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Yamaha 2002 TDM900 Service Manual

Summary of 2002 TDM900

  • Page 3

    Eas00000 tdm900 (p) 2002 service manual  2001 by yamaha motor co., ltd. First edition, november 2001 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Notice

    Note: warning caution: eas00002 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintena...

  • Page 5: How To Use This Manual

    1 2 4 5 7 8 6 3 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 ...

  • Page 6: Gen

    22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng fi elec cool chk adj trbl shtg chas eas00008 symbols 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 che...

  • Page 7: General Information

    General information specifications periodic checks and adjustments chassis engine cooling system fuel injection system electrical system troubleshooting gen info 1 spec 2 3 eng 4 cool 5 fi 6 chas 7 elec 8 trbl shtg 9 chk adj eas00012 table of contents.

  • Page 10: Gen

    Gen info chapter 1 general information motorcycle identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle identification number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . Model label 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 11: Gen

    Gen info.

  • Page 12: Gen

    1-1 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 2 is affixed to the frame. This info...

  • Page 13: Gen

    1-2 features gen info 10 fuel injector 11 o 2 sensor 12 catalytic converter 13 crankshaft position sensor 14 coolant temperature sensor 15 spark plug 16 cylinder identification sensor 17 pressure regulator 18 battery 19 ecu 20 atmospheric pressure sensor 21 fuel injection system relay 22 engine trou...

  • Page 14: Gen

    1-3 features gen info 7 throttle position sen- sor 8 intake air pressure sensor 9 ecu 10 atmospheric pressure sensor 11 coolant temperature sensor 12 o 2 sensor 13 cylinder identification sensor 14 crankshaft position sensor a fuel system b air system c control system 1 fuel pump 2 pressure regulato...

  • Page 15: Gen

    1-4 features gen info fuel control block the fuel control block consists of the following main components: component function control block ecu total fi system control throttle body air volume control pressure regulator fuel pressure detection sensor block intake air pressure sensor intake air press...

  • Page 16: Gen

    1-5 switches sensors features gen info ecu (electronic control unit) the main functions of the ecu are ignition control, fuel control, self-diagnosis, and load control. Secu’s internal construction and functions the main components and functions of the ecu can be broadly divided into the following f...

  • Page 17: Gen

    1-6 features gen info signition control the ignition control function of the ecu controls the ignition timing and the duration of ignition ener- gizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position s...

  • Page 18: Gen

    1-7 features gen info 1 fuel feed nozzle 2 fuel return nozzle 3 fuel filter 4 sender unit a fuel fuel pump the fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel ...

  • Page 19: Gen

    1-8 features gen info d fuel pressure e vacuum pressure f fuel a open b close c spring pressure 4 fuel chamber 5 valve 1 spring chamber 2 spring 3 diaphragm pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a co...

  • Page 20: Gen

    1-9 features gen info a fuel 4 needle 5 inject 6 flange 1 coil 2 core 3 spacer fuel injector upon receiving injection signals from the ecu, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with...

  • Page 21: Gen

    1-10 1 features gen info 1 pickup rotor a direction of rotation b pickup signal c trigger pole crankshaft position sensor the crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is attached to ...

  • Page 22: Gen

    1-11 features gen info c exhaust d intake e compression a crankshaft position sensor signal b cylinder identification sensor signal f combustion g injection h ignition 1 cylinder identification sensor cylinder identification sensor the cylinder identification sensor is mounted on the exhaust head co...

  • Page 23: Gen

    1-12 features gen info a output voltage b idling output position c mechanical stopper d mechanical stopper e effective electrical angle f sensor operating angle throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It de...

  • Page 24: Gen

    1-13 features gen info a atmospheric pressure, intake air pressure b output voltage c input pressure 4 vacuum chamber 5 silicon chip 6 pressure induction pipe 1 sensor unit 2 hybrid ic 3 silicon diaphragm intake air pressure sensor and atmospheric pressure sensor sintake air pressure sensor the inta...

  • Page 25: Gen

    1-14 features gen info a resistance k Ω b temperature _c a resistance k Ω b temperature _c coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compensa- tions during starting and warm-up. The coolant temperature sensor converts the tem...

  • Page 26: Gen

    1-15 features gen info a exhaust gas b atmosphere 1 inner cover 2 outer cover 3 zirconia tube o 2 sensor the o 2 sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7 : 1). This sensor, which ...

  • Page 27: Gen

    1-16 features gen info f cut-off switch tilt angle g fuel injection system relay off h lag time a normal b tilts c output voltage d high level e low level 1 float lean angle cut-off switch the lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the...

  • Page 28: Gen

    1-17 features gen info 1 ignition coil 2 injector 3 intake air temperature sensor 4 intake solenoid 5 throttle position sensor 6 intake air pressure sensor 7 crankshaft position sensor 8 o 2 sensor 9 coolant temperature sensor 10 cylinder identification sensor 11 spark plug 12 ecu 13 igniter 14 atmo...

  • Page 29: Gen

    1-18 features gen info functions of components catalyst because the conditions in which nox is generated are directly opposed to those of co and hc, there is a limit to the extent to which the concentration levels of these harmful elements can be reduced in the combustion stage. Hence, the function ...

  • Page 30: Gen

    1-19 features gen info 1 air cut-off valve 2 reed valve 3 exhaust port 4 air filter case air induction system the air induction system (ai system) introduces fresh air into the exhaust port in order to burn the un- burned gas (which is present in the exhaust gas) in the exhaust pipe. The burning of ...

  • Page 31: Gen

    1-20 features gen info a open b close c to reed valve d from air cleaner 5 core 6 valve block b 3 spring 4 coil 1 valve block a 2 valve air cut-off valve the air cut-off valve consists of a plunger that is mounted inside the core of a solenoid coil, and a valve at the end of the plunger for opening ...

  • Page 32: Gen

    1-21 features gen info 1 clock 2 trip / odo meter 3 select button 4 reset button 5 engine trouble warning light 1 2 3 4 1 instrument panel function indication the indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the multi-funct...

  • Page 33: Gen

    1-22 1 2 1 2 1 features gen info mode selection normal mode turn “on” the main switch s the self-diagnostic function starts a system check system normal normal meter dis- play malfunction detec- tion fault number appears on the clock lcd. The engine trouble warning light illu- minates. Co / diag mod...

  • Page 34: Gen

    1-23 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, alw...

  • Page 35: Gen

    1-24 1 important information gen info caution: 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 se...

  • Page 36: Gen

    1-25 checking the connections gen info note: note: note: eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: slead scoupler sconnector 2. Check: slead scoupler sconnector moisture ! Dry with an air blower. Rust / stains ! Connec...

  • Page 37: Gen

    1-26 special tools gen info eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part ...

  • Page 38: Gen

    1-27 special tools gen info tool no. Tool name / how to use illustration 90890-01403 steering nut wrench this tool is used to loosen and tighten the steering ring nut. 90890-01701 sheave holder this tool is used to hold the rotor when loosening and tightening the rotor bolt. 90890-06756 vacuum / pre...

  • Page 39: Gen

    1-28 special tools gen info tool no. Tool name / how to use illustration 90890-03153 pressure gauge this tool is needed to measure fuel pressure. 90890-03176 fuel pressure adapter this tool is needed to measure fuel pressure. 90890-04101 valve lapper this tool is needed to remove and install the val...

  • Page 41: Spec

    Spec chapter 2 specifications general specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine specifications 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis specifications 2-11 . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 42: Spec

    Spec.

  • Page 43: Spec

    2-1 general specifications spec specifications general specifications item standard limit model code 5ps1 (for eur) 5ps2 (for oce) sss sss dimensions overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 2,180 mm 800 mm 1,290 mm 825 mm 1,48...

  • Page 44: Spec

    2-2 engine specifications spec engine specifications item standard limit 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) liquid-cooled, 4-stroke, dohc 897 cm 3 f...

  • Page 45: Spec

    2-3 engine specifications spec item standard limit oil filter oil filter type bypass valve opening pressure paper 40.0 x 80.0 kpa (0.40 x 0.80 kg/cm 2 , 0.40 x 0.80 bar) sss sss oil pump oil pump type inner-rotor-to-outer-rotor- tip clearance outer-rotor-to-oil-pump-housing clearance oil-pump-housin...

  • Page 46: Spec

    2-4 engine specifications spec item standard limit camshafts drive system camshaft cap inside diameter camshaft journal diameter camshaft-journal-to-camshaft-cap clearance intake camshaft lobe dimensions measurement a measurement b exhaust camshaft lobe dimensions measurement a measurement b max. Ca...

  • Page 47: Spec

    2-5 engine specifications spec head diameter face width seat width margin thickness item standard limit timing chain model / number of links tensioning system 82rh2015 / 138 automatic sss sss valve, valve seats, valve guides valve clearance (cold) intake exhaust valve dimensions 0.15 x 0.20 mm 0.23 ...

  • Page 48: Spec

    2-6 engine specifications spec item standard limit valve springs free length intake exhaust installed length (valve closed) intake exhaust compressed spring force (installed) intake exhaust spring tilt intake exhaust winding direction (top view) intake exhaust 37.3 mm 37.3 mm 30.4 mm 30.4 mm 98.1 x ...

  • Page 49: Spec

    2-7 engine specifications spec item standard limit cylinders cylinder arrangement bore stroke compression ratio bore max. Taper max. Out-of-round forward inclined parallel 2-cylinder 92.0 67.5 mm 10.4 : 1 92.00 x 92.01 sss sss sss sss sss sss 0.05 mm 0.05 mm pistons piston-to-cylinder clearance diam...

  • Page 50: Spec

    2-8 engine specifications spec item standard limit oil ring dimensions (b t) end gap (installed) ring side clearance 1.9 2.5 mm 0.20 x 0.50 mm 0.04 x 0.14 mm sss sss sss connecting rods crankshaft-pin-to-big-end-bearing clearance bearing color code small end inside diameter 0.036 x 0.060 mm 1 = blue...

  • Page 51: Spec

    2-9 engine specifications spec item standard limit clutch plates thickness plate quantity max. Warpage clutch spring free length spring quantity 1.9 x 2.1 mm 8 sss 50 mm 6 sss sss 0.1 mm 47.5 mm sss transmission transmission type primary reduction system primary reduction ratio secondary reduction s...

  • Page 52: Spec

    2-10 engine specifications spec item standard limit throttle bodies model (manufacturer) quantity intake vacuum pressure throttle cable free play (at the flange of the throttle grip) id mark throttle valve size 38eis (mikuni) 2 33 x 36 kpa 3 x 5 mm 5ps1 00 #50 sss sss sss sss sss.

  • Page 53: Spec

    2-11 chassis specifications spec chassis specifications item standard limit frame frame type caster angle trail diamond 25.5 _ 114 mm sss sss sss front wheel wheel type rim size material wheel travel wheel runout max. Radial wheel runout max. Lateral wheel runout cast wheel 18m / c mt3.50 aluminum 1...

  • Page 54: Spec

    2-12 chassis specifications spec item standard limit rear tire tire type size model (manufacturer) tire pressure (cold) 0 x 90 kg 90 x 208 kg high-speed riding min. Tire tread depth tubeless 160 / 60zr17m / c (69w) mez4j (metzeler) / d220stj (dunlop) 250 kpa (2.5 kgf / cm 2 , 2.5 bar) 290 kpa (2.9 k...

  • Page 55: Spec

    2-13 chassis specifications spec item standard limit front suspension suspension type front fork type front fork travel spring free length spacer length installed length spring rate (k1) spring rate (k2) spring stroke (k1) spring stroke (k2) optional spring available fork oil recommended oil quantit...

  • Page 56: Spec

    2-14 chassis specifications spec item standard limit 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 spri...

  • Page 57: Spec

    2-15 electrical specifications spec electrical specifications item standard limit system voltage 12 v sss ignition system ignition system type ignition timing advancer type pickup coil resistance / color transistorized coil ignition unit model (manufacturer) transistorized coil ignition (digital) 10...

  • Page 58: Spec

    2-16 electrical specifications spec item standard limit bulbs (voltage / wattage quantity) headlight auxiliary light tail / brake light turn signal light meter light 12 v 55 w 2 12 v 5 w 1 12 v 5 w / 21 w 1 12 v 10 w 4 14 v 2 w 2 sss sss sss sss sss electric starting system system type starter motor...

  • Page 59: Spec

    2-17 electrical specifications spec item standard limit fuses (amperage quantity) main fuse fuel injection system fuse headlight fuse signaling system fuse ignition fuse radiator fan motor fuse hazard light fuse parking light fuse backup fuse reserve fuse 40 a 1 15 a 1 15 a 1 7.5 a 1 (eur) 10a 1 (oc...

  • Page 60: Spec

    2-18 conversion table/ general tightening torque specifications spec eas00029 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provid...

  • Page 61: Spec

    2-19 tightening torques spec * 3 tightening torques engine tightening torques part to be tightened part name thread size q’ty tightening torque remarks g size y nm m skg cylinder head stud bolt (exhaust pipe) camshaft cap cylinder head bolt cylinder head nut (initial) (2nd) bolt bolt bolt nut m8 m8 ...

  • Page 62: Spec

    2-20 tightening torques spec note: part to be tightened part name thread size q’ty tightening torque remarks g size y nm m skg drive chain slider engine bracket starter clutch clutch spring clutch boss bearing housing drive sprocket speed sensor rotor sift drum stopper lever shift fork guide stopper...

  • Page 63: Spec

    2-21 tightening torques spec cylinder head tightening sequence: crankcase tightening sequence: upper crankcase lower crankcase.

  • Page 64: Spec

    2-22 tightening torques spec chassis tightening torques part to be tightened thread size tightening torque remarks g size nm m skg upper bracket pinch bolt steering stem nut lower ring nut lower bracket pinch bolt horn bracket and lower bracket brake hose union bolt front cowling stay and frame grip...

  • Page 65: Spec

    2-23 tightening torques spec note: part to be tightened thread size tightening torque remarks g size nm m skg footrest bracket and frame m8 30 3.0 rear brake master cylinder and bracket m8 23 2.3 y rear footrest and footrest bracket m6 8 0.8 front wheel axle m18 72 7.2 rear wheel axle and nut m24 15...

  • Page 66: Spec

    2-24 lubrication points and lubricant types spec lubrication points and lubricant types engine lubrication points and lubricant types lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobe...

  • Page 67: Spec

    2-25 lubrication points and lubricant types spec chassis lubrication points and lubricant types lubrication point lubricant steering bearings and bearing races (upper and lower) front wheel oil seal (right and left) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surfac...

  • Page 68: Spec

    2-26 1 scavenge pump 2 feed pump 3 oil strainer 4 oil filter element 5 oil drain bolt (oil tank) 6 oil tank 7 oil level switch oil flow diagrams spec oil flow diagrams.

