressure sensor
When the main switch is turned to ON,
the atmospheric sensor voltage and intake air pressure sensor voltage differ
greatly.
S Fixes the intake air pressure and
atmospheric pressure to 760 mmHg.
Able
Able
21
Coolant temperature
sensor
Coolant temperature sensor-open or
short circuit detected.
S Fixes the coolant temperature to
60_C.
Able
Able
22
Intake temperature
sensor
Intake temperature sensor-open or
short circuit detected.
S Fixes the intake temperature to 20_C.
Able
Able
23
Atmospheric pressure
sensor
Atmospheric pressure sensor-open or
short circuit detected.
S Fixes the atmospheric pressure to
760 mmHg.
Able
Able
Faulty ignition
Open circuit detected in the primary
lead of the ignition coil.
S Cut the injection of other cylinder in
the same group with the cylinder that
the error is detected. (Example: when
the #1 cylinder is defective cut the injection of #1 and #4 cylinders)
S Turn on the power to the air induction
solenoid to always cut-off the air.
Able
(depending
on the number of faulty
cylinders)
Able
(depending
on the number of faulty
cylinders)
Lean angle cut-off
switch (latch up
detected) (open or short
circuit)
The motorcycle has over turned.
Lean angle cut-off switch-open or short
circuit detected.
S Turns OFF the fuel injection system
relay of the fuel system.
Unable
Unable
Speed sensor, neutral
switch
No normal signals are received from the
speed sensor; or, an open or short
circuit is detected in the neutral switch.
S Fixes the gear to the top gear.
Able
Able
Fuel system voltage
(monitor voltage)
Supply power to the injector and fuel
pump is not normal.
S Fixes the battery voltage to 12 V.
Depending
on the malfunction
case.
Depending
on the malfunction
case.
Error in writing the
amount of CO
adjustment on
EEPROM
An error is detected while reading or
writing on EEPROM (CO adjustment
value).
--
44
Able
Able
46
Vehicle system power
supply (Monitor voltage)
Power supply to the FI system relay is
not normal
--
Unable
Able
50
ECU internal
malfunction (memory
check error)
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the meter.
S Shut down all functions except the
communication with the meter.
Unable
Unable
Start unable warning
Relay is not turned ON even if the crank
signal is input while the start switch is
turned ON. When the start switch is
turned ON while an error is detected
with the fault code of No.11, 12, 19, 30,
33, 43, 41 or 50.
Engine trouble warning light flashes
when the start switch is turned ON.
Unable
Unable
11
12
13
14
15
16
Item
33
34
35
36
30
41
42
43
—
7-4
FI
FUEL INJECTION SYSTEM
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light does not come
on.
The engine trouble warning light comes on.
Check the fault code number displayed on the meter.
Check the operation of following sensors and actuators in the Diagnostic mode (Refer to “Diagnostic mode table” in chapter 7.)
01: Throttle position sensor (throttle angle)
30: Ignition coil #1
31: Ignition coil #2
32: Ignition coil #3
33: Ignition coil #4
36: Injector #1
37: Injector #2
38: Injector #3
39: Injector #4
48: Al system solenoid
Identify the system with the malfunction. (Refer to
the “FAIL-SAFE ACTION TABLE”.)
Identify the probable cause of malfunction. (Refer
to the “Fault code table”.)
Checking and repair the probable case of malfunction.
Fault code No. YES
Fault code No. NO
Check and repair.
(Refer to “TROUBLESHOOTING DETAILS”.)
Monitor the operation
of the sensors and
actuators in the diagnostic mode. (Refer
to “Diagnostic mode
table” in chapter 7)
Check and repair.
(Refer to “TROUBLESHOOTING DETAILS”.)
OK
NG
Malfunction of engine
Defective sensor
or actuator
Check and repair
the inner parts of
engine. (Refer to
Chapter 5)
Check and repair
the corresponding
sensor or actuator.
Perform ECU reinstatement action. (Refer to “Reinstatement method” in “TROUBLESHOOTING
DETAILS”.)
OK
NG
OK
Check the engine condition.
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number is still displayed.
Fault code
number displayed
OK
Not fault code number displayed
Repairs completed
Erasing the malfunction history:*
The Malfunction history is stored even if the main
switch is turned OFF.
The malfunction history must be erased in the * Operated when the engine trouble warning light is on.
diagnostic mode. (Refer to the “Diagnostic mode
table (Diagnostic code No.62)”)
7-5
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ON”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main
switch to “ON”, and continue to press the buttons for 8 seconds or more.
NOTE:
S All displays on the meter disappear except the
clock and tripmeter displays.
S “dIAG” appears on the clock LCD.
4. Press the “SELECT” button to select the CO
adjustment mode “CO” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection.
6. Set the engine stop switch to “OFF”.
7. Select the diagnostic code number that applies to the item that was verified with the
fault code number by pressing the “SELECT”
and “RESET” buttons.
NOTE:
S The diagnostic code number appears on the
clock LCD (01-70).
S To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers.
S To increase the selected diagnostic code number, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers.
8. Verify the operation of the sensor or actuator.
S Sensor operation
The data representing the operating conditions of the sensor appears on the trip LCD.
S Actuator operation
Set the engine stop switch to “ON” to operate
the actuator.
* If the engine stop switch is set to “ON”, set it
to “OFF”, and then set it to “ON” again.
9. Turn the main switch to “OFF” to cancel the
the diagnostic mode.
7-6
FUEL INJECTION SYSTEM
FI
Fault code table
Fault
code No.
Symptom
11
No normal signals are received from
the cylinder identification sensor when
the engine is started or while the motor cycle travels.
NOTE:
This code appears if no normal signals from the start switch is turned
ON.
S
S
S
S
S
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.
No normal signals are received from
the crankshaft position sensor.
S
S
S
S
S
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.
S
S
S
S
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 hose
system; a hose is detached, causing
constant application of the
atmospheric pressure to the sensor;
or, the hose is clogged.
S Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
S Malfunction in ECU.
Throttle position sensor-open or
short circuit detected.
S
S
S
S
S
12
13
14
15
Probable cause of malfunction
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.
Diagnostic
code
—
03
01
16
A stuck throttle position sensor is
detected.
S Stuck throttle position sensor.
S Malfunction in ECU.
19
Open circuit in the input line from the
sidestand switch to the ECU is
detected when the start switch is
pressed.
S Open circuit in wiring harness.
S Malfunction in ECU.
When the main switch is turned to
“ON”, the atmospheric sensor voltage
and intake air pressure sensor voltage
differ greatly.
S Atmospheric pressure sensor hose is clogged.
S Intake air pressure sensor hose is clogged, kinked, or pinched.
S Malfunction of the atmospheric pressure sensor in the
intermediate electrical potential.
S Malfunction of the intake air pressure sensor in the
intermediate electrical potential.
S Malfunction in ECU.
03
02
Coolant temperature sensor-open or
short circuit detected.
S
S
S
S
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.
S
S
S
S
Open or short circuit in wiring harness.
Defective intake temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
05
Atmospheric pressure sensor-open or
short circuit detected.
S
S
S
S
Open or short circuit in wiring sub lead.
Defective atmospheric pressure sensor.
Improperly installed sensor.
Malfunction in ECU.
02
The motorcycle has overturned.
S Overturned.
S Malfunction in ECU.
20
21
22
23
30
7-7
01
20
08
FUEL INJECTION SYSTEM
Fault
code No.
Symptom
FI
Probable cause of malfunction
Diagnostic
code
Open circuit is detected in the primary
lead of the ignition coil (#1).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
30
Open circuit is detected in the primary
lead of the ignition coil (#2).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
31
Open circuit is detected in the primary
lead of the ignition coil (#3).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
32
Open circuit is detected in the primary
lead of the ignition coil (#4).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
33
Lean angle cut-off switch-open or
short circuit detected.
S Open or short circuit in wiring harness.
S Defective lean angle cut-off switch.
S 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.
S
S
S
S
S
S
07
21
43
Supply power to the injector and fuel
pump is not normal
S Open circuit in wiring harness. (red / blue line)
S Malfunction in ECU.
09
44
An error is detected while reading or
writing on EEPROM.
S Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).
60
46
Powr supply to the FI system relay is
not normal.
S Open circuit in wiring harness. (red / white line)
S Malfunction in “CHARGING SYSTEM”.
—
50
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
S Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
No signal are received from the ECU.
S Open or short circuit in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
33
34
35
36
41
42
Er-1
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.
—
Er-2
No signal are received from the ECU
within the specified duration.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
Er-3
Data from the ECU cannot be
received correctly.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
Er-4
Non-registered data has been
received from the meter.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
7-8
FUEL INJECTION SYSTEM
FI
EAS00907
Diagnostic mode table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to
“DIAGNOSTIC MODE”.
NOTE:
S Check the intake temperature and coolant temperature as close as possible to the intake temperature
sensor and the coolant temperature sensor respectively.
S If it is not possible to check the atmospheric pressure with an atmospheric pressure gauge, determine
the atmospheric pressure by using 760 mmHg as the standard.
S If it is not possible to check the intake temperature, use the ambient temperature as reference.
Diagnostic
code
Item
Description of action
Data displayed on meter
(reference value)
Throttle angle
Displays the throttle angle.
S Check with throttle fully closed.
S Check with throttle fully open.