  • Page 69: Spec

    2-27 oil flow diagrams spec 1 front balancer shaft 2 oil strainer 3 feed pump 4 relief valve 5 scavenge pump.

  • Page 70: Spec

    2-28 oil flow diagrams spec 1 cam shaft 2 rear balancer shaft 3 main axle 4 drive axle 5 oil drain bolt (engine) 6 front balancer shaft.

  • Page 71: Spec

    2-29 oil flow diagrams spec 1 cylinder head 2 rear balancer shaft 3 crankshaft 4 oil drain bolt (engine).

  • Page 72: Spec

    2-30 oil flow diagrams spec 1 main axle 2 drive axle.

  • Page 73: Spec

    2-31 1 radiator 2 water pump 3 radiator outlet hose 4 thermostat assembly 5 thermostat inlet hose 6 radiator inlet hose cooling system diagrams spec cooling system diagrams.

  • Page 74: Spec

    2-32 cooling system diagrams spec 1 radiator 2 radiator outlet hose 3 water pump 4 coolant reservoir tank hose.

  • Page 75: Spec

    2-33 cooling system diagrams spec 1 thermostat assembly 2 thermostat inlet hose 3 liner control valve.

  • Page 76: Spec

    2-34 23 headlight adjusting knob 12 clamp 13 front turn signal light (right) 14 stay 1 15 meter assembly 16 auxiliary light 17 meter lead 18 auxiliary light lead 19 front turn signal light (left) 20 stay 3 21 headlight sub wire harness 22 headlight coupler 1 throttle cables 2 clutch cable 3 handleba...

  • Page 77: Spec

    2-35 cable routing spec f route the handlebar switch lead (right) and throttle cable (2 cables) through the cover 8. G route the brake hose through the guide. H always route the cables so that the brake hose passes by the outside of the throttle cables. I route the handlebar switch lead, brake hose ...

  • Page 78: Spec

    2-36 q route the wire harness so that it passes by the out- side of bolt. R to the ecu s fasten the headlight sub wire harness with the clamp that is passed through the center hole of stay 1. T clamp the meter lead, auxiliary light and headlight sub wire harness to the stay. U route each lead throug...

  • Page 79: Spec

    2-37 23 o 2 sensor 24 o 2 sensor lead 25 cylinder identification sensor 26 headlight relay (for oce) 27 ecu 28 ecu lead 29 stay 1 30 starter relay lead 31 oil pipe 32 engine 33 frame 12 battery negative lead 13 seat lock cable 14 alarm coupler 15 tail / brake light lead 16 rear turn signal light (le...

  • Page 80: Spec

    2-38 b b c d a b b a c d q h fasten the tail / brake light lead to the outside of the frame with a clamp. Connect the tail / brake light lead coupler between rear cover and frame, posi- tioning without routing above the frame. I fasten the rectifier / regulator lead with the clamp installed with the...

  • Page 81: Spec

    2-39 b b c d a b b a c d q cable routing spec o route the fuel drain hose (2 hoses), air filter case drain hose and radiator reservoir tank drain hose through the guide located behind the swingarm head pipe. Do not make hoses to cross in the area between c and d. P pass the radiator reservoir tank d...

  • Page 82: Spec

    2-40 cable routing spec 1 hose 2 2 hose 3 ignition coil 4 stay 2 5 radiator 6 clutch cable 7 rear brake light switch lead 8 starter relay lead 9 coolant reservoir tank drain hose 10 rear brake light switch 11 fuel return hose 12 fuel hose 13 fuel drain hose a route the clutch cable through the guide...

  • Page 83: Spec

    2-41 a a c c b b a a c c b b cable routing spec 1 throttle cables 2 handlebar switch lead (right) 3 stay 4 thermo wax hose 5 intake air vacuum hose 6 sub-wire harness (air filter case) 7 rear brake light switch lead 8 coolant reservoir tank hose 9 oil level switch lead 10 fuel injection system relay...

  • Page 84: Spec

    2-42 a a c c b b a a c c b b g route the starter motor lead under the rear frame attaching boss section. H route the starter motor lead by the right side of the battery and coolant reservoir tank. I pass the battery positive lead under the battery band. J pass the rear turn signal light lead (right)...

  • Page 85: Spec

    2-43 a a c c b b a a c c b b t pass the wire harness, cylinder identification sensor and radiator fan motor leads under the bracket 1. U pass the wire harness, cylinder identification sen- sor and radiator fan motor leads above the hose 1. V to the radiator fan motor w bundle the coolant temperature...

  • Page 86: Spec

    2-44 a a c c b b a a c c b b z fasten the cylinder identification sensor and radia- tor fan motor lead to the frame with a clamp. Posi- tion the clamp tip to face downward. Aa route the wire harness through the smaller diam- eter and the radiator reservoir tank drain hose through the larger diameter...

  • Page 88: Chk

    Chk adj chapter 3 periodic checks and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance and lubrication intervals 3-1 . . . . . . Seat 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 89: Chk

    Chk adj chassis 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the front brake 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the rear brake 3-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 90: Chk

    3-1 introduction/periodic maintenance and lubrication intervals chk adj note: 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 rel...

  • Page 91: Chk

    3-2 introduction/periodic maintenance and lubrication intervals chk adj note: no item check or maintenance job odometer reading ( 1,000 km) annual no. Item check or maintenance job 1 10 20 30 40 check 15 * chassis fasteners (see page 2-22) s make sure that all nuts, bolts and screws are properly tig...

  • Page 92: Chk

    3-3 seat chk adj order job / part q’ty remarks 1 removing the seat seat 1 remove the parts in the order listed. For installation, reverse the removal procedure. Eas00038 seat.

  • Page 93: Chk

    3-4 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front cowlings windshield inner panel turn signal light connector side cowling (left and right) front cowling air intake grile headlight assembly 1 1 2 2 1 2 1 remove the parts in the order listed. Disconnect. For installation, reverse the...

  • Page 94: Chk

    3-5 fuel tank chk adj order job / part q’ty remarks 1 2 3 4 5 6 removing the fuel tank seat side cowling side cover fuel hose fuel tank breather hose fuel pump coupler fuel sender coupler fuel tank 2 2 2 1 1 1 remove the parts in the order listed. Refer to “seat”. Refer to “front cowlings”. For inst...

  • Page 95: Chk

    3-6 removing the fuel tank/ removing the fuel pump chk adj caution: note: note: caution: removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: sfuel return hose sfuel hose although the fuel has been removed from the fuel tank be careful when re...

  • Page 96: Chk

    3-7 installing the fuel pump/ installing the fuel hose chk adj 4 nm (0.4 m skg) note: caution: installing the fuel pump 1. Install: sfuel pump sdo not damage the installation surfaces of the fuel tank when installing the fuel pump. Salways use a new fuel pump gasket. Sinstall the fuel pump as shown ...

  • Page 97: Chk

    3-8 rear cowling chk adj order job / part q’ty remarks 1 2 3 removing the rear cowling seat grab bar tail / brake light coupler rear cowling 1 1 1 remove the parts in the order listed. Refer to “seat”. Disconnect. For installation, reverse the removal procedure. 23 nm (2.3 m skg) 23 nm (2.3 m skg) 1...

  • Page 98: Chk

    3-9 air filter case chk adj order job / part q’ty remarks 1 2 3 4 5 6 7 removing the air filter case side cowlings seat fuel tank cylinder head breather hose ai system hose solenoid valve hose solenoid valve coupler atmospheric temperature sensor coupler drain hose air filter case 1 1 1 1 1 1 1 remo...

  • Page 99: Chk

    3-10 adjusting the valve clearance chk adj note: eas00045 engine adjusting the valve clearance the following procedure applies to all of the valves. Svalve clearance adjustment should be made on a cold engine, at room temperature. Swhen the valve clearance is to be measured or adjusted, the piston m...

  • Page 100: Chk

    3-11 adjusting the valve clearance chk adj note: note: note: a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark a on the generator rotor with the mark b on the crankcase cover. Tdc on the compression stroke can be found when the camsh...

  • Page 101: Chk

    3-12 adjusting the valve clearance chk adj note: note: 8. Adjust: svalve clearance a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 . Valve lapper 90890-04101 scover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Smake a note of th...

  • Page 102: Chk

    3-13 adjusting the valve clearance chk adj note: note: 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 an...

  • Page 103: Chk

    3-14 valve clearance (cold): 0.15 x 0.20 mm example: installed is 175 measured clearance is 0.27 mm replace 175 pad with 185 pad pad number: (example) pad no. 175 = 1.75 mm pad no. 185 = 1.85 mm measured clearance installed pad number valve clearance (cold): 0.23 x 0.28 mm example: installed is 175 ...

  • Page 104: Chk

    3-15 a b adjusting the valve clearance/ synchronizing the throttle bodies chk adj note: 10 nm (1.0 m skg) note: note: srefer to “camshafts” in chapter 5. Slubricate the camshaft bearings, camshaft lobes and camshaft journals. Sfirst, install the exhaust camshaft. Salign the camshaft marks with the c...

  • Page 105: Chk

    3-16 synchronizing the throttle bodies chk adj note: 4. Install: sengine tachometer (to the spark plug lead of cyl. #1) svacuum gauge (to the throttle body) vacuum gauge 90890-03094 engine tachometer 90890-03113 5. Install: sfuel tank refer to “fuel tank”. 6. Start the engine and let it warm up for ...

  • Page 106: Chk

    3-17 synchronizing the throttle bodies chk adj caution: note: do not use the throttle valve adjusting screws 1 to adjust the throttle body syn- chronization. Carburetor angle driver 90890-03158 vacuum pressure at engine idling speed 33.0 x 36.0 kpa (248 x 270 mm hg) the difference in vacuum pressure...

  • Page 107: Chk

    3-18 checking and adjusting the exhaust gas at idle chk adj note: note: checking and adjusting the exhaust gas at idle (measuring the exhaust gas at idle [when the air induction system does not operate]) 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand. Smake sur...

  • Page 108: Chk

    3-19 checking and adjusting the exhaust gas at idle chk adj 5. Install: sair filter case refer to “air filter case”. Sfuel tank refer to “fuel tank”. 6. Start the engine and warm it up until the spe- cified oil temperature is reached. Oil temperature 60 x 80_c 7. Measure: sengine idling speed out of...

  • Page 109: Chk

    3-20 adjusting the exhaust gas volume chk adj note: note: note: note: adjusting the exhaust gas volume be sure to set the carbon monoxide density to standard, and then adjust the exhaust gas. Setting steps if the battery is not fully charged errors one to four will be indicated on the display. A. “c...

  • Page 110: Chk

    3-21 adjusting the exhaust gas volume chk adj note: the exhaust gas volume will be indicated on the display. Spush the “reset” button to increase the vol- ume. Spush the “select” button to decrease the volume. Srelease the button to set the volume. Spush the “select” button and the “reset” button to...

  • Page 111: Chk

    3-22 checking the exhaust gas at idle chk adj note: checking the exhaust gas at idle (measuring the exhaust gas at idle [when air in- duction system is operating]) 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand. Smake sure the motorcycle is upright. 2. Remove: ...

  • Page 112: Chk

    3-23 checking the exhaust gas at idle chk adj note: 7. Install: scarbon monoxide and hydrocarbon tester 1 ssampling probe 2 ssince it is necessary to insert the sampling probe 600 mm into the exhaust pipe, be sure to use a heat-resistant rubber tube as shown in the illustration. Sbe sure to set the ...

  • Page 113: Chk

    3-24 adjusting the engine idling speed chk adj note: a b eas00052 adjusting the engine idling speed prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression. ...

  • Page 114: Chk

    3-25 adjusting the throttle cable free play chk adj note: note: eas00055 adjusting the throttle cable free play prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: sthrottle cable free play a out of spe...

  • Page 115: Chk

    3-26 a b adjusting the throttle cable free play chk adj note: a b warning direction throttle cable free play is increased. Direction throttle cable free play is decreased. E. Tighten the locknuts. If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use t...

  • Page 116: Chk

    3-27 checking the spark plugs chk adj caution: 18 nm (1.8 m skg) note: eas00059 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Disconnect: sspark plug cap 2. Remove: sspark plug before removing the spark plugs, blow away any dirt accumulated in the spark plug ...

  • Page 117: Chk

    3-28 checking the ignition timing chk adj note: note: eas00064 checking the ignition timing prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: stiming plug 1 2. Connect: stiming ligh...

  • Page 118: Chk

    3-29 measuring the compression pressure chk adj note: caution: eas00065 measuring the compression pres- sure the following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: svalve clearance out of specification ! Adjust. ...

  • Page 119: Chk

    3-30 measuring the compression pressure/ checking the engine oil level chk adj warning note: 18 nm (1.8 m skg) note: a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. To prevent sparking, ground all spark plug lead...

  • Page 120: Chk

    3-31 checking the engine oil level chk adj caution: note: note: 3. Check: sengine oil level wipe the dipstick clean, insert it into the oil filler hole (without screw it in and direct the arrow mark on the cap upward.), and then re- move it to check the oil level. The engine oil level should be betw...

  • Page 121: Chk

    3-32 changing the engine oil chk adj 35 nm (3.5 m skg) 30 nm (3.0 m skg) eas00075 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: sengine oil filler cap sengine oil drain bolt (engin...

  • Page 122: Chk

    3-33 changing the engine oil chk adj caution: the engine should be filled with oil in two steps. First fill the engine with 3.0 liters of oil. Then start the engine and race it five or six time. Stop the engine and fill it with oil to the specified level. Quantity total amount 4.7 l without oil filt...

  • Page 123: Chk

    3-34 adjusting the clutch cable free play chk adj a b note: a b eas00078 adjusting the clutch cable free play 1. Check: sclutch cable free play a out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 x 15 mm 2. Adjust: sclutch cable free play handlebar side a. Loo...

  • Page 124: Chk

    3-35 checking the air filter element chk adj note: caution: note: eas00086 checking the air filter element 1. Remove: sfuel tank refer to “fuel tank”. 2. Remove: sair filter case cover sair filter element 3. Check: sair filter element damage ! Replace. Replace the air filter element at periodic inte...

  • Page 125: Chk

    3-36 checking the fuel and vacuum hoses/ checking the crankcase breather hose chk adj caution: eas00096 checking the fuel and vacuum hoses the following procedure applies to all of the fuel and vacuum hoses. 1. Remove: sfuel tank refer to “fuel tank”. Sair filter case refer to “air filter case”. 2. ...

  • Page 126: Chk

    3-37 checking the exhaust system chk adj eas00100 checking the exhaust system the following procedure applies to all of the ex- haust pipes, mufflers and gaskets. 1. Check: sexhaust pipe 1 smuffler 2 cracks / damage ! Replace. Sgasket 3 exhaust gas leaks ! Replace. 2. Check: stightening torque exhau...