0 X 125 degrees
S Fully closed position (15 X 17)
S Fully open position (97 X 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 pressureintake air pressure).
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
10 X 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 X 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 X 1.4 V
Overturned: 3.8 X 4.2 V
09
Fuel system voltage
(battery voltage)
Displays the fuel system voltage (battery voltage).
Engine stop switch is on.
0 X 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
Ignition coil #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #1 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
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #2 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.
01
02
03
05
06
07
20
21
30
31
7-9
FUEL INJECTION SYSTEM
Diagnostic
code
Item
Data displayed on meter
(reference value)
Ignition coil #3
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #3 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 coil #4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #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.
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
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 #3
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 #4
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.
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 5 times
with the engine stop
switch ON.
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 5 times
with the engine stop
switch ON.
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 5 times
with the engine stop
switch ON.
(At that time, the fan motor
rotates.)
32
33
36
37
38
39
48
50
51
Description of action
FI
7-10
FI
FUEL INJECTION SYSTEM
Diagnostic
code
Item
Data displayed on meter
(reference value)
Headlight relay 1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
headlight 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 headlight relay
operating sound 5 times with the
engine stop switch ON.
(At that time, the headlight turns
ON.)
E2PROM fault code
display
S Transmits the abnormal portion of the data in the E2PROM
that has been detected as a fault code 44.
S If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.
(01 X 04) Displays the cylinder
number.
(00) Displays when there is no
malfunction.
Malfunction history
code display
S 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).
S If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.
11 X 50
(00) Displays when there is no
malfunction.
Malfunction history
code erasure
S Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past
history.
S 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 X 21
(00) Displays when there is no
malfunction.
Control number
S Displays the program control number.
00 X 255
52
60
61
62
70
Description of action
7-11
FUEL INJECTION SYSTEM
FI
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. Check and
service the items or components that are the probable cause of the malfunction following the order in
the “TROUBLESHOOTING CHART”.
After the check and service of the malfunctioned part has been completed, reset the meter display according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. (Refer to the
“Fault code table”.)
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. (Refer to “DIAGNOSTIC
MODE”.)
Fault code No.
11
Symptom
No normal signals are received from the cylinder identification sensor when the
engine is started or while the motorcycle travels.
Used diagnostic code No. – –
Inspection operation item
Operation item and countermeasure
Reinstatement
method
Installed condition of sensor
Check the installed area for looseness or
pinching.
Defective cylinder identification sensor.
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
cylinder identification sensor coupler terminal
as shown.
Reinstated by
starting the engine
and operating it at
idle.
Tester positive probe ! white 1
Tester negative probe ! black / blue 2
2. Turn the main switch to “ON”.
3. Measure the cylinder identification sensor output voltage.
Cylinder identification sensor
output voltage
When sensor is on
4.8 V or more
When sensor is off
0.8 V or less
4. Is the cylinder identification sensor OK?
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short circuit.
sub lead.
Between sensor coupler and ECU coupler
Blue – Blue
White / Black – White / Black
Black / Blue – Black / Blue
Connected condition 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
7-12
Reinstated by
starting the engine
and operating it at
idle.
FI
FUEL INJECTION SYSTEM
Fault 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 condition of sensor
Check the installed area for looseness or
pinching.
Defective crankshaft position sensor.
Replace if defective.
1. Disconnect the crankshaft position sensor coupler from the wire harness.
2. Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
Reinstated by
cranking the
engine.
Tester positive probe ! gray 1
Tester negative probe ! black 2
2
1
3. Measure the crankshaft position sensor resistance.
Crankshaft position sensor
resistance
248 X 372 Ω at 20_C (68 _F)
(between gray and black)
4. Is the crankshaft position sensor OK?
Open or short circuit in wiring harness.
Repair or replace if there is an open or short
circuit between the main wiring harnesses.
Between sensor coupler and ECU coupler
Gray - Gray
Black / Blue - Black / Blue
Connected condition of connector
Inspect the coupler for any pins that may
have pulled cut.
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
7-13
FUEL INJECTION SYSTEM
Fault 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.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler terminal as
shown.
Reinstated by
turning the main
switch ON.
Tester positive probe ! pink / white 1
Tester negative probe ! black / blue 2
2
1
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
Intake air pressure sensor output
voltage
3.75 X 4.25 V
4. Is the intake air pressure sensor OK?
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Pink / White - Pink / White
Blue - Blue
Connected condition 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
7-14
FUEL INJECTION SYSTEM
Fault code No.
14
Used diagnostic code
Symptom
FI
Intake air pressure sensor - hose system malfunction (clogged or detached hose).
No. 03 (intake air pressure sensor)
Inspection operation item and probable
cause
Operation item and countermeasuer
Reinstatement
method
Intake air pressure sensor hose detached,
clogged, kinked, or pinched.
Intake air pressure sensor malfunction at
intermediate electrical potential.
Atmospheric pressure sensor malfunction at
intermediate electrical potential.
Repair or replace the sensor hose.
Inspect and repair the connection.
Reinstated by
starting the engine
and operating it at
idle.
Defective intake air pressure sensor.
Replace if defective.
Refer to “Fault code No. 13”.
Fault code No.
15
Symptom
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 “THROTTLE BODIES” section.
Reinstated by
turning the main
switch ON.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Yellow - Yellow
Blue - Blue
Installed condition of throttle position sensor.
Check the installed area for looseness or
pinching.
Check that it is installed in the specified
position.
Refer to “THROTTLE BODIES” section.
Connected condition 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
Fault code No.
16
Used diagnostic code
Symptom
Stuck throttle position sensor detected.
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 “THROTTLE BODIES” section.
Installed condition of throttle position sensor.
Check the installed area for looseness or pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODIES” section.
Reinstated by
starting the engine,
operating it at idle,
and then racing it.
7-15
FUEL INJECTION SYSTEM
Fault code No.
19
Symptom
FI
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.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
If the transmission
is in gear, it is
reinstated by
retracting the
sidestand.
If the transmission
is in neutral, it is
reinstated by
reconnecting the
wiring.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sidestand switch coupler and starting
circuit cut-off relay coupler, starting circuit cut-off
relay coupler and ECU coupler
Blue / Black – Blue / Black,
Blue / Yellow – Blue / Yellow
Fault code No.
20
Symptom
Faulty atmospheric pressure sensor or intake air pressure sensor.
Used diagnostic code No. 03 (intake air pressure sensor)
02 (atmospheric pressure sensor)
Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Intake air pressure sensor hose detached,
clogged, kinked, or pinched.
Atmospheric pressure sensor hose is
clogged.
Repair or replace the sensor hose.
Reinstated by
turning the main
switch ON.
Defective intake air pressure sensor or
atmospheric pressure sensor.
Replace if defective.
Refer to “Fault code No.13 or No.23”.
Fault 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 condition of sensor
Check the installed area for looseness or
pinching.
Defective coolant temperature sensor.
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
Reinstated by
turning the main
switch ON.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Green / White - Green / White
Connected condition 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.
Coolant temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7-16
FUEL INJECTION SYSTEM
FI
Fault 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
Installed condition of sensor
Defective intake temperature sensor.
Operation item and countermeasure
Check the installed area for looseness or
pinching.
Replace if defective.
1. Remove the intake air temperature sensor
from the air filter case.
2. Connect the pocket tester (Ω
100) to the
intake air temperature sensor terminal as
shown.
Tester positive probe ! brown / white 1
Tester negative probe ! black / blue 2
3. Measure the intake air temperature sensor
resistance.
Intake air temperature sensor
resistance
2.2 X 2.7 Ω at 20_C (68 _F)
WARNING
S Handle the intake air temperature sensor
with special care.
S Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.
4. Is the intake air temperature sensor OK?
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Brown / White - Brown / White
Connected condition 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 temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
7-17
Reinstatement
method
Reinstated by
turning the main
switch ON.
FUEL INJECTION SYSTEM
Fault 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.
1. Connect the pocket tester (DC 20 V) to the
atmospheric pressure sensor coupler terminal
as shown.
Reinstated by
turning the main
switch ON.
Tester positive probe ! blue 1
Tester negative probe ! black / blue 2
1
2
2. Set the main switch to “ON”.
3. Measure the atmospheric pressure sensor output voltage.
Atmospheric pressure sensor
output voltage
3.75 X 4.25 V
4. Is the atmospheric pressure sensor OK?
Open or short circuit in wiring harness.
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
Blue - Blue
Black / Blue - Black / Blue
Pink - Pink
Installed condition of atmospheric pressure
sensor
Check the installed area for looseness or
pinching.
Connected condition 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.
Atmospheric pressure sensor coupler
Main wiring harness ECU coupler
7-18
FUEL INJECTION SYSTEM
Fault 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
Reinstatement
method
Defective lean angle cut-off switch
Replace if defective.
1. Remove the lean angle cut-off switch from the
motorcycle.
2. Connect the lean angle cut-off switch coupler
to the wireharness.
3. Connect the pocket tester (DC 20 V) to the
lean angle cut-off switch coupler as shown.
Reinstated by
turning the main
switch ON
(however, the
engine cannot be
restarted unless
the main switch is
first turned OFF).
Tester positive prove ! blue 1
Tester negative prove ! yellow / green 2
4. When turn the lean angle cut-off switch
approx. 65_, the voltage reading is 1.0 V to 4.0
V.
5. Is the lean angle cut-off switch OK?
The motorcycle has overturned.
Raise the motorcycle upright.
Installed condition of the lean angle cut-off
switch
Check the installed area for looseness or
pinching.
Connected condition 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
7-19
FUEL INJECTION SYSTEM
Fault code No.
33
Symptom
FI
Malfunction detected in the primary lead of the ignition coil (#1).
Used diagnostic code No. 30 (ignition coil #1)
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.
Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#1) and ECU
coupler / main harness
Orange – Orange
Black – Black
Connected condition 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
Sub-wire harness coupler
Reinstated by
starting the engine
and
d operating
ti it att
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
Fault code No.
34
Symptom
Malfunction detected in the primary lead of the ignition coil (#2).
Used diagnostic code No. 31 (ignition coil #2)
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.
Between ignition coil coupler (#2) and ECU
coupler / main harness
Gray / Red – Gray / Red
Black – Black
Connected condition 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
Sub-wire harness coupler
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
Fault code No.
35
Symptom
Malfunction detected in the primary lead of the ignition coil (#3).
Used diagnostic code No. 32 (ignition coil #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.
Between ignition coil coupler (#3) and ECU
coupler / main harness
Orange / Green – Orange / Green
Black – Black
Connected condition 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 /
Green
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
7-20
FUEL INJECTION SYSTEM
Fault code No.
36
Symptom
FI
Malfunction detected in the primary lead of the ignition coil (#4).
Used diagnostic code No. 33 (ignition coil #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.
Between ignition coil coupler (#4) and ECU
coupler / main harness
Gray / Green – Gray / Green
Black – Black
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 / Green
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
Fault 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.
Refer to Fault code No. 30.
Open or short circuit in wiring harness.
Repair or replace if there is an open or short
circuit.
Between switch coupler and ECU coupler
Black / Blue - Black / Blue
Yellow / Green - Yellow / Green
Blue - Blue
Reinstated by
turning the main
switch ON.
Connected condition 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
7-21
FUEL INJECTION SYSTEM
Fault code No.
42
1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.
Used diagnostic code
No. 07 (speed sensor)
No. 21 (neutral switch)
Inspection operation item and probable
Operation item and countermeasure
cause
Defective speed sensor
Replace if defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler terminal as shown.
FI
Symptom
Tester positive probe ! pink 1
Tester negative probe ! black / white 2
3. Measure the speed sensor output voltage.
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less
Open or short circuit in speed sensor lead.
Gear for detecting vehicle speed has broken.
Connected condition of speed sensor
connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
4. Is the speed sensor OK?
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler.
Blue - Blue
White / Yellow - White / Yellow
Black / Blue - Black / Blue
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
If there is a malfunction, repair it and connect it
securely.
Speed sensor coupler
Main wiring harness ECU coupler
Defective neutral switch
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
Faulty shift drum
(neutral detection area)
Open or short circuit in neutral switch lead.
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
Repair or replace if there is an open or short
circuit.
Between switch connector and ECU coupler
Sky blue - Black / Yellow
If there is a malfunction, repair it and connect it
securely.
Neutral switch connector
Main wiring harness ECU coupler
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
7-22
Reinstatement
method
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.
FUEL INJECTION SYSTEM
Fault code No.
43
Symptom
FI
The ECU is unable to monitor the battery voltage.
Used diagnostic code No. 09 (fuel system voltage)
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.
Between starting circuit cut-off relay (fuel injection
system relay), fuel pump, injector (#1 X #4)
Red / Blue – Red / Blue
Reinstated by
starting the engine
and operating it at
idle.
Malfunction or open circuit in fuel injection
system relay
Replace if defective.
1. Disconnect the starting circuit cut-off relay
from the wire harness.
2. 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 positive terminal ! light green 2
Tester positive probe ! red 3
Tester negative probe ! red / blue 4
3. Does the starting circuit cut-off relay have continuity between red and red / blue?
Connected condition 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.
Starting circuit cut-off relay coupler
(fuel injection system relay)
Fuel pump coupler
Injector coupler
ECU coupler
7-23
FUEL INJECTION SYSTEM
Fault code No.
44
Symptom
FI
Error is detected while reading or writing on EEP-ROM
(CO adjustment value).
Used diagnostic No. 60 (EEP-ROM improper cylinder indication)
Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Malfunction in ECU
Execute diagnostic code 60
* Check the faulty cylinder. (If there are multiple
cylinders, the number of the faulty cylinders
appear alternately at 2-second intervals.)
* Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS
VALUME” in chapter 3.
Replace ECU if defective.
Reinstated by
turning the main
switch ON.
Fault code No.
46
Symptom
Power supply to the FI system relay is not normal.
Used diagnostic code No. – –
Inspection operation item and probable
cause
Operation item and countermeasure
Faulty battery
Reinstated by
Replace or change the battery
Refer to “CHECKING AND CHARGING THE BAT- starting the engine
and operating it at
TERY” in chapter 3.
idle.
Repair or replace if there is an open or short cir-
Open or short circuit in wiring hanress.
Reinstatement
method
cuit.
S Between battery and main switch
Red – Red
S Between main switch and Fuse (ignition)
Brown/blue – Brown/blue
S Between Fuse (ignition) and ECU
Red/white – Red/white
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Fault code No.
50
Symptom
If there is a malfunction, repair it and connect it
securely.
ECU coupler.
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
Replace the ECU.
Reinstated by
turning the main
switch ON.
7-24
FUEL INJECTION SYSTEM
Fault code No.
Er-1
Symptom
FI
No signal are received from the ECU.
Used diagnostic code No. – –
Inspection operation item and probable
cause
Operation item and countermeasure
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition 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
Malfunction in meter
Replace the meter.
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-2
Symptom
Reinstatement
method
Reinstated by
turning the main
switch ON.
No signal are received from the ECU within the specified duration.
Used diagnostic code No. – –
Inspection operation item and probable
cause
Operation item and contermeasure
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition 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
Malfunction in meter
Replace the meter.
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-3
Symptom
Reinstatement
method
Reinstated by
turning the main
switch ON.
Data from the ECU cannot be received correctly.
Used diagnostic code No. – –
Inspection operation item and probable
cause
Operation item and countermeasure
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition 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
Malfunction in meter
Replace the meter.
Malfunction in ECU
Replace the ECU.
7-25
Reinstatement
method
Reinstated by
turning the main
switch ON.
FUEL INJECTION SYSTEM
Fault code No.
Er-4
Symptom
FI
Non-registered data has been received from the meter.
Used diagnostic code No. – –
Inspection operation item and probable
cause
Operation item and countermeasure
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition 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
Malfunction in meter
Replace the meter.
Malfunction in ECU
Replace the ECU.
7-26
Reinstatement
method
Reinstated by
turning the main
switch ON.
THROTTLE BODIES
FI
THROTTLE BODIES
Order
Job/Part
Q’ty
Removing the throttle bodies
Seats/fuel tank/rubber sheet
Air filter case
Coolant
1
2
3
4
5
Sub-wire harness coupler
Coolant temp sensor coupler
Throttle stop screw
Throttle body joint clamp screw
Throttle bodies
2
1
1
4
1
7-27
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.
Loosen.
THROTTLE BODIES
Order
6
7
8
9
Job/Part
Throttle cable
Plunger control unit hose
Throttle body joint
Heat protector
Q’ty
2
2
4
1
FI
Remarks
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
7-28
THROTTLE BODIES
Order
1
2
3
4
5
6
7
8
9
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
Sub wire harness 2
Negative pressure hose
Pressure regulator
Q’ty
1
1
1
1
1
1
1
1
1
7-29
FI
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
THROTTLE BODIES
Order
10
11
12
13
14
Job/Part
Intake air pressure sensor
Fuel distributor
Injector
Throttle position sensor
Throttle body assembly
Q’ty
FI
Remarks
1
1
4
1
1
For installation, reverse the removal
procedure.
7-30
THROTTLE BODIES
FI
EAS00911
CAUTION:
The throttle bodies should not be disassembled.
EAS00912
CHECKING THE INJECTOR
1. Check:
S injector
Damage ! Replace.
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
S throttle body
Cracks/damage ! Replace the throttle bodies.
2. Check:
S 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.
7-31
THROTTLE BODIES
FI
CHECKING THE PRESSURE REGULATOR
1. Check:
S pressure regulator
Damage ! Replace.
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION
1. Check:
S pressure regulator operation
a. Remove the fuel tank.
Refer to “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 injection pipe.
Vacuum/pressure pump gauge set
90890-06756, YB-35956
Pressure gauge
90890-03153, YU-03153
Adapter
90890-03176, YM-03176
e. Install the fuel tank.
Refer to “FUEL TANK” in chapter 3.
f. Start the engine.
g. Measure the fuel pressure.
Fuel pressure
284 kPa (2.84 kg/cm2, 40.4 psi)
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 (760 mmHg, 29.9 inHg).
7-32
THROTTLE BODIES
FI
Increase the vacuum pressure !
Fuel pressure is decreased
Decrease the vacuum pressure !
Fuel pressure is increased
Faulty ! Replace the pressure regulator.
EAS00916
CHECKING
AND
ADJUSTING
THROTTLE POSITION SENSOR
THE
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly adjusted.