  • Page 127: Chk

    3-38 checking the coolant level chk adj note: caution: note: eas00102 checking the coolant level 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand. Smake sure the motorcycle is upright. 2. Remove: sseat refer to “seat”. 3. Check: scoolant level the coolant level s...

  • Page 128: Chk

    3-39 checking the cooling system chk adj eas00104 checking the cooling system 1. Remove: sfuel tank refer to “fuel tank”. Sair filter case refer to “air filter case”. 2. Check: sradiator 1 sradiator inlet hose 2 sradiator outlet hose 3 sradiator reservoir tank hose 4 sradiator cover 5 cracks / damag...

  • Page 129: Chk

    3-40 changing the coolant chk adj warning 10 nm (1.0 m skg) 10 nm (1.0 m skg) eas00105 changing the coolant 1. Remove: sseat refer to “seat”. 2. Disconnect: scoolant reservoir hose 1 3. Drain: scoolant (from the coolant reservoir tank) 4. Remove: scoolant reservoir tank cap 2 a hot radiator is under...

  • Page 130: Chk

    3-41 changing the coolant chk adj warning 8. Connect: scoolant reservoir hose 9. Fill: scooling system (with the specified amount of the recom- mended coolant) recommended antifreeze high-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines mixing ratio 1:1 (antifr...

  • Page 131: Chk

    3-42 changing the coolant chk adj note: 12. Install: scoolant reservoir cap 13. Start the engine, warm it up for several min- utes, and then stop it. 14. Check: scoolant level refer to “checking the coolant lev- el”. Before checking the coolant level, wait a few minutes until the coolant has settled...

  • Page 132: Chk

    3-43 adjusting the front brake chk adj note: a a warning caution: easd0107 chassis adjusting the front brake 1. Adjust: sbrake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the des...

  • Page 133: Chk

    3-44 adjusting the rear brake chk adj a b warning warning caution: eas00110 adjusting the rear brake 1. Check: sbrake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) out of specification ! Adjust. Brake pedal position (below the top of the rider footrest)...

  • Page 134: Chk

    3-45 a b adjusting the rear brake/ checking the brake fluid level chk adj note: warning caution: 3. Adjust: srear 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. Splace the motorcycle on a suitab...

  • Page 135: Chk

    3-46 checking the brake fluid level/ checking the front and rear brake pads chk adj a b note: in order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. Eas00122 checking the front and rear brake pads the following procedure applies t...

  • Page 136: Chk

    3-47 adjusting the rear brake light switch/ checking the front and rear brake hoses chk adj a b note: a b eas00128 adjusting the rear brake light switch the rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light com...

  • Page 137: Chk

    3-48 a b bleeding the hydraulic brake system chk adj warning note: note: eas00134 bleeding the hydraulic brake sys- tem bleed the hydraulic brake system whenev- er: sthe system is disassembled. Sa brake hose is loosened, disconnected or replaced. Sthe brake fluid level is very low. Sbrake operation ...

  • Page 138: Chk

    3-49 bleeding the hydraulic brake system/ adjusting the shift pedal chk adj warning note: b c 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 ...

  • Page 139: Chk

    3-50 adjusting the drive chain slack chk adj note: caution: warning note: eas00140 adjusting the drive chain slack the drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can s...

  • Page 140: Chk

    3-51 a b adjusting the drive chain slack/ lubricating the drive chain chk adj note: 4. Adjust: sdrive chain slack a. Loosen the brake caliper bracket bolt 1 . B. Loosen the wheel axle nut 2 . C. Loosen locknuts 3 (left and right). D. Turn the each side adjusting bolts 4 in direc- tion a or b until t...

  • Page 141: Chk

    3-52 checking and adjusting the steering head chk adj warning note: eas00146 checking and adjusting the steer- ing head 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the fron...

  • Page 142: Chk

    3-53 checking and adjusting the steering head chk adj note: warning note: 4. Adjust: ssteering 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 . Set the torque wrench ...

  • Page 143: Chk

    3-54 checking and adjusting the steering head chk adj 26 nm (2.6 m skg) 113 nm (11.3 m skg) 23 nm (2.3 m skg) note: 5. Install: supper bracket ssteering stem nut shandlebar 6. Measure: ssteering head tension make sure all of the cables and wires are prop- erly routed. A. Point the front wheel straig...

  • Page 144: Chk

    3-55 checking the front fork/ adjusting the front fork legs chk adj warning warning caution: eas00149 checking the front fork 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Check: sinner tube 1 damage / scratches ! Replac...

  • Page 145: Chk

    3-56 adjusting the front fork legs chk adj a b caution: a b 1. Adjust: sspring preload a. Turn the adjusting bolt 1 in direction a or b . Direction spring preload is increased (suspension is harder). Direction spring preload is decreased (suspension is softer). Adjusting positions minimum: 8 standar...

  • Page 146: Chk

    3-57 adjusting the rear shock absorber assembly chk adj warning caution: a b eas00158 adjusting the rear shock absorber assembly securely support the motorcycle so that there is no danger of it falling over. Spring preload never go beyond the maximum or minimum adjustment positions. 1. Adjust: sspri...

  • Page 147: Chk

    3-58 adjusting the rear shock absorber assembly chk adj caution: a b caution: a b rebound damping never go beyond the maximum or minimum adjustment positions. 1. Adjust: srebound damping a. Turn the adjusting knob 1 in direction a or b . Direction rebound damping is increased (suspension is harder)....

  • Page 148: Chk

    3-59 checking the tires chk adj warning warning eas00166 checking the tires the following procedure applies to both of the tires. 1. Check: stire pressure out of specification ! Regulate. Sthe tire pressure should only be checked and regulated when the tire temperature equals the ambient air tempera...

  • Page 149: Chk

    3-60 checking the tires chk adj warning warning minimum tire tread depth 1.6 mm 1 tire tread depth 2 sidewall 3 wear indicator sdo not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden defla- tion. Swhen using tube tires, be sure to...

  • Page 150: Chk

    3-61 checking the tires/ checking the wheels chk adj warning note: front tire manufacturer size model dunlop 120 / 70zr18 m / c (59w) d220fstj metzeler 120 / 70zr18 m / c (59w) mez4j front bridge- stone 120 / 70zr18 m / c (59w) bt020f pirelli 120 / 70zr18 m / c (59w) mtr23 dragon gts front rear tire...

  • Page 151: Chk

    3-62 checking and lubricating the cables / lubricating the levers and pedals / lubricating the sidestand/lubricating the rear suspension chk adj warning note: eas00170 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Damaged outer cable may ...

  • Page 152: Chk

    3-63 checking and charging the battery chk adj warning caution: eas00178 electrical system checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive meas...

  • Page 153: Chk

    3-64 checking and charging the battery chk adj relationship between the open-circuit voltage and the charging time at 20 _c open-circuit voltage (v) these values vary with the temperature, the condition of the battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 charging time (hou...

  • Page 154: Chk

    3-65 charging ambient temperature 20 _c open-circuit voltage (v) check the open-circuit voltage. Time (minutes) ambient temperature 20 _c open-circuit voltage (v) charging condition of the battery (%) checking and charging the battery chk adj warning caution: 5. Charge: sbattery (refer to the approp...

  • Page 155: Chk

    3-66 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charged and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. By turning the charging voltage adjust...

  • Page 156: Chk

    3-67 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s...

  • Page 157: Chk

    3-68 checking and charging the battery/ checking the fuses chk adj caution: caution: note: 6. Install: sbattery 7. Connect: sbattery leads (to the battery terminals) first, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: sbattery terminals dirt ! Clean with a w...

  • Page 158: Chk

    3-69 checking the fuses chk adj warning pocket tester 90890-03132 b. If the pocket tester indicates “ ∞”, replace the fuse. 3. Replace: sblown 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 ope...

  • Page 159: Chk

    3-70 replacing the headlight bulbs chk adj warning caution: eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: sheadlight coupler 1 2. Remove: sheadlight bulb holder cover 2 3. Remove: sheadlight bulb holder 1 4. Remove: sheadlight b...

  • Page 160: Chk

    3-71 adjusting the headlight beams chk adj a b a b eas00185 adjusting the headlight beams 1. Adjust: sheadlight beam (vertically) a. To adjust the height of headlight, use the no.2 phillips screwdriver 1 and then adjust the headlight height by inserting it from the downside. B. Turn the adjusting sc...

  • Page 163: Chas

    Chas chapter 4 chassis front wheel and brake discs 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front wheel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 164: Chas

    Chas front fork 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front fork legs 4-47 . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the front fork legs 4-48 . . . . . . . . . . . . . . . . . . Checking the front fork ...

  • Page 165: Chas

    4-1 front wheel and brake discs chas order job / part q’ty remarks 1 2 3 4 5 6 removing the front wheel and brake discs wheel axle pinch bolt brake caliper front wheel axle collar brake disc front wheel 1 2 1 2 2 1 remove the parts in the order listed. Place the motorcycle on a suitable stand so tha...

  • Page 166: Chas

    4-2 front wheel and brake discs chas order job / part q’ty remarks disassembling the front wheel oil seal bearing collar 2 2 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 eas00518 front wheel.

  • Page 167: Chas

    4-3 front wheel and brake discs chas warning note: note: note: eas00521 removing the front wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevated. 2....

  • Page 168: Chas

    4-4 front wheel and brake discs chas warning eas00525 checking the front wheel 1. Check: swheel axle roll the wheel axle on a flat surface. Bends ! Replace. Do not attempt to straighten a bent wheel axle. 2. Check: stire refer to “checking the tires” in chapter 3. Sfront wheel damage / wear ! Replac...

  • Page 169: Chas

    4-5 front wheel and brake discs chas note: eas00531 checking the brake discs the following procedure applies to all of the brake discs. 1. Check: sbrake disc damage / galling ! Replace. 2. Measure: sbrake disc deflection out of specification ! Correct the brake disc deflection or replace the brake d...

  • Page 170: Chas

    4-6 front wheel and brake discs chas note: note: 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. Eas0...

  • Page 171: Chas

    4-7 front wheel and brake discs chas note: note: 3. Adjust: sfront wheel static balance a. Install a balancing weight 1 onto the rim ex- actly opposite the heavy spot “x”. 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...

  • Page 172: Chas

    4-8 front wheel and brake discs chas caution: note: 72 nm (7.2 m skg) 20 nm (2.0 m skg) caution: 40 nm (4.0 m skg) warning eas00539 assembling the front wheel 1. Install: swheel bearings soil seals new a. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contac...

  • Page 173: Chas

    4-9 rear wheel, brake disc and rear wheel sprocket chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the rear wheel brake caliper bracket brake caliper bracket bolt lock nut adjusting bolt wheel axle nut washer rear wheel axle adjusting block rear wheel 1 1 2 2 1 1 1 2 1 remove the parts...

  • Page 174: Chas

    4-10 rear wheel, brake disc and rear wheel sprocket chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the brake disc and rear wheel sprocket collar rear wheel sprocket oil seal bearing rear wheel drive hub collar damper rear brake disc 2 1 1 1 1 1 6 1 for installation, reverse the disassem...

  • Page 175: Chas

    4-11 rear wheel, brake disc and rear wheel sprocket chas order job / part q’ty remarks disassembling the rear wheel bearing oil seal spacer 2 1 1 disassembly the parts in the order listed. For installation, reverse the disassembly procedure. 1 2 3 eas00560

  • Page 176: Chas

    4-12 rear wheel, brake disc and rear wheel sprocket chas warning note: note: note: eas00561 removing the rear wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear whe...

  • Page 177: Chas

    4-13 rear wheel, brake disc and rear wheel sprocket chas note: 2. Check: stire refer to “checking the tires” in chap- ter3. Srear wheel damage / wear ! Replace. 3. Measure: sradial wheel runout slateral wheel runout refer to “checking the front wheel”. Eas00567 checking the rear wheel drive hub 1. C...

  • Page 178: Chas

    4-14 rear wheel, brake disc, and rear wheel sprocket chas 150 nm (15.0 m skg) 40 nm (4.0 m skg) eas00572 installing the rear wheel 1. Lubricate: swheel axle swheel bearings soil seal lips recommended lubricant lithium-soap-based grease 2. Install: srear wheel drive hub damper srear wheel drive hub s...

  • Page 179: Chas

    4-15 rear wheel, brake disc, and rear wheel sprocket chas note: eas00575 adjusting the rear wheel static balance safter replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Sadjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1...

  • Page 180: Chas

    4-16 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front brake pads brake caliper bolt brake pad clip brake pad pin brake pad spring brake pad brake pad shim bleed screw 2 2 1 1 2 2 1 remove the parts in the order listed. For installation, reverse the removal pr...

  • Page 181: Chas

    4-17 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the rear brake pads. Rear brake caliper brake pad brake pad shim bleed screw 1 2 2 1 remove the parts in the order listed. For installation, reverse the removal procedure. 6 nm (0.6 m skg) 27 nm (2.7 m skg) rear brake pad...

  • Page 182: Chas

    4-18 front and rear brakes chas caution: note: eas00579 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: snever disassemble brake components un- less absolutely necessary. Sif any connection on the hydraulic brake system is disconnected, the ent...

  • Page 183: Chas

    4-19 front and rear brakes chas note: note: 2. Remove: sbrake pad clips 1 sbrake pad pin 2 sbrake pad spring 3 sbrake pads (along with the brake pad shims) 3. Measure: sbrake pad wear limit a out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: sbrake pad s...

  • Page 184: Chas

    4-20 front and rear brakes chas 40 nm (4.0 m skg) 5. Install: sbrake pad spring 1 sbrake pad pin 2 sbrake pad clips 3 sbrake caliper 6. Check: sbrake 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...

  • Page 185: Chas

    4-21 front and rear brakes chas note: note: eas00583 replacing the rear brake pads when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: sbrake caliper 1 sbrake caliper bolts 2 2. Remove: sbrake pads (along with the brake pad...

  • Page 186: Chas

    4-22 front and rear brakes chas 27 nm (2.7 m skg) d. Install a new brake pad shim onto each new brake pad. 5. Lubricate: sbrake caliper bolt recomended lubricant lithium-sope-based grease 6. Install: sbrake caliper 1 sbrake caliper bolts 2 7. Check: sbrake fluid level below the minimum level mark a ...

  • Page 187: Chas

    4-23 front and rear brakes chas 10 nm (1.0 m skg) order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front brake master cylinder brake fluid brake lever front brake light switch lead coupler front brake switch union bolt copper washer master cylinder bracket master cylinder assembly 1 1 1 1 2 ...

  • Page 188: Chas

    4-24 front and rear brakes chas order job / part q’ty remarks disassembling the front brake master cylinder dust boot circlip master cylinder kit spring master cylinder body 1 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 eas00585.

  • Page 189: Chas

    4-25 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the rear brake master cylinder brake fluid brake fluid reservoir cap rear brake fluid reservoir diaphragm holder rear brake fluid reservoir diaphragm brake fluid reservoir brake fluid reservoir hose union bolt c...

  • Page 190: Chas

    4-26 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake master cylinder dust boot circlip master cylinder kit spring master cylinder body 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 eas00587.

  • Page 191: Chas

    4-27 front and rear brakes chas note: note: note: eas00588 disassembling the front brake master cylinder before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: sbrake switch coupler (from the brake switch) 2. Remove: sunion bolt 1 sco...

  • Page 192: Chas

    4-28 a b c d front and rear brakes chas eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: sbrake master cylinder 1 damage / scratches / wear ! Replace. Sbrake fluid delivery passages (brake master cylinder...

  • Page 193: Chas

    4-29 a front and rear brakes chas warning 10 nm (1.0 m skg) warning 30 nm (3.0 m skg) caution: warning note: eas00598 assembling and installing the front brake master cylinder before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never u...

  • Page 194: Chas

    4-30 front and rear brakes chas warning caution: 3. Install: sfront brake lever 4. Connect: sbrake switch coupler (to the brake switch) 5. Fill: sbrake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 suse only the designated brake ...

  • Page 195: Chas

    4-31 front and rear brakes chas 30 nm (3.0 m skg) warning caution: warning eas00608 assembling the rear brake master cylinder 1. Install: smaster cylinder kit scirclip new 2. Install: srear brake master cylinder assembly 3. Install: spin (to the brake pedal link) 4. Connect: sbrake fluid reservoir h...

  • Page 196: Chas

    4-32 front and rear brakes chas caution: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: sbrake system refer to “bleeding the hydraulic brake system” in chapter 3. 4. Check: sbrake fluid level below the minimum level ...

  • Page 197: Chas

    4-33 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 removing the front brake calipers brake fluid front brake caliper bolt union bolt copper washer brake hose brake caliper 2 1 2 1 1 remove the parts in the order listed. The following procedure applies to both of the front brake ...

  • Page 198: Chas

    4-34 front and rear brakes chas order job / part q’ty remarks disassembling the front brake calipers brake pad clip brake pad pin brake pad spring brake pad shim brake caliper piston brake caliper piston seal kit bleed screw 2 1 1 2 2 4 4 1 disassemble the parts in the order listed. The following pr...

  • Page 199: Chas

    4-35 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the rear brake caliper brake fluid union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. Drain. For installation, reverse the removal procedure. 30 nm (3.0 m skg) 27 nm (2.7 m skg...

  • Page 200: Chas

    4-36 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake caliper brake pad shim brake pad spring brake caliper piston brake caliper piston seal kit bleed screw 2 2 2 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 6 ...

  • Page 201: Chas

    4-37 front and rear brakes chas note: note: warning eas00625 disassembling the front brake calipers the following procedure applies to both of the brake calipers. Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: sbrake caliper bolts sunion bolt 1...

  • Page 202: Chas

    4-38 front and rear brakes chas note: note: warning eas00626 disassembling the rear brake caliper before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: sbrake caliper bolts 1 sunion bolt 2 scopper washers 3 new sbrake hose sbrake caliper put the end o...

  • Page 203: Chas

    4-39 a b front and rear brakes chas warning 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 disas- sembled 1. C...

  • Page 204: Chas

    4-40 front and rear brakes chas warning 40 nm (4.0 m skg) 30 nm (3.0 m skg) warning caution: eas00638 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. Sbefore installation, all internal brake com- ponents should be cleaned and lubricat...

  • Page 205: Chas

    4-41 front and rear brakes chas warning caution: 4. Fill: sbrake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 suse only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage an...

  • Page 206: Chas

    4-42 front and rear brakes chas warning 27 nm (2.7 m skg) 30 nm (3.0 m skg) warning caution: eas00642 assembling and installing the rear brake caliper sbefore installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Snever use solvents on internal...

  • Page 207: Chas

    4-43 front and rear brakes chas warning caution: 5. Fill: sbrake fluid reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 suse only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor bra...

  • Page 208: Chas

    4-44 front fork chas order job / part q’ty remarks 1 2 3 4 5 6 removing the front fork legs front wheel front brake caliper front fender brake hose holder cap bolt upper bracket pinch bolt lower bracket pinch bolt front fork 1 2 1 2 2 1 remove the parts in the order listed. Refer to “front wheel and...

  • Page 209: Chas

    4-45 front fork chas order job / part q’ty remarks disassembling the front fork legs cap bolt o-ring washer spacer washer fork spring damper rod bolt dust seal oil seal clip oil seal washer damper rod inner tube 1 1 1 1 1 1 1 1 1 1 1 1 1 disassembly the parts in the order listed. 23 nm (2.3 m skg) 3...

  • Page 210: Chas

    4-46 front fork chas order job / part q’ty remarks oil lock piece outer tube bushing outer tube 1 1 1 for assembly, reverse the disassembly procedure. 23 nm (2.3 m skg) 30 nm (3.0 m skg) 14 15 16.

  • Page 211: Chas

    4-47 front fork chas warning note: warning eas00651 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitab...

  • Page 212: Chas

    4-48 front fork chas caution: note: note: eas00655 disassembling the front fork legs the following procedure applies to both of the front fork legs. 1. Remove: scap bolt swashers sspacer sspring 2. Drain: sfork oil 3. Remove: sdust seal 1 soil seal clip 2 (with a flat-head screwdriver) do not scratc...

  • Page 213: Chas

    4-49 front fork chas warning caution: eas00657 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: sinner tube 1 souter tube 2 bends / damage / scratches ! Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2....

  • Page 214: Chas

    4-50 front fork chas warning note: warning caution: eas00661 assembling the front fork legs the following procedure applies to both of the front fork legs. Smake sure the oil levels in both front fork legs are equal. Suneven oil levels can result in poor han- dling and a loss of stability. Swhen ass...

  • Page 215: Chas

    4-51 front fork chas note: caution: note: note: while holding the damper rod assembly with the damper rod holder 1 and t-handle 2 , tighten the damper rod assembly bolt. Damper rod holder (29 mm) 90890-01375 t-handle 90890-01326 4. Install: souter tube bushing 1 new (with the fork seal driver weight...

  • Page 216: Chas

    4-52 front fork chas caution: note: 7. Install: sdust seal 1 (with the fork seal driver weight) 8. Fill: sfront fork leg (with the specified amount of the recom- mended fork oil) quantity (each front fork leg) 0.507 l recommended oil yamaha fork and shock oil 10w or equivalent sbe sure to use the re...

  • Page 217: Chas

    4-53 front fork chas note: 11. Measure: sfront 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) 133 mm 12. Install: sspring sspring seat sspacer swasher scap bolt 1 sinstall th...

  • Page 218: Chas

    4-54 front fork chas note: 28 nm (2.8 m skg) 23 nm (2.3 m skg) 26 nm (2.6 m skg) warning 40 nm (4.0 m skg) eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: sfront fork leg temporarily tighten the upper and lower bracket pinch bolts. ...

  • Page 219: Chas

    4-55 handlebar chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 removing the handlebar band clutch cable clutch switch lead coupler clutch switch left handlebar switch grip end handlebar grip (left) clutch lever assembly front brake light switch lead coupler master cylinder ...

  • Page 220: Chas

    4-56 handlebar chas order job / part q’ty remarks 17 18 19 upper handlebar holder handlebar rear view mirror 2 1 2 for installation, reverse the removal procedure. 26 nm (2.6 m skg) 10 nm (1.0 m skg) 26 nm (2.6 m skg) 23 nm (2.3 m skg).

  • Page 221: Chas

    4-57 handlebar chas warning note: note: eas00666 removing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: sthrottle cable housing 1 sthrottle grip 2 while removing the throttle cable housing, pull bac...

  • Page 222: Chas

    4-58 handlebar chas warning warning eas00668 checking the handlebar 1. Check: shandlebar 1 bends / cracks / damage ! Replace. Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. 2. Install: shandlebar grip a. Apply a thin coat of rubber adhesive onto the left end of th...

  • Page 223: Chas

    4-59 handlebar chas warning 23 nm (2.3 m skg) caution: note: note: note: eas00670 installing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Install: shandlebar 1 supper handlebar holders 2 sfirst, tighten th...

  • Page 224: Chas

    4-60 handlebar chas note: 5. Install: sclutch cable 6. Connect: sclutch switch coupler lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 7. Adjust: sclutch cable free play refer to “adjusting the clutch cable free play” in chapter 3. Clutch cable free play (at the ...

  • Page 225: Chas

    4-61 steering head chas 1st 2nd order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the lower bracket front wheel front fork legs handlebar main switch lead coupler cable guide horn brake hose bracket steering stem nut washer upper bracket lock washer upper ling nut 1 1 1 1 1 1 1 1 1 remove the...

  • Page 226: Chas

    4-62 steering head chas 1st 2nd 10 nm (1.0 m skg) 10 nm (1.0 m skg) 7 nm (0.7 m skg) 52 nm (5.2 m skg) 15 nm (1.5 m skg) order job / part q’ty remarks 10 11 12 13 14 15 16 17 18 rubber washer lower ring nut lower bracket bearing cover bearing inner race upper bearing lower bearing bearing outer race...

  • Page 227: Chas

    4-63 steering head chas warning warning eas00679 removing the lower bracket 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove ssteering stem nut 3. Remove: supper ring nut slower ring nut 1 (with the special tool 2 ) ...

  • Page 228: Chas

    4-64 steering head chas caution: note: eas00682 checking the steering head 1. Wash: sbearings (upper and lower) sbearing races recommended cleaning solvent kerosene 2. Check: sbearinsgs 1 sbearing races 2 damage / pitting ! Replace. 3. Replace: sbearings sbearing races a. Remove the bearing races 1 ...

  • Page 229: Chas

    4-65 steering head chas note: note: eas00683 installing the steering head 1. Lubricate: supper bearing slower bearing sbearing races recommended lubricant lithium-soap-based grease 2. Install: slower ring nut 1 srubber washer 2 supper ring nut 3 slock washer 4 refer to “checking the steering head” i...

  • Page 230: Chas

    4-66 rear shock absorber assembly chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the rear shock absorber assembly seat nut / washer / bolt nut / washer / bolt nut / bolt nut rear shock absorber upper bracket rear shock absorber oil seal bearing collar bearing 2/2/2 1/1/1 1/1 1 1 1 ...

  • Page 231: Chas

    4-67 rear shock absorber assembly chas 52 nm (5.2 m skg) 44 nm (4.4 m skg) 40 nm (4.0 m skg) 49 nm (4.9 m skg) 40 nm (4.0 m skg) order job / part q’ty remarks 11 12 13 collar connecting arm relay arm 2 2 1 for installation, reverse the removal procedure..

  • Page 232: Chas

    4-68 rear shock absorber assembly chas warning warning eas00687 handling the rear shock absorber and gas cylinder 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 under- stand the followi...

  • Page 233: Chas

    4-69 rear shock absorber assembly chas warning note: caution: note: note: eas00694 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the...

  • Page 234: Chas

    4-70 rear shock absorber assembly chas 44 nm (4.4 m skg) note: eas00696 checking the rear shock absorber assembly and gas cylinder 1. Check: srear shock absorber rod bends / damage ! Replace the rear shock absorber assembly. Srear shock absorber gas leaks / oil leaks ! Replace the rear shock absorbe...

  • Page 235: Chas

    4-71 rear shock absorber assembly chas 40 nm (4.0 m skg) 40 nm (4.0 m skg) 40 nm (4.0 m skg) 52 nm (5.2 m skg) caution: 3. Tighten: srear shock absorber assembly upper nut srear shock absorber assembly lower nut 1 sconnecting arm nut 2 srear shock absorber upper bracket nut 4. Connect: sbattery lead...

  • Page 236: Chas

    4-72 swingarm and drive chain chas order job / part q’ty remarks 1 2 3 4 removing the swingarm and drive chain rear wheel rear shock absorber assembly pivot shaft nut / washer pivot shaft swingarm dust cover 1 / 1 1 1 1 remove the parts in the order listed. Refer to “rear wheel, brake disc, and rear...

  • Page 237: Chas

    4-73 swingarm and drive chain chas 7 nm (0.7 m skg) 7 nm (0.7 m skg) 95 nm (9.5 m skg) 5 nm (0.5 m skg) order job / part q’ty remarks 5 6 7 8 9 10 11 12 13 bearing collar oil seal washer spacer rear fender chain protector pivot shaft adjusting bolt drive chain 2 1 1 1 1 1 1 1 1 for installation, rev...

  • Page 238: Chas

    4-74 swingarm and drive chain chas warning note: note: eas00703 removing the swingarm 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: sco...

  • Page 239: Chas

    4-75 swingarm and drive chain chas warning note: warning eas00706 removing the drive chain 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove...

  • Page 240: Chas

    4-76 swingarm and drive chain chas note: disassembling the swingarm 1. Remove: sdust covers 1 sspacer 2 soil seals 3 sbearings 4 2. Check: soil seals 3 damage / wear ! Replace. Sbearings 4 damage / pitting ! Replace. Checking the conecting arm and relay arms 1. Check: sconnecting arms 1 srelay arm 2...

  • Page 241: Chas

    4-77 swingarm and drive chain chas note: caution: eas00709 checking the drive chain 1. Measure: sten-link section a of the drive chain out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm swhile measuring the ten-link section, push down on the drive c...

  • Page 242: Chas

    4-78 swingarm and drive chain chas 4. Check: so-rings 1 damage ! Replace the drive chain, drive sprocket and rear wheel sprocket as a set. Sdrive chain rollers 2 damage / wear ! Replace the drive chain, drive sprocket and rear wheel sprocket as a set. Sdrive chain side plates 3 damage / wear ! Repla...

  • Page 243: Chas

    4-79 swingarm and drive chain chas 40 nm (4.0 m skg) 49 nm (4.9 m skg) note: 95 nm (9.5 m skg) note: eas00711 installing the swingarm 1. Lubricate: sbearings sspacers sdust covers spivot shaft recommended lubricant molybdenum disulfide grease 2. Lubricate: sdrive chain recommended lubricant engine o...

  • Page 244: Chas

    4-80 swingarm and drive chain chas 85 nm (8.5 m skg) note: caution: 8. Install: sdrive sprocket 1 swasher 2 new sdrive sprocket nut 3 sdrive chain guide 4 while applying the rear brake, tighten the drive sprocket nut. 9. Bend the lock washer tab a along a flat side of the nut. 10. Adjust: sdrive cha...