1. Check:
S throttle position sensor
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor from the
throttle body.
c. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Positive tester probe ! blue terminal 1
Negative tester probe ! black terminal 2
d. Measure the maximum throttle position sensor resistance.
Out of specification ! Replace the throttle
position sensor.
Maximum throttle position
sensor resistance
3.5 X 6.5 kΩ at 20_C (68_F)
(blue - black)
e. Connect the pocket tester (Ω
throttle position sensor.
1k) to the
Positive tester probe ! yellow terminal 3
Negative tester probe ! black terminal 2
7-33
THROTTLE BODIES
FI
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 X 5 " 1.5 kΩ at 20_C (68_F)
(yellow - black)
2. Adjust:
S throttle position sensor angle
a. Connect the throttle position sensor coupler
to the wire harness.
b. Connect the digital circuit tester to the throttle
position sensor.
Tester positive probe ! blue terminal 1
Tester negative probe !
yellow terminal 2
Digital circuit tester
90890-03174
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
the measured voltage is within the specified
range.
Throttle position sensor voltage
0.63 X 0.73 V
(yellow – blue)
g. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
7-34
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 (1112 to
1292_F).
EAS0097
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.
A From the air cleaner
B To the cylinder head
7-35
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Air cut-off valve
2 Reed valve
3 To air filter case
A To cylinder #1 and #2
B To cylinder #3 and #4
7-36
FI
AIR INDUCTION SYSTEM
FI
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
S hoses
Loose connection ! Connect properly.
Cracks/damage ! Replace.
S pipes
Cracks/damage ! Replace.
2. Check:
S reed valve 1
S reed valve stopper
S reed valve seat
Cracks/damage ! Replace the reed valve.
3. Measure:
S reed valve bending limit a
Out of specification ! Replace the reed
valve.
Reed valve bending limit
0.4 mm (0.016 in)
1 Surface plate
4. Check:
S air cut-off valve
Cracks/damage ! Replace.
7-37
AIR INDUCTION SYSTEM
FI
5. Check
S air induction system solenoid
a. Remove the air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (Ω
1) to the air
induction system solenoid terminal as
shown.
Tester positive probe ! orange 1
Tester negative probe ! green 2
c. Measure the air induction system solenoid
resistance.
Air induction system solenoid
resistance
18 X 22 Ω at 20_C (68_F)
d. Out of specification ! Replace.
7-38
ELECTRICAL COMPONENTS
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Main switch
Front brake light switch
Clutch switch
Battery
Starter relay
Fuse (main)
Neutral switch
Rear brake light switch
9
10
11
12
13
14
8-1
Sidestand switch
Oil level switch
Radiator fan motor
Horn
Ignition coil
Fuse box
ELEC
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Coolant temperature sensor
Intake air temperature sensor
Intake air pressure sensor
Lean angle cut-off switch
Atmospheric pressure sensor
ECU
Starting circuit cut-off relay
Turn signal relay
9
10
11
12
13
14
ELEC
Speed sensor
Crankshaft position sensor
Cylinder identification sensor
Radiator fan motor relay
Headlight relay (on / off)
Headlight relay (dimmer)
8
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. Always insert the probes
from the opposite end of the coupler 1 taking care not to loosen or damage the leads.
Pocket tester
90890-03112, YU-3112
NOTE:
S Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
S When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between red and brown/blue
when the switch is set to “ON”.
8-3
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.
1
2
3
4
5
Main switch
Horn switch
Dimmer switch
Turn signal switch
Clutch switch
6
7
8
9
10
Sidestand switch
Engine stop switch
Front brake light switch
Start switch
Oil level switch
8-4
11 Neutral switch
12 Rear brake light switch
13 Fuse box
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.
S 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.
S 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.
S Bulbs D and E are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
8-5
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
S bulb
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
S 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.
S 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:
S bulb (for continuity)
(with the pocket tester)
No continuity ! Replace.
Pocket tester
90890-03112, YU-3112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
2 , and check the continuity.
b. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
8-6
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
S bulb socket (for continuity)
(with the pocket tester)
No continuity ! Replace.
Pocket tester
90890-03112, YU-3112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
CHECKING THE LEDs
The following procedures applies to all of the
LEDs.
1. Check:
S LED (for proper operation)
Improper operation ! Replace.
a. Disconnect the meter assembly coupler (meter assembly side).
b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown.
WARNING
S A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
S This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
c. When the jumper leads are connected to the
terminals the respective LED should illuminate.
Does not light ! Replace the meter assembly.
8-7
IGNITION SYSTEM
ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
5
6
10
11
12
14
15
16
19
20
28
44
55
8-8
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
ECU
Ignition coil
Spark plug
Neutral switch
Crankshaft position sensor
Lean angle cut-off switch
Engine stop switch
Clutch switch
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S 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).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. ignition coil resistance
6. crankshaft position sensor
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. starting circuit cut-off relay
13. lean angle cut-off switch
14. wiring connections
(of the entire ignition system)
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00741
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. air filter case
4. bottom cowling
5. side cowlings
S Troubleshoot with the following special tool(s).
3. Spark plugs
The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK or CR10EK (NGK)
Spark plug gap
0.6 X 0.7 mm (0.0236 X 0.0276 in)
Dynamic spark tester
YM-34487
Pocket tester
90890-03112, YU-3112
S Is the spark plug in good condition, is it of the
correct type, and is its gap within specification?
EAS00738
1. Main and ignition fuses
YES
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
8-9
ELEC
IGNITION SYSTEM
EAS00743
EAS00747
4. Ignition spark gap
5. Ignition coil resistance
The following procedure applies to all of the
spark plugs.
S Disconnect the ignition coil from the spark
plug.
S Connect the dynamic spark tester 1 and
ignition coil 2 as shown.
S Turn the main switch to “ON”.
S Measure the ignition spark gap a .
S Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil leads from the
wire harness.
S Connect the pocket tester (Ω
1) to the
ignition coil as shown.
Positive tester probe !
ignition coil terminal
Negative tester probe !
ignition coil terminal
S Measure the primary coil resistance.
Primary coil resistance
0.17 X 0.23 Ω at 20_C (68_F)
Minimum ignition spark gap
6 mm (0.24 in)
S Connect the pocket tester (Ω
ignition coil as shown.
S Is there a spark and is the spark gap within
specification?
NO
1k) to the
Negative tester probe !
ignition coil terminal 1
Positive tester probe !
spark plug terminal 2
YES
The ignition system
is OK.
S Measure the secondary coil resistance.
Secondary coil resistance
4.8 X 7.2 kΩ at 20_C (68_F)
S Is the ignition coil OK?
YES
NO
Replace the ignition
coil.
8-10
IGNITION SYSTEM
EAS00748
ELEC
EAS00750
6. Crankshaft position sensor resistance
8. Engine stop switch
S Disconnect the crankshaft position sensor
coupler from the wire harness.
S Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
YES
Positive tester probe ! gray 1
Negative tester probe ! black 2
NO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
S Measure the crankshaft position sensor
resistance.
YES
Crankshaft position sensor
resistance
248 X 372Ω at 20_C (68_F)
(between gray and black)
NO
Replace the neutral
switch.
S Is the crankshaft position sensor OK?
EAS00752
10. Sidestand switch
YES
NO
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?
Replace the
crankshaft position
sensor.
YES
Replace the sidestand switch.
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
EAS00763
11. Clutch switch
S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the clutch switch OK?
NO
Replace the main
switch.
YES
NO
Replace the clutch
switch.
8-11
IGNITION SYSTEM
ELEC
EAS00753
12. Starting circuit cut-off relay
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.
S Check the starting circuit cut-off relay for
continuity.
S Are the tester readings correct?
YES
Positive tester probe !
sky blue 1
Negative tester probe !
black/yellow 2
Positive tester probe !
sky blue 1
Negative tester probe !
blue/yellow 3
Replace the starting
circuit cut-off relay.
13. Lean angle cut-off switch voltage
Continuity
S Remove the lean angle cut-off switch.
S Connect the pocket tester (Ω
1) to the
lean angle cut-off switch terminals as
shown.
Positive tester probe !
blue/black 4
Negative tester probe !
blue/yellow 3
Positive tester probe ! blue
Negative tester probe ! yellow/green
Positive tester probe !
black/yellow 2
Negative tester probe !
sky blue 1
Positive tester probe !
blue/yellow 3
Negative tester probe !
sky blue 1
NO
No
continuity
Positive tester probe !
blue/yellow 3
Negative tester probe !
blue/black 4
Lean angle cut-off switch voltage
Less than 65_ a !
Approximately 1 V
More than 65_ b !
Approximately 4 V
S Is the lean angle cut-off switch OK?
8-12
IGNITION SYSTEM
YES
NO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring
S Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the ignition system’s wiring properly connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the ignition
system’s wiring.
8-13
ELEC
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
1
5
6
7
8
10
11
12
19
44
45
55
8-14
Main switch
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Engine stop switch
Start switch
Clutch switch
ELECTRIC STARTING SYSTEM
ELEC
EAS00756
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:
S The transmission is in neutral (the neutral
switch is closed).
S 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
2
3
4
5
6
7
8
9
10
11
12
13
8-15
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Starting circuit cut-off relay
Diode
Clutch switch
Sidestand switch
Neutral switch
Start switch
Starter relay
Starter motor
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S 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 relay
6. main switch
7. engine stop switch
8. neutral switch
9. sidestand switch
10. clutch switch
11. start switch
12. wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00758
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. left side cowling
S Troubleshoot with the following special tool(s).