  • Page 246: Eng

    Eng chapter 5 engine engine 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust pipes 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive sprocket 5-2 . . . . . . . . . . . . . . . . . . ....

  • Page 247: Eng

    Eng checking the pressure plate 5-47 . . . . . . . . . . . . . . . . . . . . . . . . . Checking the pull lever shaft and pull rod 5-48 . . . . . . . . . Checking the primary drive 5-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the clutch 5-49 . . . . . . . . . . . . . . . . . ...

  • Page 248: Eng

    Eng installing the connecting rods 5-80 . . . . . . . . . . . . . . . . . . . . . . Installing the crankshaft 5-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the crankcase 5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the balancer shaft 5-85 . . . ...

  • Page 249: Eng

    Eng.

  • Page 250: Eng

    5-1 order job / part q’ty remarks 1 2 3 4 5 removing the exhaust pipes muffler exhaust pipe gasket o 2 sensor coupler o 2 sensor protector 1 1 2 1 1 remove the parts in the order listed. Disconnect. For installation, reverse the removal procedure. First, disconnect the negative battery lead, and the...

  • Page 251: Eng

    5-2 engine eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the drive sprocket drive sprocket cover shift arm shift rod cover 1 speed sensor rotor cover 2 nut / lock washer drive sprocket 1 1 1 1 1 1 1 / 1 1 remove the parts in the order listed. For installation, reverse the removal proced...

  • Page 252: Eng

    5-3 engine eng order job / part q’ty remarks 1 2 3 removing the leads and hoses seat side cover side cowlings fuel tank air filter case throttle body radiator battery negative lead battery positive lead starter motor lead 1 1 1 remove the parts in the order listed. Refer to “fuel injection system” i...

  • Page 253: Eng

    5-4 engine eng order job / part q’ty remarks 4 5 6 7 neutral switch lead coupler generator lead coupler throttle body sub-wire harness coupler speed sensor lead 1 1 2 1 disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure..

  • Page 254: Eng

    5-5 engine eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the engine starter motor engine mounting bolt (front) engine mounting bolt (rear lower) engine mounting bolt (rear upper) collar adjusting bolt engine bracket engine 2 1 1 2 2 1 1 remove the parts in the order listed. Place a suitab...

  • Page 255: Eng

    5-6 engine eng note: 7 nm (0.7 m skg) 45 nm (4.5 m skg) 45 nm (4.5 m skg) 55 nm (5.5 m skg) 26 nm (2.6 m skg) 30 nm (3.0 m skg) note: 10 nm (1.0 m skg) note: eas00192 installing the engine 1. Install: scollars 1 sadjusting bolt 2 sengine mounting nut (rear lower) 3 sengine mounting nut (rear upper) ...

  • Page 256: Eng

    5-7 camshaft eng order job / part q’ty remarks 1 2 3 4 removing the cylinder head cover seat side cowlings fuel tank air filter case ai system radiator thermostat assembly cylinder identification sensor spark plug cylinder head cover cylinder head gascket 1 2 1 1 remove the parts in the order listed...

  • Page 257: Eng

    5-8 camshaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the camshafts spark plug timing chain tensioner / gascket camshaft cap dowel pin intake camshaft exhaust camshaft camshaft sprocket 2 1 / 1 4 8 1 1 2 remove the parts in the order listed. For installation, reverse the removal proc...

  • Page 258: Eng

    5-9 camshaft eng note: note: eas00199 removing the camshafts 1. Remove: scylinder head cover 2. Align: s“t” mark on the generator rotor a (with the stationary pointer on the generator cover b ) a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align th...

  • Page 259: Eng

    5-10 camshaft eng caution: note: to prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 7. Remove: sintake camshaft 1 sexhaust camshaft 2 stiming chain guide (exhaust side) to prevent the...

  • Page 260: Eng

    5-11 camshaft eng eas00204 checking the camshafts 1. Check: scamshaft lobes blue discoloration / pitting / scratches ! Re- place the camshaft. 2. Measure: scamshaft lobe dimensions a and b out of specification ! Replace the cam- shaft. Camshaft lobe dimension limit intake camshaft a 35.60 mm b 27.85...

  • Page 261: Eng

    5-12 camshaft eng note: 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. Stighten the camshaft cap bolts in stages and in a crisscross pattern...

  • Page 262: Eng

    5-13 camshaft eng eas00208 checking camshaft sprockets, and timing chain guides the following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: scamshaft sprocket more than 1 / 4 tooth wear a ! Replace the camshaft sprockets and the timing chain as a set. A 1 / 4 ...

  • Page 263: Eng

    5-14 camshaft eng note: eas00210 checking the timing chain tensioner 1. Check: stiming chain tensioner cracks / damage ! Replace. 2. Check: sone-way cam operation rough movement ! Replace the timing chain tensioner assembly. A. Lightly press the timing chain tensioner rod into the timing chain tensi...

  • Page 264: Eng

    5-15 camshaft eng note: note: 10 nm (1.0 m skg) note: caution: installing the camshafts 1. Align: s“t” mark on the generator rotor a (with the stationary pointer on the generator cover b ) a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc, align the “t” mark a with the stationary ...

  • Page 265: Eng

    5-16 camshaft eng note: note: note: 10 nm (1.0 m skg) note: 5. Install: stiming chain guide (exhaust side) swhen installing the timing chain guide, be sure to keep the timing chain as tight as possible on the exhaust side. Smake sure the match marks a are parallel with the edge of the cylinder head....

  • Page 266: Eng

    5-17 camshaft eng caution: note: warning slubricate the camshaft cap botls with the engine oil. Sthe camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Sdo not turn the crankshaft when installing the camshaft to avoid damage or impro...

  • Page 267: Eng

    5-18 camshaft eng 24 nm (2.4 m skg) caution: 10. Turn: scrankshaft (several full turns counterclockwise) 11. Check: s“t” mark a make sure the “t” mark on the generator ro- tor is aligned with the stationary pointer b on the generator rotor cover. Scamshaft punch mark c make sure the punch marks on t...

  • Page 268: Eng

    5-19 cylinder head eng order job / part q’ty remarks 1 2 3 4 5 removing the cylinder head exhaust pipe, muffler camshaft throttle body cylinder head head gascket dowel pin timing chain guide (exhaust side) collar 1 1 2 1 2 remove the parts in the order listed. Refer to “exhaust pipes” and “drive spr...

  • Page 269: Eng

    5-20 cylinder head eng note: note: note: eas00223 removing the cylinder head 1. Remove: scylinder head bolts scylinder head nuts sloosen the nuts in the proper sequence as shown. Sloosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas00229 checking the cy...

  • Page 270: Eng

    5-21 cylinder head eng note: 18 nm (1.8 m skg) 18 nm (1.8 m skg) 150 _ note: note: caution: eas00233 installing the cylinder head 1. Install: sgasket new 1 sdowel pins 2 2. Install: scylinder head pass the timing chain through the timing chain cavity. 3. Tighten: scylinder head nuts 1 x 6 initial 2n...

  • Page 271: Eng

    5-22 valves and valve springs eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the valves and valve springs valve lifter valve pad valve cotter upper valve spring seat valve spring valve spring seat valve stem seal exhaust valve intake valve (center) intake valve (left and right) 10 1...

  • Page 272: Eng

    5-23 valves and valve springs eng note: note: note: note: eas00237 removing the valves the following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal...

  • Page 273: Eng

    5-24 valves and valve springs eng note: note: valve spring compressor 90890-04019 valve spring compressor attachment 90890-04108 4. Remove: supper valve spring seat 1 svalve spring 2 svalve stem seal 3 slower valve spring seat 4 svalve 5 identify the position of each part very carefully so that it c...

  • Page 274: Eng

    5-25 valves and valve springs eng note: note: 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 p...

  • Page 275: Eng

    5-26 valves and valve springs eng note: note: eas00240 checking the valve seats the following procedure applies to all of the valves and valve seats. 1. Eliminate: scarbon deposits (from the valve face and valve seat) 2. Check: svalve seat pitting/ wear ! Replace the cylinder head. 3. Measure: svalv...

  • Page 276: Eng

    5-27 valves and valve springs eng caution: note: a. Apply a coarse lapping compound a to the valve face. 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. Tu...

  • Page 277: Eng

    5-28 valves and valve springs eng eas00241 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: svalve spring free length a out of specification ! Replace the valve spring. Valve spring free length intake and exhaust valve spring 37.3 mm :35.4 mm 2. Mea...

  • Page 278: Eng

    5-29 valves and valve springs eng eas00242 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: svalve lifter damage / scratches ! Replace the valve lift- ers and cylinder head. Eas00247 installing the valves the following procedure applies to all of the ...

  • Page 279: Eng

    5-30 valves and valve springs eng note: note: caution: smake sure each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(s): “3ld:” middle intake valve(s): “3ld.” exhaust valve(s): “5ps:” sinstall the valve spring with the larger pitch a fac...

  • Page 280: Eng

    5-31 valves and valve springs eng note: 6. Lubricate: svalve pad recommended lubricant molybdenum disulfide oil svalve lifter (with the recommended lubricant) recommended lubricant engien oil 7. Install: svalve pad svalve lifter sthe valve lifter must move smoothly when ro- tated with a finger. Seac...

  • Page 281: Eng

    5-32 cylinder and pistons eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the cylinder and pistons cylinder head cylinder cylinder gascket circlip piston pin piston piston ring set dowel pin 1 1 4 2 2 2 2 remove the parts in the order listed. Refer to “cylinder head”. For installation, reve...

  • Page 282: Eng

    5-33 cylinder and pistons eng caution: note: note: eas00254 removing the cylinder and pistons the following procedure applies to all of the cyl- inders and pistons. 1. Remove: spiston pin clip 1 spiston pin 2 spiston 3 do not use a hammer to drive the piston pin out. Sbefore removing the piston pin ...

  • Page 283: Eng

    5-34 cylinder and pistons eng note: ea262 checking the cylinder and pistons the following procedure applies to all of the cyl- inders and pistons. 1. Check: spiston wall scylinder wall vertical scratches ! Replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: spiston-to...

  • Page 284: Eng

    5-35 cylinder and pistons eng piston-to-cylinder clearance 0.025 x 0.050 mm : 0.11 mm f. If out of specification, replace the cylinder, and the piston and piston rings as a set..

  • Page 285: Eng

    5-36 cylinder and pistons eng note: note: note: eas00264 checking the piston rings 1. Measure: spiston ring side clearance out of specification ! Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring groove...

  • Page 286: Eng

    5-37 cylinder and pistons eng a b eas00266 checking the piston pins the following procedure applies to all of the pis- ton pins. 1. Check: spiston pin blue discoloration / grooves ! Replace the piston pin and then check the lubrication sys- tem. 2. Measure: spiston pin outside diameter a out of spec...

  • Page 287: Eng

    5-38 cylinder and pistons eng note: note: eas00272 installing the pistons and cylinder the following procedure applies to all of the pis- tons and cylinders. 1. Install: stop ring s2nd ring slower oil ring rail supper oil ring rail soil ring expander be sure to install the piston rings so that the m...

  • Page 288: Eng

    5-39 cylinder and pistons eng note: 5. Offset: spiston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ring a intake side 6. Install: scylinder swhile compressing the piston rings with one hand, install the cylinder with the other hand. Spass the timing chain and timing ch...

  • Page 289: Eng

    5-40 clutch eng order job / part q’ty remarks 1 2 3 4 5 removing the clutch cover engine oil clutch cable clutch cable stay clutch cover gascket dowel pin 1 1 1 1 2 remove the parts in the order listed. Drain refer to “changing the engine oil” in chapter 3. For installation, reverse the removal proc...

  • Page 290: Eng

    5-41 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the pull lever shaft circlip pull lever pull lever spring pull lever shaft oil seal bearing washer 2 1 1 1 1 2 2 remove the parts in the order listed. For installation, reverse the removal procedure. Clutch eng eb405010 pull lever shaft.

  • Page 291: Eng

    5-42 clutch eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 removing the clutch clutch spring pressure plate pull rod friction plate 1 clutch plate friction plate 2 nut lock washer clutch boss thrust plate bearing spacer clutch housing 6 1 1 2 8 7 1 1 1 1 1 1 1 remove the parts in th...

  • Page 292: Eng

    5-43 clutch eng order job / part q’ty remarks 14 15 thrust plate 1 thrust plate 2 1 1 for installation, reverse the removal procedure. 70 nm (7.0 m skg) 8 nm (0.8 m skg).

  • Page 293: Eng

    5-44 clutch eng note: note: note: eas00275 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: sclutch boss nut 1 while holding the clutch boss 3 with the univer- sal clutch holder 4 , loosen the clutch boss nut. Universal clutch holder 90890-04086 3. Remove: slock washer 2 sclutch bos...

  • Page 294: Eng

    5-45 clutch eng note: 3. Measure: sassembly width a out of specification ! Adjust. Assembly width 42.5 x 43.7 mm a. Assembly width adjusted by clutch plate 1 and 2 . B. Select the clutch plate from the following table. Clutch plate 1 part no. Thickness 168-16325-00 1.6 mm 3j2-16324-00 2.0 mm std 168...

  • Page 295: Eng

    5-46 clutch eng eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: sclutch plate damage ! Replace the clutch plates as a set. 2. Measure: sclutch plate warpage (with a surface plate and thickness gauge 1 ) out of specification ! Replace the clu...

  • Page 296: Eng

    5-47 clutch eng note: note: eas00284 checking the clutch housing 1. Check: sclutch housing dogs damage / pitting / wear ! Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: sbearing damage / wear ! Replace...

  • Page 297: Eng

    5-48 clutch eng eas00287 checking the pull lever shaft and pull rod 1. Check: spull lever shaft 1 spull rod 2 damage / wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: spull rod bearing damage / wear ! Replace. Eas00292 checking the primary drive 1. Check: sprimary dr...

  • Page 298: Eng

    5-49 clutch eng 70 nm (7.0 m skg) note: note: note: eas00299 installing the clutch 1. Install: sclutch boss 1 slock washer new 2 sclutch boss nut 3 2. Tighten: sclutch boss nut while holding the clutch boss with the universal clutch holder 4 , tighten the clutch boss nut. Universal clutch holder 908...

  • Page 299: Eng

    5-50 clutch eng 8 nm (0.8 m skg) note: 10 nm (1.0 m skg) note: note: 8. Install: sclutch springs sclutch spring bolts tighten the clutch spring bolts in stages and in a crisscross pattern. 9. Install: sdowel pins sgasket new sclutch cover swhen installing the clutch cover, push the pull lever and ch...

  • Page 300: Eng

    5-51 shift shaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the generator rotor cover drive sprocket cover shift arm cover 1 speed sensor rotor cover 2 generator rotor cover gasket dowel pin drive chain slider 1 1 1 1 1 1 1 2 1 remove the parts in the order listed. For installation...

  • Page 301: Eng

    5-52 shift shaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the shift shaft and stopper lever clutch shift arm circlip washer shift shaft shift shaft spring stopper lever bearing retainer stopper lever spring 2 2 1 1 1 1 1 remove the parts in the order listed. Refer to “clutch”. Refer ...

  • Page 302: Eng

    5-53 shift shaft eng note: note: eas00328 checking the shift shaft 1. Check: sshift shaft 1 sshift shaft pawl 2 bends / damage / wear ! Replace. Sshift lever spring 3 damage / wear ! Replace. Eas00330 checking the stopper lever 1. Check: sstopper lever 1 bends / damage ! Replace. Roller turns roughl...

  • Page 303: Eng

    5-54 starter clutch and generator eng order job / part q’ty remarks 1 2 3 4 5 6 removing the stator coil assembly engine oil generator rotor cover stator coil coupler / pickup coil coupler stator coil pickup coil generator cover gasket dowel pin 1 1 1 1 1 2 remove the parts in the order listed. Drai...

  • Page 304: Eng

    5-55 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the starter clutch and generator rotor generator rotor idle gear shaft starter motor idle gear starter clutch washer woodruff key starter clutch gear 1 1 1 1 1 1 1 remove the parts in the order listed. For installation, reverse the removal pr...

  • Page 305: Eng

    5-56 starter clutch and generator eng note: caution: note: eas00347 removing the generator 1. Remove: sgenerator rotor bolt 1 swasher swhile holding the generator rotor 2 with the sheave holder 3 , loosen the generator rotor bolt. Sdo not allow the sheave holder to touch the projection on the genera...

  • Page 306: Eng

    5-57 starter clutch and generator eng note: removing the starter clutch 1. Remove: sstarter clutch bolt 1 swhile holding the generator rotor with the sheave holder, remove the starter clutch bolt. Sdo not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-017...

  • Page 307: Eng

    5-58 starter clutch and generator eng a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. B. When turning the starter clutch gear clock- wise a , the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be r...

  • Page 308: Eng

    5-59 starter clutch and generator eng 10 nm (1.0 m skg) note: note: 130 nm (13.0 m skg) note: eas00352 installing the starter clutch 1. Install: sstarter clutch swhile holding the generator rotor 1 with the sheave holder, tighten the starter clutch bolt. Sdo not allow the sheave holder to touch the ...

  • Page 309: Eng

    5-60 oil pan and oil pump eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the oil pump cover and oil pump driven gear engine oil oil pipe o-ring oil pump cover gascket dowel pin collar gascket circlip oil pump driver gear 1 1 1 1 2 1 1 2 2 remove the parts in the order listed. Drain. Re...

  • Page 310: Eng

    5-61 oil pan and oil pump eng order job / part q’ty remarks 1 2 3 4 5 removing the oil pump scavenge pump gascket dowel pin feed pump gascket 1 1 1 1 1 remove the parts in the order listed. For installation, reverse the removal procedure. 6 nm (0.6 m skg) 6 nm (0.6 m skg) eas00359 oil pump.

  • Page 311: Eng

    5-62 oil pan and oil pump eng order job / part q’ty remarks disassembling the oil pump oil pump cover oil pump housing inner rotor outer rotor rotor shaft dowel pin stay 2 2 2 2 2 4 1 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 eas00360

  • Page 312: Eng

    5-63 oil pan and oil pump eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the oil hose and oil tank oil hose 1 o-ring oil tank union bolt oil pipe oil hose 2 oil level switch coupler 1 1 1 2 1 1 1 remove the parts in the order listed. Disconnect. For installation, reverse the removal proced...

  • Page 313: Eng

    5-64 oil pan and oil pump eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the oil pan engine oil oil hose oil filter cover o-ring collar oil filter oil pan gascket dowel pin o-ring / collar oil strainer (cover / filter / bracket) relief valve 1 1 1 1 1 1 2 1 / 1 1/1/1 1 remove the pa...

  • Page 314: Eng

    5-65 oil pan and oil pump eng note: eas00364 checking the oil pump 1. Check: soil pump driven gear 1 soil pump housing 2 soil pump housing cover 3 cracks / damage / wear ! Replace the de- fective part(s). 2. Measure: sinner-rotor-to-outer-rotor-tip clearance a souter-rotor-to-oil-pump-housing cleara...

  • Page 315: Eng

    5-66 oil pan and oil pump eng eas00365 checking the relief valve 1. Check: srelief valve body 1 srelief valve 2 sspring 3 eas00367 checking the oil delivery pipes the following procedure applies to all of the oil delivery pipes. 1. Check: soil delivery pipes damage ! Replace. Obstruction ! Wash and ...

  • Page 316: Eng

    5-67 oil pan and oil pump eng 6 nm (0.6 m skg) note: 6 nm (0.6 m skg) caution: eas00375 assembling the oil pump 1. Lubricate: sinner rotor souter rotor soil pump shaft (with the recommended lubricant) recommended lubricant engine oil 2. Install: soil pump shaft 1 (to the oil pump cover 2 ) spin 3 si...

  • Page 317: Eng

    5-68 oil pan and oil pump eng 10 nm (1.0 m skg) note: 10 nm (1.0 m skg) 30 nm (3.0 m skg) warning note: eas00378 installing the oil strainer 1. Install: scollar so-ring soil strainer 1 the mark a on the oil strainer housing must point towards the front of the engine. Eas00380 installing the oil pan ...

  • Page 318: Eng

    5-69 crankshaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the balancer shaft engine oil tank oil pan crankcase upper cover gascket dowel pin balancer shaft retainer rear balancer holder dowel pin rear balancer shaft / o-ring 1 1 2 2 1 2 1 / 1 remove the parts in the order listed. Refe...

  • Page 319: Eng

    5-70 crankshaft eng order job / part q’ty remarks 8 9 10 11 12 rear balancer weight front balancer holder dowel pin front balancer shaft / o-ring front balancer weight water pump drive gear 1 1 2 1 / 1 1 for installation, reverse the removal procedure. 10 nm (1.0 m skg) 12 nm (1.2 m skg) 12 nm (1.2 ...

  • Page 320: Eng

    5-71 crankshaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the crankshaft assembly balancer weight water pump timing chain cover plate pin timing chain guide (intake) lower crankcase dowel pin crankshaft assembly main journal bealing upper crankcase 1 1 1 1 1 1 1 6 1 remove the par...

  • Page 321: Eng

    5-72 crankshaft eng order job / part q’ty remarks 1 2 3 4 5 removing the connecting rod nut connecting rod bolt connecting rod connecting rod cap connecting rod bearing 4 4 2 2 4 remove the parts in the order listed. For installation, reverse the removal procedure. 62 nm (6.2 m skg) eas00382 connect...

  • Page 322: Eng

    5-73 a b crankshaft eng note: caution: note: eas00384 disassembling the crankcase 1. Remove: scover plate stiming chain guide (intake) 2. Remove: scrankcase bolts sloosen 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....

  • Page 323: Eng

    5-74 crankshaft eng note: note: eas00387 removing the crankshaft assembly 1. Remove: scrankshaft assembly 1 scrankshaft journal upper bearings (from the upper crankcase) identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Eas00391 remov...

  • Page 324: Eng

    5-75 crankshaft eng caution: note: eas00395 checking the crankshaft and connecting rods 1. Measure: scrankshaft runout out of specification ! Replace the crank- shaft. Crankshaft runout less than 0.03 mm 2. Check: scrankshaft journal surfaces scrankshaft pin surfaces sbearing surfaces scratches / we...

  • Page 325: Eng

    5-76 crankshaft eng note: note: caution: note: do not put the plastigauge over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. Salign the projections of the crankshaft journal lower bearings with the...

  • Page 326: Eng

    5-77 crankshaft eng note: caution: 4. Select: scrankshaft journal bearings (j1 x j3) sthe numbers a stamped into the crankshaft web and the numbers 1 stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. S“j1 x j3” refer to the bearings shown in...

  • Page 327: Eng

    5-78 crankshaft eng note: note: caution: 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 con- necting rod and the big end lower bearing into the connecting rod cap. Align the projections a on the big end bear...

  • Page 328: Eng

    5-79 crankshaft eng note: g. Measure the compressed plastigauge width a on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings. 6. Select: sbig end bearings (p1 x p2) sthe numbers a stamped into the crankshaft web and ...

  • Page 329: Eng

    5-80 crankshaft eng note: eas00402 checking the circlips and washers 1. Check: scirclips bends / damage / looseness ! Replace. Swashers bends / damage ! Replace. Eas00404 installing the connecting rods 1. Lubricate: sbolt threads snut seats (with the recommended lubricant) recommended lubricant moly...

  • Page 330: Eng

    5-81 crankshaft eng caution: 4. Align: sbolt heads (with the connecting rod caps) 5. Tighten: sconnecting rod nuts connecting rod nuts 62 nm (6.2 m skg) swhen tightening the connecting rod nuts, be sure to use an f-type torque wrench. Swithout pausing, tighten the connecting rod nuts to the specifie...

  • Page 331: Eng

    5-82 crankshaft eng note: note: eas00407 installing the crankshaft 1. Install: scrankshaft journal upper bearings (into the upper crankcase) salign the projections a on the crankshaft jour- nal upper bearings 1 with the notches b in the upper crankcase. Sbe sure to install each crankshaft journal up...

  • Page 332: Eng

    5-83 crankshaft eng note: note: eas00415 assembling the crankcase 1. Lubricate: scrankshaft journal bearings (with the recommended lubricant) recommended lubricant engine oil 2. Apply: ssealant (onto the crankcase mating surfaces) yamaha bond no. 1215 90890-85505 do not allow any sealant to come int...

  • Page 333: Eng

    5-84 crankshaft eng a b 10 nm (1.0 m skg) 20 nm (2.0 m skg) 55 _ caution: 12 nm (1.2 m skg) 24 nm (2.4 m skg) note: 6. Install: scrankcase bolts (m10) initial 2nd final suse an angle torgue gauge 1 and tighten at the correct angle. Sif an angle torgue gauge is not available, do not tighten at an ang...

  • Page 334: Eng

    5-85 crankshaft eng 10 nm (1.0 m skg) eas00411 installing the balancer shaft 1. Install: sfront balancer shaft weight 1 sfront balancer shaft 2 so-ring new 3 splate (balancer shaft) a. Turn the crankshaft until the keyway a on the crankshaft is aligned with the mark b on the crankcase. B. While hold...

  • Page 335: Eng

    5-86 crankshaft eng 10 nm (1.0 m skg) a. Turn the crankshaft until the keyway a on the crankshaft is aligned with the mark b on the crankcase. B. While holding the crankshaft, install the rear balancer shaft weight and align the mark c on the rear balancer shaft gear with the mark d on the crankcase...

  • Page 336: Eng

    5-87 transmission eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the transmission, shift drum assembly, and shift forks engine cover plate collar oil seal bearing circrip main axle assembly shift fork “r” shift fork “l” shift fork guide bar shift fork “c” 1 1 1 4 1 1 1 1 2 1 remove ...

  • Page 337: Eng

    5-88 transmission eng order job / part q’ty remarks 11 12 13 shift drum bearing housing drive axle assembly 1 1 1 for installation, reverse the removal pro- cedure. 12 nm (1.2 m skg) 10 nm (1.0 m skg).

  • Page 338: Eng

    5-89 transmission eng order job / part q’ty remarks disassembling the main axle assembly. 2nd pinion gear lock washer lock washer retainer 6th pinion gear collar washer circlip 3rd / 4th pinion gear 5th pinion gear main axle 1 1 1 1 2 2 2 1 1 1 disassemble the parts in the order listed. For assembly...

  • Page 339: Eng

    5-90 transmission eng order job / part q’ty remarks disassembling the drive axle assembly. Washer 1st wheel gear collar 5th wheel gear circlip washer 3rd wheel gear lock washer lock washer retainer 4th wheel gear 1 1 4 1 3 4 1 1 1 1 disassemble the parts in the order listed. 1 2 3 4 5 6 7 8 9 10

  • Page 340: Eng

    5-91 transmission eng order job / part q’ty remarks 6th wheel gear 2nd wheel gear drive axle 1 1 1 for assembly, reverse the disassembly procedure. 13 12 11.

  • Page 341: Eng

    5-92 transmission eng note: warning eas00420 removing the transmission 1. Remove: sdrive axle assembly sbearing housing 1 (with the torx wrench) remove the bearing housing with the slide hammer bolt 2 and weight 3 . Slide hammer bolt 90890-01083 weight 90890-01084 2. Remove: smain axle assembly (fro...

  • Page 342: Eng

    5-93 transmission eng 3. Check: sshift fork movement (along the shift fork guide bar) rough movement ! Replace the shift forks and shift fork guide bar as a set. Eas00422 checking the shift drum assembly 1. Check: sshift drum grooves damage / scratches / wear ! Replace the shift drum assembly. Sshif...

  • Page 343: Eng

    5-94 transmission eng note: 12 nm (1.2 m skg) note: 3. Check: stransmission gears blue discoloration / pitting / wear ! Replace the defective gear(s). Stransmission gear dogs cracks / damage / rounded edges ! Replace the defective gear(s). 4. Check: stransmission gear engagement (each pinion gear to...

  • Page 344: Eng

    5-95 transmission eng note: note: note: 3. Install: sshift drum assembly 1 sshift fork “c” 2 sshift fork “l” 3 sshift fork “r” 4 sshift fork guide bars 5 sthe embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “r”, “c”, “l”. Sinstall ...

  • Page 346: Cool

    Cool 6.

  • Page 347: Cool

    Cool chapter 6 cooling system radiator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the radiator 6-3 . . . . . . . . . . . . . . . . ....

  • Page 348: Cool

    Cool.

  • Page 349: Cool

    6-1 radiator cool order job / part q’ty remarks 1 2 3 4 5 6 removing the radiator side cowlings coolant fuel tank air filter case radiator fan coupler coolant reservoir hose radiator outlet hose radiator inlet hose radiator cover radiator 1 1 1 1 1 1 remove the parts in the order listed. Refer to “f...

  • Page 350: Cool

    6-2 radiator cool note: eas00455 checking the radiator 1. Check: sradiator fins obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: sradiator hoses sradiator pipes cracks / d...

  • Page 351: Cool

    6-3 radiator cool eas00456 installing the radiator 1. Fill: scooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: scooling system leaks ! Repair or replace any faulty part. A. Attach the radiator cap tester 1 to the radia- to...