3. Starter motor
S Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
90890-03112, YU-3112
EAS00738
1. Main and ignition fuses
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
WARNING
S 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.
S This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
Replace the fuse(s).
S Does the starter motor turn?
YES
NO
Repair or replace the
starter motor.
8-16
ELECTRIC STARTING SYSTEM
ELEC
EAS00759
4. Starting circuit cut-off relay
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω
1) and battery (12 V) to the starting circuit cut-off relay
coupler as shown.
Positive battery terminal ! red/black 1
Negative battery terminal !
black/yellow 2
S Does the starter relay have continuity between red and black?
Positive tester probe ! blue/white 3
Negative tester probe ! blue/white 4
YES
NO
Replace the starter
relay.
EAS00749
6. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
S Does the starting circuit cut-off relay have
continuity
between
blue/white
and
blue/white?
YES
YES
NO
NO
Replace the main
switch.
Replace the starting
circuit cut-off relay.
EAS00750
7. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
EAS00761
5. Starter relay
S Disconnect the starter relay coupler from the
coupler.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the starter relay coupler as shown.
YES
NO
Replace the right
handlebar switch.
Positive battery terminal ! red/white 1
Negative battery terminal ! blue/white 2
Positive tester probe ! red 3
Negative tester probe ! black 4
EAS00751
8. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
8-17
ELECTRIC STARTING SYSTEM
EAS00752
ELEC
EAS00766
9. Sidestand switch
12. Wiring
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?
S Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the starting system’s wiring properly connected and without defects?
YES
NO
YES
Replace the sidestand switch.
The starting system
circuit is OK.
EAS00763
10. Clutch switch
S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
EAS00764
11. Start switch
S Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
8-18
NO
Properly connect or
repair the starting
system’s wiring.
STARTER MOTOR
ELEC
EAS00767
STARTER MOTOR
10 Nm (1.0 mSkg, 7.2 ftSlb)
5 Nm (0.5 mSkg, 3.6 ftSlb)
Order
1
2
Job/Part
Removing the starter motor
Rider seat
Fuel tank
Left side cowling
Starter motor lead
Starter motor
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
1
1
For installation, reverse the removal
procedure.
8-19
STARTER MOTOR
ELEC
EAS00768
7 Nm (0.7 mSkg, 5.1 ftSlb)
3.4 Nm (0.34 mSkg, 2.5 ftSlb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Disassembling the starter motor
O-ring
Front cover
Lock washer
Oil seal
Bearing
Washer set
Rear cover
Washer set
O-ring
Brush holder
Armature assembly
Starter motor yoke
Q’ty
Remarks
Disassembly the parts in the order listed.
1
1
1
1
1
1
1
1
2
1
1
1
For assembly, reverse the disassembly
procedure.
8-20
STARTER MOTOR
ELEC
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
S commutator
Dirt ! Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification ! Replace the starter
motor.
Commutator wear limit
27 mm (1.06 in)
3. Measure:
S mica undercut a
Out of specification ! Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut
0.7 mm (0.03 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure:
S 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, YU-3112
Armature coil
Commutator resistance 1
0.0012 X 0.0022 Ω
at 20_C (68_F)
Insulation resistance 2
Above 1 MΩ at 20_C (68_F)
b. If any resistance is out of specification, replace the starter motor.
8-21
STARTER MOTOR
ELEC
5. Measure:
S brush length a .
Out of specification ! Replace the brushes
as a set.
Brush length wear limit
3.5 mm (0.14 in)
6. Measure:
S brush spring force
Out of specification ! Replace the brush
springs as a set.
Brush spring force
7.16 X 9.52 N
(730 X 971 gf, 25.77 X 34.27 oz)
7. Check:
S gear teeth
Damage/wear ! Replace the gear.
8. Check:
S bearing
S oil seal
Damage/wear ! Replace the defective
part(s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
S brush seat 1
NOTE:
Align the tab a on the brush seat with the slot b
in the starter motor rear cover.
2. Install:
S starter motor yoke 1
S O-ring 2 New
S front cover 3
Srear cover 4
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear covers.
8-22
ELEC
CHARGING SYSTEM
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
3
5
6
8-23
A.C. magneto
Rectifier/ regulator
Battery
Fuse (main)
CHARGING SYSTEM
ELEC
EAS00774
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
TROUBLESHOOTING
The battery is not being charged.
S Is the battery OK?
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance 1
5. stator coil resistance 2
6. wiring connections
(of the entire charging system)
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00775
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
S Troubleshoot with the following special tool(s).
3. Charging voltage
S Set the engine tachometer to the ignition coil
of cylinder #1.
S Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe !
positive battery terminal
Negative tester probe !
negative battery terminal
Pocket tester
90890-03112, YU-3112
EAS00738
1. Main fuse
S Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main fuse OK?
YES
NO
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
Replace the fuse.
Charging voltage
14 V at 5,000 r/min
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
NOTE:
Make sure the battery is fully charged.
S Is the charging voltage within specification?
NO
YES
The charging circuit
is OK.
8-24
ELEC
CHARGING SYSTEM
EAS00776
4. Stator coil resistance 1
5. Stator coil resistance 2
S Disconnect stator coil lead coupler.
S Connect the pocket tester (Ω 1) to the stator coil lead coupler as shown.
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the stator coils as shown.
Positive tester probe !
white 1
Negative tester probe !
ground
Positive tester probe ! white 1
Negative tester probe ! white 2
Positive tester probe ! white 1
Negative tester probe ! white 3
Positive tester probe !
white 2
No
Negative tester probe !
continuity
ground
Positive tester probe !
white 3
Negative tester probe !
ground
S Measure the stator coil resistances.
Stator coil resistance
0.18 X 0.26 Ω at 20_C (68_F)
S Is the stator coil OK?
YES
S Are the tester readings correct?
YES
NO
Replace the stator
coil assembly.
NO
EAS00779
6. Wiring
Replace the stator
coil assembly.
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly connected and without defects?
YES
Replace the rectifier/regulator.
8-25
NO
Properly connect or
repair the charging
system’s wiring.
LIGHTING SYSTEM
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
8-26
ELEC
LIGHTING SYSTEM
1
5
6
10
14
38
40
47
51
52
56
63
64
65
66
67
Main switch
Battery
Fuse (main)
Fuse (ignition)
ECU
High beam indicator light
Meter light
Fuse (headlight)
Headlight relay (on / off)
Headlight relay (dimmer)
Dimmer switch
Front turn signal/position light (right)
Front turn signal/position light (left)
Headlight
License light
Tail/ brake light
8-27
ELEC
LIGHTING SYSTEM
ELEC
EAS00781
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
TROUBLESHOOTING
Any of the following fail to light: headlight,
high beam indicator light, taillight, licence
light or meter light.
S Is the battery OK?
YES
Check:
1. main, ignition and headlight fuses
2. battery
3. main switch
4. dimmer switch
5. headlight relay (on/off)
6. headlight relay (dimmer)
7. wiring connections
(of the entire lighting system)
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings
4. rear cowling
S Troubleshoot with the following special tool(s).
YES
NO
Replace the main
switch.
EAS00784
Pocket tester
90890-03112, YU-3112
4. Dimmer switch
S Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the dimmer switch OK?
EAS00738
1. Main, ignition and headlight fuses
S Check the main, ignition and headlight fuses
for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, ignition and headlight fuses
OK?
YES
YES
NO
The dimmer switch is
faulty. Replace the
left
handlebar
switch.
NO
Replace the fuse(s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
8-28
LIGHTING SYSTEM
ELEC
5. Headlight relay (on/off)
S Disconnect the headlight relay (on/off) from
the coupler.
S Connect the pocket tester (Ω
1) and battery (12 V) to the headlight relay (on/off)
coupler as shown.
Positive battery lead ! blue/black 1
Negative battery lead ! yellow/white 2
S Does the headlight relay (dimmer) have
continuity?
Positive tester probe ! red/yellow 3
Negative tester probe ! black/blue 4
YES
NO
Replace the headlight relay (dimmer).
EAS00787
7. Wiring
S Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the lighting system’s wiring properly connected and without defects?
S Does the headlight relay (on/off) have continuity between red/yellow and black/blue?
YES
NO
YES
Replace the headlight relay (on/off).
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
6. Headlight relay (dimmer)
S Disconnect the headlight relay (dimmer)
from the coupler.
S Connect the pocket tester (Ω
1) and battery (12 V) to the headlight relay (dimmer)
coupler as shown.
High beam
Positive battery lead ! yellow 1
Negative battery lead ! black 2
Positive tester probe ! black/blue 3
Negative tester probe ! black/yellow 4
8-29
NO
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
ELEC
EAS00788
Headlight
Positive tester probe ! black/yellow 3
Negative tester probe ! black 4
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
B High beam
1. Headlight bulb and socket
S Check the headlight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
S Are the headlight bulb and socket OK?
YES
NO
Replace the headlight bulb, socket or
both.
High beam indicator light (LEDs)
Positive tester probe !
black/yellow 5
Negative tester probe !
black/white 6
Meter assembly coupler (wire harness side)
2. Voltage
S Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
A When the dimmer switch is set to “
B When the dimmer switch is set to “
”
”
Headlight
Positive tester probe ! black/blue 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Start the engine.