  • Page 352: Cool

    6-4 thermostat cool order job / part q’ty remarks 1 2 3 4 5 removing the thermostat assembly fuel tank air filter case coolant bracket thermo unit lead coupler thermostat inlet hose thermostat outlet hose thermostat assembly 1 1 1 1 1 remove the parts in the order listed. Refer to “fuel tank” in cha...

  • Page 353: Cool

    6-5 thermostat cool order job / part q’ty remarks disassembling the thermostat assembly thermo unit thermostat cover o-ring thermostat thermostat housing 1 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 18 nm (1.8 m skg) 10 nm (1.0 m skg...

  • Page 354: Cool

    6-6 opening (mm) temperature thermostat cool note: eas00463 checking the thermostat 1. Check: sthermostat 1 does not open at 82 x 95_c ! Replace. A. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring the water, ob...

  • Page 355: Cool

    6-7 thermostat cool note: 18 nm (18 m skg) caution: eas00464 assembling the thermostat as- sembly 1. Install: sthermostat housing 1 sthermostat 2 so-ring new 3 sthermostat housing cover install the thermostat with its breather hole a facing up. 2. Install: sthermo unit 1 use extreme care when handli...

  • Page 356: Cool

    6-8 water pump cool order job / part q’ty remarks 1 2 3 4 5 removing the water pump coolant water pump assembly washer o-ring pipe housing 1 1 4 1 1 remove the parts in the order listed. It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains en...

  • Page 357: Cool

    6-9 water pump cool 10 order job / part q’ty remarks disassembling the water pump water pump cover circlip impeller water pump seal bearing oil seal water pump housing rubber damper holder rubber damper o-ring 1 1 1 1 1 1 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the d...

  • Page 358: Cool

    6-10 water pump cool note: note: note: eas00470 disassembling the water pump 1. Remove: simpeller swater pump seal 1 remove the water pump seal from the inside of the water pump housing. 2 water pump housing 2. Remove: sbearing 1 soil seal 2 remove the bearing and oil seal from the inside of the wat...

  • Page 359: Cool

    6-11 water pump cool note: caution: note: note: eas00475 assembling the water pump 1. Install: soil seal new 1 (into the water pump housing 3 ) sbearing 2 sbefore installing the oil seal, apply tap water or coolant onto its out surface. Sinstall the oil seal with a socket that matches its outside di...

  • Page 360: Cool

    6-12 water pump cool caution: note: 10 nm (1.0 m skg) note: 10 nm (1.0 m skg) 4. Measure: simpeller shaft tilt out of specification ! Repeat steps (3) and (4). Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm 1 straightedge 2 impelle...

  • Page 362

    Fi chapter 7 fuel injection system fuel injection system 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecu’s self-diagnostic function 7-3 . . . . . . . . . . . . . . ...

  • Page 363

    Fi.

  • Page 364: Fuel Injection System

    7-1 fuel injection system fi 1 ignition coil 2 air filter case 3 intake temperature sensor 4 fuel delivery hose 5 fuel tank 6 fuel pump 7 fuel return hose 8 intake air pressure sensor 9 throttle position sensor 10 fuel injector 11 o 2 sensor 12 catalytic converter 13 crankshaft position sensor 14 co...

  • Page 365

    7-2 4 main fuse 5 battery 6 fuel injection system fuse 9 main switch 16 cylinder identification sensor 17 fuel injection system relay 18 speed sensor 19 intake air pressure sensor 20 atmospheric pressure sensor 21 intake air temperature sensor 22 coolant temperature sensor 23 lean angle cut-off swit...

  • Page 366

    7-3 30: lean angle cut-off switch (latch up detected) 41: lean angle cut-off switch (open or short circuit) 50: ecu internal malfunction (memory check error) fuel injection system fi ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine...

  • Page 367

    7-4 fuel injection system fi substitute characteristics operation control (fail-safe action) if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven, the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic op- erati...

  • Page 368

    7-5 fuel injection system fi “engine runs irregularly.” or “engine trouble warning light is illuminated.” * engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is illumi- nated checking the self-diagnostic fault code number: ...

  • Page 369

    7-6 turn off the main switch. Turn on the main switch while pressing both the select-button and the reset button of meter. (if the state of pressing buttons is continued over 8 seconds, the lcd display of the clock display will be switched to “diag”.) stop pressing the select-button and the reset bu...

  • Page 370

    7-7 fuel injection system fi diagnostic monitoring code table fault code no. Symptom probable cause of malfunction diagnostic monitoring code no. 11 no normal signals are received from the cylinder identification sensor. S open or short circuit in wiring sub lead. S open or short circuit in wiring h...

  • Page 371

    7-8 fuel injection system fi fault code no. Symptom probable cause of malfunction diagnostic monitoring code no. 33 open circuit is detected in the primary wire of the ignition coil (#1). S open or short circuit in wiring harness. S malfunction in ignition coil. S malfunction in ecu. S malfunction i...

  • Page 372

    7-9 fuel injection system fi sensor operation table diagnostic monitoring code no. Item meter display checking method 01 throttle angle fully closed position fully opened position 15-17 97-100 s check with throttle fully closed. S check with throttle fully open. 02 atmospheric pressure — compare the...

  • Page 373

    7-10 fuel injection system fi actuator operation table diagnostic monitoring code no. Item actuation checking method 30 ignition coil #1 actuates the ignition coils #1 for five times every second. Illuminates the engine trouble warning light check the spark five times. S connect an ignition checker....

  • Page 374

    7-11 fuel injection system fi troubleshooting details this section dscribes the measures per fault code number displayd on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the or- der. When the check and maintenance of malfunct...

  • Page 375

    7-12 fuel injection system fi fault code no. 12 symptom no normal signals are received from the crankshaft position sensor. Diagnostic monitoring code no. Order item / components check or maintenance job restore method 1 installed state of crankshaft position sensor check the installed area for loos...

  • Page 376

    7-13 fuel injection system fi fault code no. 14 symptom intake air pressure sensor-pipe system malfunction (clogged or deteched hose). Diagnostic monitoring code no. 03 intake air pressure sensor order item / components check or maintenance job restore method 1 intake air pressure sensor hose detach...

  • Page 377

    7-14 fuel injection system fi fault code no. 15 symptom throttle position sensor-open or short circuit defected. Diagnostic monitoring code no. 01 throttle position sensor order item / components check or maintenance job restore method 1 installed state of throttle position sensor. Check the install...

  • Page 378

    7-15 fuel injection system fi fault code no. 19 symptom open circuit is detected in the input line from the sidestand switch to the ecu. Diagnostic monitoring code no. 20 sidestand switch order item / components check or maintenance job restore method 1 connected state of connector main wiring harne...

  • Page 379

    7-16 fuel injection system fi fault code no. 20 symptom a. Intake air pressure sensor-open or short circuit detected. B. Defective values are detected due to the internal malfunction of the intake air pressure sensor or the atmospheric pressure sensor. Diagnostic monitoring d n a 03 intake air press...

  • Page 380

    7-17 fuel injection system fi fault code no. 21 symptom open or short sircuit is detected from the coolant temperature sensor. Diagnostic monitoring code no. 06 coolant temperature sensor order item / components check or maintenance job restore method 1 installed state of coolant temperature sensor ...

  • Page 381

    7-18 fuel injection system fi fault code no. 23 symptom open or short circuit detected from the atmospheric pressure sensor. Diagnostic monitoring code no. 02 atmospheric pressure sensor order item / components check or maintenance job restore method 1 installed state of atmospheric pressure sensor ...

  • Page 382

    7-19 fuel injection system fi fault code no. 30 symptom the motorcycle has overturned. Diagnostic monitoring code no. 08 lean angle cut-off switch order item / components check or maintenance job restore method 1 the motorcycle has overturned. Raise the motorcycle upright. Reinstated by i h 2 instal...

  • Page 383

    7-20 fuel injection system fi fault code no. 34 symptom malfunction detected in the primary wire of the ignition coil (#2). Diagnostic monitoring code no. 31 ignition coil (#2) order item / components check or maintenance job restore method 1 connected state of connector ignition coil primary side c...

  • Page 384

    7-21 fuel injection system fi fault code no. 42 symptom a. No normal signal are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Diagnostic monitoring d n a 07 speed sensor code no. B 21 neutral switch order item / components check or maintenance job restor...

  • Page 385

    7-22 fuel injection system fi fault code no. 43 symptom the ecu is unable to monitor the battery voltage. Diagnostic monitoring code no. 50 fuel injection system relay order item / components check or maintenance job restore method 1 connected state of connector fuel injection system relay coupler m...

  • Page 386

    7-23 fuel injection system fi fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic monitoring code no. Order item / components check or maintenance job restore method 1 connected state of connector main wiring harness ecu coupler main wiring harness meter coupler check the co...

  • Page 387

    7-24 fuel injection system fi fault code no. Er-4 symptom non-registered data has been received from the meter. Diagnostic monitoring code no. Order item / components check or maintenance job restore method 1 connected state of connector main wiring harness ecu coupler main wiring harness meter coup...

  • Page 388

    7-25 order job / part q’ty remarks 1 2 3 4 5 removing the throttle body assembly seat fuel tank air filter case coolant throttle stop screw fast idle plunger hose throttle cable throttle body sub-wire harness coupler fuel return hose 1 2 2 2 1 remove the parts in the order listed. Drain. Refer to “c...

  • Page 389

    7-26 fuel injection system fi order job / part q’ty remarks 6 7 8 9 fuel hose vacuum hose throttle body assembly throttle body joint 1 1 1 2 disconnect. Disconnect. For installation, reverse the removal procedure. 10 nm (1.0 m skg).

  • Page 390

    7-27 fuel injection system fi order job / part q’ty remarks disassembling the throttle body throttle position sensor fast idle plunger pressur regulator intake air pressure sensor fuel injection pipe fuel distributor injector throttle body sub-wire harness 1 1 1 1 1 1 2 1 disassemble the parts in th...

  • Page 391

    7-28 fuel injection system fi caution: the throttle bodies should not be disas- sembled unnecessarily. Checking the injector 1. Check: sinjector damage ! Replace. Checking the throttle body 1. Check: sthrottle body cracks / damage ! Replace the throttle bo- dies. 2. Check: sfuel passages obstruction...

  • Page 392

    7-29 fuel injection system fi note: checking the fuel pump and pressure regulator operation 1. Check: spressure regulator operation a. Remove the fuel tank. Refer to “fuel tank” in chapter 3. B. Disconnect the vacuum hose 1 from the pressure regulator. C. Connect the vacuum / pressure pump gauge set...

  • Page 393

    7-30 fuel injection system fi eas00095 checking the throttle body joints the following procedure applies to all of the throttle body joints. 1. Remove: sfuel tank refer to “fuel tank” in chapter 3. Sair filter case refer to “air filter case” in chapter 3. 2. Check: sthrottle body joint 1 cracks / da...

  • Page 394

    7-31 air induction system fi eas00507 air induction system air injection the air induction system bums unburned ex- haust 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 ope...

  • Page 395

    7-32 air induction system fi 1 air cut-off valve 2 reed valve 3 exhaust port 4 air filter case eas00509 air induction system diagrams.

  • Page 396

    7-33 air induction system fi order job / part q’ty remarks 1 2 3 4 5 removing the air cut-off valve and reed valve seat fuel tank air filter case air cut-off valve hose reed valve cover reed valve assembly plate 1 2 1 2 2 remove the parts in teh order listed. For installation, reverse the removal pr...

  • Page 397

    7-34 air induction system fi eas00510 checking the air induction system 1. Check: shoses loose connection ! Connect properly. Cracks / damage ! Replace. Spipes cracks / damage ! Replace. 2. Check: ssteel reed ssteel reed stopper sreed valve seat cracks / damage ! Replace the reed valve. 3. Check: sa...

  • Page 398: Elec

    Elec 8.

  • Page 399: Elec

    Elec chapter 8 electrical electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking switch continuity 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the switches 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 400: Elec

    Elec fuel injection system 8-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 8-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 401: Elec

    8-1 electrical components elec 12 radiator fan motor 13 horn 1 wire harness 2 ignition coil 3 front brake light switch 4 clutch switch 5 starter relay 6 fuse box 7 battery 8 neutral switch 9 sidestand switch 10 rear brake light switch 11 oil level switch eas00729 electrical electrical components.

  • Page 402: Elec

    8-2 1 coolant temperature sensor 2 atomospheric pressure sensor 3 intake air tempreture sensor 4 intake air pressure sensor 5 lean angle cut-off switch 6 turn signal relay 7 fuel injection system relay 8 radiator fan motor relay 9 starting circuit cut-off relay 10 speed sensor 11 o 2 sensor 12 crank...

  • Page 403: Elec

    8-3 checking switch continuity elec caution: note: note: 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. Never insert the tester probes into the cou...

  • Page 404: Elec

    8-4 1 main switch 2 horn switch 3 pass switch 4 dimmer switch 5 hazard switch 6 turn signal switch 7 clutch switch 8 light switch 9 engine stop switch 10 start switch 11 front brake light switch 12 neutral switch 13 rear brake light switch 14 fuses 15 sidestand switch checking the switches elec eas0...

  • Page 405: Elec

    8-5 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 continu- ity between the terminals. Damage / wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! P...

  • Page 406: Elec

    8-6 checking the bulbs and bulb sockets elec warning caution: note: since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Sbe sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be...

  • Page 407: Elec

    8-7 checking the bulbs and bulb sockets elec note: checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: sbulb socket (for continuity) (with the pocket tester) no continuity ! Replace. Pocket tester 90890-03132 check each bulb socket for con...

  • Page 408: Elec

    8-8 checking the bulbs and bulb sockets elec warning checking the leds the following procedures applies to all of the leds. 1. Check: sled (for proper operation) improper operation ! Replace. A. Disconnect the meter assembly coupler (me- ter assembly side). B. Connect two jumper leads 1 from the bat...

  • Page 409: Elec

    8-9 ignition system elec 1 crankshaft position sensor 4 main fuse 5 battery 9 main switch 13 starting circuit cut-off relay 14 sidestand switch 23 lean angle cut-off switch 24 ecu 30 ignition coil 31 spark plug 33 throttle position sensor 46 engine stop switch 57 ignition fuse eas00735 ignition syst...

  • Page 410: Elec

    8-10 yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _c s is the battery ok? S clean the battery terminals. S recharge or re- place the battery. Eas00739 yes no eas00741 3. Spark plug...

  • Page 411: Elec

    8-11 ignition system elec no yes eas00745 yes no 1 a 2 4. Ignition spark gap the following procedure applies to all of the spark plugs. S disconnect the spark plug cap from the spark plug. S connect the ignition checker as shown. S spark plug cap s set the main switch to “on”. S measure the ignition...