S Set the dimmer switch to “
” or “
”.
S Measure the voltage (DC 12 V) of black/blue
1 or black/yellow 3 on the headlight coupler (wire harness side).
S Is the voltage within specification?
Headlight coupler (wire harness side)
A Low beam
YES
This circuit is OK.
8-30
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
ELEC
LIGHTING SYSTEM
EAS00789
EAS00790
2. The meter light fails to come on.
3. The tail/brake light fails to come on.
1. Meter light (LEDs)
1. Tail/brake light (LEDs)
S Check the meter light for continuity.
Refer to “CHECKING THE LEDs”
S Are the meter light OK?
S Check the tail/brake light for continuity.
Refer to “CHECKING THE LEDs”
S Are the tail/brake light OK?
YES
NO
YES
Replace the meter
assembly.
NO
Replace
the
tail/brake light assembly.
2. Voltage
2. Voltage
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
S Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe ! blue 1
Negative tester probe ! black/white 2
Positive tester probe ! blue/red 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue 1 on
the meter assembly coupler (wire harness
side).
S Is the voltage within specification?
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue/red
1 on the tail/brake light coupler (wire harness side).
S Is the voltage within specification?
YES
This circuit is OK.
NO
YES
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
This circuit is OK.
8-31
NO
Wiring circuit from
the main switch to
the tail/brake light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
ELEC
EAS00792
5. The turn signal/position light fails to come
on.
4. The license light fails to come on.
1. License light bulb and socket
1. Turn signal/position light bulb and socket
S Check the license light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
S Are the license light bulb and socket OK?
YES
S Check the turn signal/position light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
S Are the turn signal/position light bulb and
socket OK?
NO
YES
Replace the license
light bulb, socket or
both.
NO
Replace the turn signal/position light bulb,
socket or both.
2. Voltage
2. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal/position light couplers (wire harness side) as shown.
S Connect the pocket tester (DC 20 V) to the
license light coupler (wire harness light side)
as shown.
Tester positive probe ! blue 1
Tester negative probe ! black 2
Positive tester probe ! blue/red 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Measure the voltage (12 V) of blue 1 on the
turn signal/position light couplers (wire harness side).
S Is the voltage within specification?
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue/red
1 on the license light coupler (wire harness
side).
S Is the voltage within specification?
YES
This circuit is OK.
YES
NO
This circuit is OK.
The wiring circuit
from the main switch
to the license light
coupler is faulty and
must be repaired.
8-32
NO
The wiring circuit
from the main switch
to the turn signal/
position light connectors is faulty and
must be repaired.
SIGNALING SYSTEM
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
8-33
ELEC
SIGNALING SYSTEM
1
5
6
10
11
13
14
19
27
30
31
32
33
34
35
37
39
41
43
46
53
57
58
59
60
61
62
63
64
67
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Fuel pump
ECU
Neutral switch
Speed sensor
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Coolant temperature indicator light
Turn signal indicator light
Oil level switch
Front brake light switch
Fuse (signal)
Rear brake light switch
Horn switch
Turn signal switch
Horn
Turn signal relay
Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Tail/ brake light
8-34
ELEC
SIGNALING SYSTEM
ELEC
EAS00794
TROUBLESHOOTING
YES
S Any of the following fail to light: turn signal light, brake light or an indicator light.
S The horn fails to sound.
S Clean the battery
terminals.
S Recharge or replace the battery.
Check:
1. main, ignition and signaling fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
4. side cowlings
5. rear cowling
S Troubleshoot with the following special tool(s).
YES
NO
Replace the main
switch.
4. Wiring
Pocket tester
90890-03112, YU-3112
S Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the signaling system’s wiring properly
connected and without defects?
EAS00738
1. Main, ignition and signaling fuses
S Check the main, ignition and signaling fuses
for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, ignition and signaling fuses
OK?
YES
NO
YES
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
NO
NO
Properly connect or
repair the signaling
system’s wiring.
Replace the fuse(s).
EAS00796
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
1. Horn switch
S Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the horn switch OK?
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
YES
S Is the battery OK?
NO
Replace the left handlebar switch.
8-35
ELEC
SIGNALING SYSTEM
EAS00797
2. Voltage
2. The tail/brake light fails to come on.
S Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
1. Tail/brake light (LEDs)
S Check the tail/brake light for continuity.
Refer to “CHECKING THE LEDs”
S Are the tail/brake light OK?
Positive tester probe ! black/white 1
Negative tester probe ! ground
YES
NO
Replace
the
tail/brake light assembly.
2. Brake light switches
S Turn the main switch to “ON”.
S Push the horn switch.
S Measure the voltage (DC 12 V) of
black/white at the horn terminal.
S Is the voltage within specification?
YES
S Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the brake light switch OK?
YES
NO
NO
Replace the brake
light switch.
The wiring circuit
from the main switch
to the horn connector is faulty and must
be repaired.
3. Voltage
S Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
3. Horn
Positive tester probe ! yellow 1
Negative tester probe ! black 2
S Disconnect the black connector at the horn
terminal.
S Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
S Turn the main switch to “ON”.
S Push the horn switch.
S Does the horn sound?
S Turn the main switch to “ON”.
S Pull in the brake lever or push down on the
brake pedal.
S Measure the voltage (DC 12 V) of yellow 1
on the tail/brake light coupler (wire harness
side).
S Is the voltage within specification?
YES
The horn is OK.
NO
Replace the horn.
8-36
SIGNALING SYSTEM
YES
This circuit is OK.
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) on brown 1
at the turn signal relay coupler (wire harness
side).
S Is the voltage within specification?
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
YES
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and must be repaired.
EAS00799
3. The turn signal/position light, turn signal
indicator light or both fail to blink.
1. Turn signal indicator light (LEDs)
S Check the turn signal indicator light for continuity.
Refer to “CHECKING THE LEDs”
S Are the turn signal indicator light OK?
YES
ELEC
4. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
NO
Positive tester probe ! brown/white 1
Negative tester probe ! ground
Replace the meter
assembly.
2. Turn signal switch
S Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the turn signal switch OK?
YES
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) on
brown/white 1 at the turn signal relay coupler (wire harness side).
S Is the voltage within specification?
NO
Replace the left handlebar switch.
YES
NO
3. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
The turn signal relay
is faulty and must be
replaced.
Positive tester probe ! brown 1
Negative tester probe ! ground
5. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal/position light connector or meter
assembly coupler (wire harness side) as
shown.
A Front turn signal/position light
B Rear turn signal light
C Turn signal indicator light
8-37
SIGNALING SYSTEM
ELEC
YES
Left turn signal light
Positive tester probe ! chocolate 1
Negative tester probe ! ground
Right turn signal light
Positive tester probe ! dark green 2
Negative tester probe ! ground
A
B
NO
Replace the meter
assembly.
2. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
C
3. Voltage
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Positive tester probe ! brown 1
Negative tester probe ! ground
S Turn the main switch to “ON”.
S Set the turn signal switch to “
” or “
”.
S Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light
connector (wire harness side).
S Is the voltage within specification?
YES
This circuit is OK.
NO
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of brown at
the meter assembly coupler (wire harness
side).
S Is the voltage within specification?
The wiring circuit
from the turn signal
switch to the turn signal light connector is
faulty and must be
repaired.
YES
NO
EAS00801
4. The neutral indicator light fails to come on.
This circuit is OK.
1. Neutral indicator light (LEDs)
S Check the neutral indicator light for continuity.
Refer to “CHECKING THE LEDs”
S Are the neutral indicator light OK?
8-38
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
SIGNALING SYSTEM
ELEC
EAS00802
3. Voltage
5. The oil level warning light fails to come on.
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
1. Oil level warning light (LEDs)
S Check the oil level warning light for continuity.
Refer to “CHECKING THE LEDs”
S Are the oil level warning light OK?
YES
Positive tester probe ! black/red 1
Negative tester probe ! black/white 2
NO
Replace the meter
assembly.
2. Oil level switch
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of black/red
1 and black/white 2 at the meter assembly coupler.
S Is the voltage within specification?
S Drain the engine oil and remove the oil level
switch from the oil pan.
S Connect the pocket tester (Ω
100) to the
oil level switch as shown.
Positive tester probe !
Connector 1 (white)
Negative tester probe ! Body earth 2
1
2
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly is faulty and must
be repaired.
EAS00803
6. The fuel level warning light fails to come on.
S Measure the oil level switch resistance.
1. Fuel level warning light (LEDs)
Oil level switch resistance
1 484 X 536 Ω at 20_C (68_F)
2 114 X 126 Ω at 20_C (68_F)
S Check the fuel level warning light for continuity.
Refer to “CHECKING THE LEDs”
S Are the fuel level warning light OK?
S Is the oil level switch OK?
YES
YES
NO
NO
Replace the meter
assembly.
Replace the oil level
switch.
8-39
SIGNALING SYSTEM
ELEC
2. Fuel sender
3. Voltage
S Drain the fuel from the fuel tank and remove
the fuel pump from the fuel tank.
S Disconnect the fuel sender coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
sender as shown.
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Positive tester probe ! green/white 1
Negative tester probe ! black/white 2
Positive tester probe ! green/white 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of
green/white 1 and black/white 2 at the
meter assembly coupler.
S Is the voltage within specification?
S Check the fuel sender for continuity.
S Is the fuel sender OK?
YES
NO
YES
Replace the fuel
pump assembly.
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
EAS00806
7. The speedometer fails to operate.
1. Multi-function meter LEDs
S Check the multi-function meter LEDs for
continuity.
Refer to “CHECKING THE LEDs”.
S Is the multi-function meter LEDs OK?
YES
NO
Replace the meter
assembly.
8-40
SIGNALING SYSTEM
ELEC
2. Speed sensor
3. Voltage
S Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
side) as shown.
Positive tester probe ! white/yellow 1
Negative tester probe ! blue 2
Positive tester probe ! yellow/blue 1
Negative tester probe ! black/white 2
S Turn the main switch to “ON”.
S Elevate the rear wheel and slowly rotate it.
S Measure the voltage (DC 5 V) of blue and
white/yellow. With each full rotation of the
rear wheel, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
S Does the voltage reading cycle correctly?
S Turn the main switch to “ON”.
S Elevate the rear wheel and slowly rotate it.
S Measure the voltage (DC 5 V) of yellow/blue
1 on the meter assembly coupler (wire harness side).
S Is the voltage within specification?
NO
YES
YES
NO
This circuit is OK.
Replace the speed
sensor.
8-41
Replace the meter
assembly.
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
1
5
6
10
14
Main switch
Battery
Fuse (main)
Fuse (ignition)
ECU
22
48
49
50
Coolant temperature sensor
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
8-42
ELEC
COOLING SYSTEM
EAS00808
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
S The radiator fan motor fails to turn.
S The coolant temperature indicator light
fails to light when the engine is warm.
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
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)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
4. side cowlings
S Troubleshoot with the following special tool(s).
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
Pocket tester
90890-03112, YU-3112
NO
Replace the main
switch.
EAS00738
1. Main, ignition and radiator fan motor fuses
S Check the main, ignition and radiator fan
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, ignition and radiator fan motor
fuses OK?
YES
NO
Replace the fuse(s).
8-43
COOLING SYSTEM
ELEC
EAS00809
4. Radiator fan motor
5. Radiator fan motor relay
S Disconnect the radiator fan motor coupler
from the wire harness.
S Connect the battery (DC 12 V) as shown.
S Disconnect the radiator fan motor relay
form the wire harness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the radiator fan motor terminal
as shown.
S Check the radiator fan motor of continuity.
Battery positive terminal ! red/white 1
Battery negative terminal !
green/yellow 2
Tester positive probe ! brown/green 3
Tester negative probe ! blue 4
Positive battery lead ! blue 1
Negative battery lead ! black 2
S Does the radiator fan motor turn?
YES
NO
The radiator fan motor is faulty and must
be replaced.
S Does the radiator fan motor relay have continuity between brown/green and blue?
YES
NO
Replace the radiator
fan motor relay.
8-44
COOLING SYSTEM
ELEC
EAS00812
6. Coolant temperature sensor
S Remove the coolant temperature sensor.
S Connect the pocket tester (Ω
1k) to the
1
coolant temperature sensor
as shown.
S Immerse the coolant temperature sensor in
a container filled with coolant 2 .
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant, and then let it cool to
the specified temperature indicated in the
table.
S Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
Coolant temperature sensor
resistance
0_C (132_F): 5.21 X 6.37 kΩ
80_C (176_F): 0.29 X 0.35 kΩ
WARNING
S Handle the coolant temperature sensor
with special care.
S Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
S Does the coolant temperature sensor operate properly?
YES
NO
Replace the coolant
temperature sensor.
Coolant temperature sensor
20 Nm (2.0 mSkg, 14 ftSlb)
Three bond sealock10
EAS00813
7. Wiring
S Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the cooling system’s wiring properly connected and without defects?
YES
This circuit is OK.
8-45
NO
Properly connect or
repair the cooling
system’s wiring.
FUEL PUMP SYSTEM
ELEC
EAS00814
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
1
5
6
9
10
11
13
14
44
8-46
Main switch
Battery
Fuse (main)
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Fuel pump
ECU
Engine stop switch
FUEL PUMP SYSTEM
ELEC
EAS00815
FUEL PUMP SYSTEM
The ECU includes the control unit for the
fuel pump.
1 Battery
2 Fuse (main)
3 Main switch
4 Fuse (ignition)
5 Engine stop switch
6 ECU
7 Fuse (fuel injection)
8 Starting circuit cut-off relay
9
8-47
(fuel pump injection system relay)
Fuel pump
FUEL PUMP SYSTEM
EAS00816
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
If the fuel pump fails to operate.
S Check the condition of the battery
Refer to “CHECKING THE BATTERY” in
chapter 3.
Check:
1. Main, ignition and fuel injection fuses
2. Battery
3. Main switch
4. Engine stop switch
5. Starting circuit cut-off relay
(the fuel pump injection system relay)
6. Fuel pump
7. Wiring connections
(the entire fuel system)
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(s):
1. Seat
2. Fuel tank
Troubleshoot with the following special tool(s).
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Pocket tester
90890-03112, YU-3112
S Is the main switch OK?
EAS00738
YES
NO
1. Main, ignition and fuel injection fuses
S Check the main, ignition and fuel injection
fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
Replace the main
switch.
EAS00750
S Are the main ignition and fuel injection fuses
OK?
YES
4. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
NO
S Is the engine stop switch OK?
Replace the fuse(s).
YES
NO
Replace the right
handlebar switch.
8-48
ELEC
FUEL PUMP SYSTEM
EAS00759
EAS00817
5. Starting circuit cut-off relay
6. Fuel pump resistance
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω
1) and battery (12V) to the starting circuit cut-off relay
coupler as shown.
S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler as shown.
Positive tester probe ! red/blue 1
Negative tester probe ! black 2
Positive battery lead ! red/black 1
Negative battery lead ! light green 2
Positive tester probe ! red 3
Negative tester probe ! red/blue 4
S Measure the fuel pump resistance.
Fuel pump resistance
0.2 X 3.0 Ω at 20_C (68_F)
S Does the starting circuit cut-off relay have
continuity between red and red/blue?
YES
S Is the fuel pump OK?
YES
NO
NO
Replace
pump.
Replace the starting
circuit cut-off relay.
the
fuel
EAS00818
7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the fuel system’s wiring properly connected and without defects?
YES
Replace the ECU.
8-49
NO
Properly connect or
repair the fuel system’s wiring.
FUEL PUMP 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:
S Stop the engine before refueling.
S Do not smoke, and keep away from open
flames, sparks, or any other source of fire.
S If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
S 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:
S 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 (DC 12 V) to the fuel
pump coupler as shown.
Positive battery lead ! red/blue 2
Negative battery lead ! black 3
e. If fuel flows out of the fuel hose, the fuel pump
is OK. If fuel does not flow, replace the fuel
pump.
8-50
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The YZF-R6 features a self-diagnosing system for the following circuit(-s):
S Fuel sender
S Oil level switch
If any of these circuits are defective, their respective condition codes will be displayed on the warning
light when the main switch is turn to “ON” (irrespective of whether the engine is running or not)
Circuit
Defect(-s)
System response
Condition code
Fuel sender
S Open-circuit
S Short-circuit
S The fuel warning light indicate the
condition code.
Refer to *1
Oil level switch
S Open-circuit
S Short-circuit
S The oil level warning light indicate
the condition code.
Refer to *2
*1 Condition code
Fuel warning light
*2 Condition code
Oil level warning light
8-51
SELF-DIAGNOSIS
TROUBLESHOOTING
ELEC
1. Wire harness
The warning light starts to indicate the
self-diagnosis sequence.
S Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
S Is the wire harness OK?
Check:
1. Fuel sender
2. Oil level switch
YES
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Seats
2) Fuel tank
3) Lower cowling
S Troubleshoot with the following special
tool(-s).
NO
Repair or replace the
wire harness.
2. Fuel sender
S Check the fuel sender for continuity.
Refer to “The fuel level indicator light fails to
come on”.
S Is the fuel sender OK?
Pocket tester
90890-03112, YU-3112
YES
1. Fuel sender
CIRCUIT DIAGRAM
Replace the multifunction meter.
13 Fuel pump
35 Multi-function meter
8-52
NO
Replace
pump.
the
fuel
SELF-DIAGNOSIS
2. Oil level switch
CIRCUIT DIAGRAM
2. Oil level switch
S Check the oil level switch for continuity.
Refer to “The oil level warning light fails to
come on”.
S Is the oil level switch OK?
YES
Replace the multifunction meter.
35 Multi-function meter
41 Oil level switch
1. Wire harness
S Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
S Is the wire harness OK?
YES
ELEC
NO
Repair or replace the
wire harness.
8-53
NO
Replace the oil level
switch.
STARTING FAILURES
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 FAILURES
ENGINE
Cylinder(s) and cylinder head(s)
S Loose spark plug
S Loose cylinder head or cylinder
S Damaged cylinder head gasket
S Worn or damaged cylinder
S Incorrect valve clearance
S Improperly sealed valve
S Incorrect valve-to-valve-seat contact
S Incorrect valve timing
S Faulty valve spring
S Seized valve
Piston(s) and piston ring(s)
S Improperly installed piston ring
S Damaged, worn or fatigued piston ring
S Seized piston ring
S Seized or damaged piston
Air filter
S Improperly installed air filter
S Clogged air filter element
Crankcase and crankshaft
S Improperly assembled crankcase
S Seized crankshaft
FUEL SYSTEM
Fuel tank
S Empty fuel tank
S Clogged fuel filter
S Clogged fuel tank drain hose
S Clogged rollover valve
S Clogged rollover valve hose
S Deteriorated or contaminated fuel
Fuel pump
S Faulty fuel pump
S Faulty fuel pump relay
Throttle body (-ies)
S Deteriorated or contaminated fuel
S Sucked-in air
ELECTRICAL SYSTEMS
Battery
S Discharged battery
S Faulty battery
Fuse(s)
S Blown, damaged or incorrect fuse
S Improperly installed fuse
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
Ignition coil(s)
S Cracked or broken ignition coil body
S Broken or shorted primary or secondary
coils
Ignition system
S Faulty ECU
S Faulty crankshaft position sensor
S Faulty cylinder identification sensor
9
9-1
STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Switches and wiring
S Faulty main switch
S Faulty engine stop switch
S Broken or shorted wiring
S Faulty neutral switch
S Faulty start switch
S Faulty sidestand switch
S Faulty clutch switch
S Improperly grounded circuit
S Loose connections
TRBL
SHTG
Starting system
S Faulty starter motor
S Faulty starter relay
S Faulty starting circuit cut-off relay
S Faulty starter clutch
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder(s) and cylinder head(s)
S Incorrect valve clearance
S Damaged valve train components
Air filter
S Clogged air filter element
FUEL SYSTEM
Throttle body (-ies)
S Damaged or loose throttle body joint
S Improperly synchronized throttle bodies
S Improperly adjusted engine idling speed
(throttle stop screw)
S Improper throttle cable free play
S Flooded throttle body
S Faulty air induction system
ELECTRICAL SYSTEMS
Battery
S Discharged battery
S Faulty battery
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
Ignition coil(s)
S Broken or shorted primary or secondary
coils
S Cracked or broken ignition coil
Ignition system
S Faulty ECU
S Faulty crankshaft position sensor
S Faulty cylinder identification sensor
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES”.
ENGINE
Air filter
S Clogged air filter element
FUEL SYSTEM
Fuel pump
S Faulty fuel pump
9-2
FAULTY GEAR SHIFTING/FAULTY CLUTCH
TRBL
SHTG
EAS00850
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
S Improperly adjusted shift rod
S Bent shift shaft.
Shift drum and shift forks
S Foreign object in a shift drum groove
S Seized shift fork
S Bent shift fork guide bar
Transmission
S Seized transmission gear
S Foreign object between transmission gears
S Improperly assembled transmission
JUMPS OUT OF GEAR
Shift shaft
S Incorrect shift pedal position
S Improperly returned stopper lever
Shift forks
S Worn shift fork
Shift drum
S Incorrect axial play
S Worn shift drum groove
Transmission
S Worn gear dog
EAS00851
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
S Unevenly tensioned clutch springs
S Warped pressure plate
S Bent clutch plate
S Swollen friction plate
S Bent clutch push rod
S Broken clutch boss
S Burnt primary driven gear bushing
S Match marks not aligned
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (high)
S Deteriorated oil
CLUTCH SLIPS
Clutch
S Improperly assembled clutch
S Improperly adjusted clutch cable
S Loose or fatigued clutch spring
S Worn friction plate
S Worn clutch plate
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (low)
S Deteriorated oil
9-3
OVERHEATING/OVERCOOLING/
POOR BRAKING PERFORMANCE
TRBL
SHTG
EAS00855
OVERHEATING
ENGINE
Cylinder head(s) and piston(s)
S Heavy carbon buildup
Engine oil
S Incorrect oil level
S Incorrect oil viscosity
S Inferior oil quality
COOLING SYSTEM
Coolant
S Low coolant level
Radiator
S Damaged or leaking radiator
S Faulty radiator cap
S Bent or damaged radiator fin
Water pump
S Damaged or faulty water pump
S Thermostat
S Thermostat stays closed
S Oil cooler
S Clogged or damaged oil cooler
S Hose(s) and pipe(s)
S Damaged hose
S Improperly connected hose
S Damaged pipe
S Improperly connected pipe
FUEL SYSTEM
Throttle body (-ies)
S Damaged or loose throttle body joint
Air filter
S Clogged air filter element
CHASSIS
Brake(s)
S Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
Ignition system
S Faulty ignitor unit
Cooling system
S Faulty radiator fan motor relay
S Faulty coolant temperature sensor
S Faulty ECU
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
S Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
S Loose union bolt
S Damaged brake hose
S Oil or grease on the brake disc
S Oil or grease on the brake pad
S Incorrect brake fluid level
S Worn brake pad
S Worn brake disc
S Air in hydraulic brake system
S Leaking brake fluid
S Faulty brake caliper kit
S Faulty brake caliper seal
9-4
FAULTY FRONT FORK LEGS/UNSTABLE HANDLING
TRBL
SHTG
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL
S Bent, damaged or rusty inner tube
S Cracked or damaged outer tube
S Improperly installed oil seal
S Damaged oil seal lip
S Incorrect oil level (high)
S Loose damper rod assembly bolt
S Damaged damper rod assembly bolt
copper washer
S Cracked or damaged cap bolt O-ring
MALFUNCTION
S Bent or damaged inner tube
S Bent or damaged outer tube
S Damaged fork spring
S Worn or damaged outer tube bushing
S Bent or damaged damper rod
S Incorrect oil viscosity
S Incorrect oil level
EAS00863
UNSTABLE HANDLING
Handlebars
S Bent or improperly installed right handlebar
S Bent or improperly installed left handlebar
Steering head components
S Improperly installed upper bracket
S Improperly installed lower bracket
(improperly tightened ring nut)
S Bent steering stem
S Damaged ball bearing or bearing race
Front fork leg(s)
S Uneven oil levels (both front fork legs)
S Unevenly tensioned fork spring (both front
fork legs)
S Broken fork spring
S Bent or damaged inner tube
S Bent or damaged outer tube
Swingarm
S Worn bearing or bushing
S Bent or damaged swingarm
Rear shock absorber assembly(-ies)
S Faulty rear shock absorber spring
S Leaking oil or gas
Tire(s)
S Uneven tire pressures (front and rear)
S Incorrect tire pressure
S Uneven tire wear
Wheel(s)
S Incorrect wheel balance
S Deformed cast wheel
S Damaged wheel bearing
S Bent or loose wheel axle
S Excessive wheel runout
Frame
S Bent frame
S Damaged steering head pipe
S Improperly installed bearing race
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON
S Wrong headlight bulb
S Too many electrical accessories
S Hard charging
S Incorrect connection
S Improperly grounded circuit
S Poor contacts (main switch)
S Burnt-out headlight bulb
S Faulty headlight relay (on/off)
HEADLIGHT BULB BURNT OUT
S Wrong headlight bulb
S Faulty battery
S Faulty rectifier/regulator
S Improperly grounded circuit
S Faulty main switch
S Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
S Too many electrical accessories
S Incorrect connection
TAIL/BRAKE LIGHT BULB BURNT OUT
S Faulty battery
S Incorrectly adjusted rear brake light switch
TURN SIGNAL DOES NOT COME ON
S Faulty turn signal switch
S Faulty turn signal relay
S Burnt-out turn signal bulb
S Incorrect connection
S Damaged or faulty wire harness
S Improperly grounded circuit
S Faulty battery
S Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
S Faulty turn signal relay
S Faulty main switch
S Faulty turn signal switch
S Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
S Faulty turn signal relay
S Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
S Incorrect turn signal bulb
S Faulty turn signal relay
S Burnt-out turn signal bulb
HORN DOES NOT SOUND
S Improperly adjusted horn
S Damaged or faulty horn
S Faulty main switch
S Faulty horn switch
S Faulty battery
S Blown, damaged or incorrect fuse
S Faulty wire harness
9-6
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Fuel pump
ECU
Ignition coil
Spark plug
Fuel injector
Air induction system solenoid
Neutral switch
Crankshaft position sensor
Intake air temperature sensor
Coolant temperature sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Cylinder identification sensor
Speed sensor
Lean angle cut-off switch
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
Headlight relay (on / off)
Headlight relay (dimmer)
Rear brake light switch
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Horn
Turn signal relay
61
62
63
64
65
66
67
Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Headlight
License light
Tail/ brake light
COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ R . . . .
B/ W . . . .
B/ Y . . . .
Br/ G . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
Br/ Y . . . .
G/B . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
O/B . . . .
O/G . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
Sb/ W . . .
W/ B . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .
Y/ W . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Green
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Black
Orange / Green
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red White
Red/ Yellow
Sky blue / White
White/ Black
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Yellow/ White
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM
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Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Fuel pump
ECU
Ignition coil
Spark plug
Fuel injector
Air induction system solenoid
Neutral switch
Crankshaft position sensor
Intake air temperature sensor
Coolant temperature sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Cylinder identification sensor
Speed sensor
Lean angle cut-off switch
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
Headlight relay (on / off)
Headlight relay (dimmer)
Rear brake light switch
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Horn
Turn signal relay
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Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Headlight
License light
Tail/ brake light
PRINTED IN U.S.A.
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM
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