  • Page 412: Elec

    8-12 ignition system elec negative tester probe ! Spark plug lead positive tester probe ! Spark plug lead 1 2 s measure the secondary coil resistance. Secondary coil resistance 10.4 x 15.6 kΩ at 20_c s is the ignition coil ok? Yes no replace the ignition coil. Eas00749 7. Main switch s check the mai...

  • Page 413: Elec

    8-13 when you switch the positive and negative tester probes, the readings in the above chart will be reversed. S are the tester readings correct? 11. 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) to th...

  • Page 414: Elec

    8-14 electric starting system elec 4 main fuse 5 battery 7 starter relay 8 starter motor 9 main switch 11 diode 13 starting circuit cut-off relay 14 sidestand switch 15 neutral switch 46 engine stop switch 47 start switch 54 clutch switch 57 ignition fuse eas00755 electric starting system circuit di...

  • Page 415: Elec

    8-15 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: sthe transmission is in ...

  • Page 416: Elec

    8-16 eas00739 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Yes no s clean the battery terminals. S recharge or re- place the battery. Minimum open-circuit voltage 12.8 v or more at 20 _c s is the battery ok? Yes no 3. Starter motor s con...

  • Page 417: Elec

    8-17 4. Starting circuit cut-off relay s disconnect the starting circuit cut-off relay from the wire harness. S connect the pocket tester (Ω 1) and bat- tery (12 v) to the starting circuit cut-off relay terminals as shown. Yes no replace the starting circuit cut-off relay. S does the starting circui...

  • Page 418: Elec

    8-18 6. Starter relay s disconnect the starter relay from the cou- pler. S connect the pocket tester (Ω 1) and bat- tery (12 v) to the starter relay terminals as shown. Yes no replace the starter relay. S does the starter relay have continuity be- tween red and black? Eas00761 battery positive termi...

  • Page 419: Elec

    8-19 electric starting system elec 12. 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. Eas00764 13. Wiring s check the entire starting system’s wiring. Refer to “circuit diagram”. S is the st...

  • Page 420: Elec

    8-20 order job / part q’ty remarks 1 2 3 removing the starter motor exhaust pipe starter motor lead starter motor o-ring 1 1 1 remove the parts in the order listed. Disconnect. For installation, reverse the removal procedure. 10nm (1.0 m skg) starter motor elec eas00767 starter motor.

  • Page 421: Elec

    8-21 order job / part q’ty remarks disassembling the starter motor front bracket washer kit rear bracket washer kit brush holder brush armature coil o-ring starter motor yoke seal bearing 1 1 1 1 1 2 1 2 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure...

  • Page 422: Elec

    8-22 starter motor elec note: eas00770 checking the starter motor 1. Check: scommutator dirt ! Clean with 600 grit sandpaper. 2. Measure: scommutator diameter a out of specification ! Replace the starter motor. Commutator diameter limit 27 mm 3. Measure: smica undercut a out of specification ! Scrap...

  • Page 423: Elec

    8-23 starter motor elec armature coil resistance 0.03 x 0.04 Ω at 20_c b. If any resistance is out of specification, re- place the starter motor. 5. Measure: sbrush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 5 mm 6. Measure: sbrush spring force out of spe...

  • Page 424: Elec

    8-24 starter motor elec note: note: 10 nm (1.0 m skg) eas00772 assembling the starter motor 1. Install: sbrush holder 1 align the tab a on the brush holder with the slot b in the starter motor yoke. 2. Install: sarmature coil 1 swashers 2 sstarter motor front cover 3 sstarter motor rear cover 4 alig...

  • Page 425: Elec

    8-25 charging system elec 2 generator 3 rectifier / regulator 4 main fuse 5 battery eas00773 charging system circuit diagram.

  • Page 426: Elec

    8-26 3. Charging voltage s connect the engine tachometer to the spark plug lead 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 s start the engine and let it run at appr...

  • Page 427: Elec

    8-27 charging system elec yes no 5. Wiring s check the wiring connections of the entire charging system. Refer to “circuit diagram”. S is the charging system’s wiring properly con- nected and without defects? Properly connect or repair the charging system’s wiring. Eas00779 replace the rectifi- er /...

  • Page 428: Elec

    8-28 lighting system elec 4 main fuse 5 battery 9 main switch 38 high beam indicator light 41 meter light 45 light switch 50 pass switch 51 dimmer switch 58 headlight fuse 60 parking light fuse 62 auxiliary light 64 tail / brake light switch 65 headlight eas00780 lighting system circuit diagram.

  • Page 429: Elec

    8-29 yes no 4. Light switch s check the light switch for continuity. Refer to “checking the switches”. S is the light switch ok? The light switch is faulty. Replace the right handlebar switch. Eas00783 yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the batter...

  • Page 430: Elec

    8-30 lighting system elec eas00784 yes no 5. Dimmer switch s check the dimmer switch for continuity. Refer to “checking the switches”. S is the dimmer switch ok? The dimmer switch is faulty. Replace the left handlebar switch. Eas00786 yes no 6. Pass switch s check the pass switch for continuity. Ref...

  • Page 431: Elec

    8-31 eas00788 checking the lighting system 1. The headlight and the high beam indicator light fail to come on. Yes no 1. Headlight bulb and socket s check the headlight bulb and socket for con- tinuity. Refer to “checking the bulbs and bulb sockets” s are the headlight bulb and socket ok? Replace th...

  • Page 432: Elec

    8-32 lighting system elec yes no 1. Meter light bulb and socket s check the meter light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” s are the meter light bulb and socket ok? Replace the meter light bulb, socket or both. Eas00789 2. The meter light fails to come on....

  • Page 433: Elec

    8-33 eas00791 4. The auxiliary light fails to come on. Yes no 1. Auxiliary light bulb and socket replace the auxiliary light bulb, socket or both. S check the auxiliary light bulb and socket for continuity. Refer to “checking the bulbs and sockets” s are the auxiliary light bulb and socket ok? Yes n...

  • Page 434: Elec

    8-34 signaling system elec eas00780 signaling system circuit diagram.

  • Page 435: Elec

    8-35 signaling system elec 4 main fuse 5 battery 9 main switch 12 buck up fuse 13 starting circuit cut-off relay 15 neutral switch 32 fuel pump 35 oil level warning light 36 neutral indicator light 37 engine trouble warning light 39 left turn signal indicator light 40 right turn signal indicator lig...

  • Page 436: Elec

    8-36 signaling system elec yes no 4. Wiring s check the entire signal system’s wiring. Refer to “circuit diagram”. S is the signaling system’s wiring properly connected and without defects? Properly connect or repair the signaling system’s wiring. Check the condition of each of the signal- ing syste...

  • Page 437: Elec

    8-37 signaling system elec s check the horn switch for continuity. Refer to “checking the switches”. S is the horn switch ok? Yes replace the left han- dlebar switch. No s connect the pocket tester (dc 20 v) to the horn connector at the horn terminal as shown. Yes the wiring circuit from the main sw...

  • Page 438: Elec

    8-38 signaling system elec replace the tail / brake light bulb, socket or both. No eas00797 2. The tail / brake light fails to come on. 1. Tail / brake light bulb and socket s check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” s are the tail/bra...

  • Page 439: Elec

    8-39 signaling system elec 2. Turn signal switch s check the turn signal switch for continuity. Refer to “checking the switches”. S is the turn signal switch ok? The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re- paired. No yes replace the left han- dl...

  • Page 440: Elec

    8-40 signaling system elec the wiring circuit from the turn signal switch to the turn sig- nal light coupler (me- ter assembly cou- pler) is faulty and must be repaired. No 5. Voltage s connect the pocket tester (dc 20 v) to the turn signal light coupler or meter assembly coupler (wire harness side)...

  • Page 441: Elec

    8-41 signaling system elec 1 2 4. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! Brown negative tester probe ! Light green 1. Oil level warning light bulb and socket s check the oil level warning light bulb and socket...

  • Page 442: Elec

    8-42 signaling system elec 4. Voltage s connect the pocket tester (dc 20 v) to the engine oil level switch coupler as shown. No yes the wiring circuit from the meter as- sembly to the oil lev- el switch coupler is faulty and must be repaired. Tester positive probe ! White tester negative probe ! Bla...

  • Page 443: Elec

    8-43 signaling system elec replace the fuel pump. No 1. Fuel sender s drain the fuel from the fuel tank and remove the fuel pump assembly from the fuel tank. S connect the pocket tester (Ω 1) to the fuel sender as shown. Yes positive tester probe ! Green negative tester probe ! Black/white 1 2 s mea...

  • Page 444: Elec

    8-44 signaling system elec the wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. No 1. Voltage s connect the pocket tester (dc v 20) to the meter assembly (wire harness side) as shown. Yes eas00805 7. The clock fails to operate. Positive tester pro...

  • Page 445: Elec

    8-45 cooling system elec 4 main fuse 5 battery 9 main switch 22 coolant temperature sensor 24 ecu 57 ignition fuse 70 radiator fan motor fuse 71 radiator fan relay 72 radiator fan motor eas00807 cooling system circuit diagram.

  • Page 446: Elec

    8-46 cooling system elec yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. S clean the battery terminals. S recharge or re- place the battery. Eas00739 minimum open-circuit voltage 12.8 v or more at 20 _c s is the battery ok? Yes no 3....

  • Page 447: Elec

    8-47 cooling system elec s remove the coolant temperature sensor from the thermostat assembly. S connect the pocket tester (Ω 1) to the coolant temperature sensor as shown. S immerse the coolant temperature sensor in a container filled with coolant . Make sure that the coolant temperature sen- sor t...

  • Page 448: Elec

    8-48 cooling system elec s does the coolant temperature sensor oper- ate properly as described above? Replace the coolant temperature sensor. No yes 7. Wiring s check the entire cooling system’s wiring. Refer to “circuit diagram”. S is the cooling system’s wiring properly con- nected and without def...

  • Page 449: Elec

    8-49 4 main fuse 5 battery 6 fuel injection system fuse 9 main switch 16 cylinder identification sensor 17 fuel injection system relay 18 speed sensor 19 intake air pressure sensor 20 atmospheric pressure sensor 21 intake air temperature sensor 22 coolant temperature sensor 23 lean angle cut-off swi...

  • Page 450: Elec

    8-50 yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. S clean the battery terminals. S recharge or re- place the battery. Eas00739 minimum open-circuit voltage 12.8 v or more at 20 _c s is the battery ok? Yes no 3. Main switch s check...

  • Page 451: Elec

    8-51 fuel injection system elec 5. Fuel injection system relay s disconnect the fuel injection system relay from the wire harness. S connect the pocket tester (Ω 1) and bat- tery (12 v) to the fuel injection system relay terminals as shown. Battery positive terminal ! Red/black battery negative term...

  • Page 452: Elec

    8-52 8. Cylinder identification sensor output volt- age s connect the pocket tester (dc 20 v) to the cylinder identification sensor coupler termi- nal as shown. Tester positive probe ! White tester negative probe ! Black/blue 1 2 yes no 9. Speed sensor output voltage s measure the speed sensor outpu...

  • Page 453: Elec

    8-53 s remove the coolant temperature sensor from the thermostat assembly. S connect the pocket tester (Ω 1) to the coolant temperature sensor as shown. S immerse the coolant temperature sensor in a container filled with coolant . Make sure that the coolant temperature sen- sor terminals do not get ...

  • Page 454: Elec

    8-54 s remove the intake air temperature sensor from the air filter case. S connect the pocket tester (Ω 100) to the intake air temperature sensor terminal as shown. 11. Intake air temperature sensor resistance warning s handle the intake air temperature sen- sor with special care. S never subject t...

  • Page 455: Elec

    8-55 yes no 14.Ai system solenoid s remove the ai system solenoid coupler from the wire harness. S connect the pocket tester (Ω 1) to the ai system solenoid terminal as shown. Replace the ai sys- tem solenoid. Tester positive probe ! Orange tester negative probe ! Green 1 2 s measure the ai system s...

  • Page 456: Elec

    8-56 fuel injection system elec warning 2 3 eas00819 checking the fuel pump 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: sstop the engine before refueling. Sdo not smoke, and keep aw...

  • Page 457: Elec

    8-57 fuel injection system elec note: note: eas00502 checking and adjusting the throttle position sensor before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: sthrottle position sensor (installed on the throttle body) a. Disconnect the thrott...

  • Page 458: Elec

    8-58 fuel injection system elec throttle position sensor resistance (520 x 900 Ω) x (4.0 x 6.0 kΩ) at 20 _c (yellow – black / blue) 2. Check: sthrottle position sensor angle a. Connect the throttle position sensor coupler to the throttle position sensor. B. Connect the pocket tester (dc 20 v) to the...

  • Page 459: Elec

    8-59 fuel injection system elec d. Adjust the throttle position sensor angle so the measured output voltage is within the specified range. Throttle position sensor output voltage 0.53 x 0.83 v e. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws 4 ..

  • Page 461: Trbl

    9 trbl shtg.

  • Page 462: Trbl

    Trbl shtg chapter 9 troubleshooting starting failures 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 9-1 . . . . . . . . . . . . . . . ....

  • Page 463: Trbl

    Trbl shtg faulty lighting or signaling system 9-6 . . . . . . . . . . . . . . . . . . . . Headlight does not come on 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulb burnt out 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail/ brake light does not come on 9-6 ....

  • Page 464: Trbl

    9-1 starting failures trbl shtg note: electrical systems battery sdischarged battery sfaulty battery fuse(s) sblown, damaged or incorrect fuse simproperly installed fuse spark plug(s) sincorrect spark plug gap sincorrect spark plug heat range sfouled spark plug sworn or damaged electrode sworn or da...

  • Page 465: Trbl

    9-2 starting problems/ incorrect engine idling speed trbl shtg electrical systems battery sdischarged battery sfaulty battery spark plug(s) sincorrect spark plug gap sincorrect spark plug heat range sfouled spark plug sworn or damaged electrode sworn or damaged insulator sfaulty spark plug cap ignit...

  • Page 466: Trbl

    9-3 poor medium-and-high-speed performance/ faulty gear shifting trbl shtg fuel system fuel pump sfaulty fuel pump jumps out of gear shift shaft sincorrect shift pedal position simproperly returned stopper lever shift forks sworn shift fork shift drum sincorrect axial play sworn shift drum groove tr...

  • Page 467: Trbl

    9-4 faulty clutch/overheating trbl shtg clutch drags clutch sair in hydraulic clutch system sunevenly tensioned clutch springs swarped pressure plate sbent clutch plate sswollen friction plate sbent clutch push rod sdamaged clutch boss sburnt primary driven gear bushing sdamaged clutch release cylin...

  • Page 468: Trbl

    9-5 overcooling/poor braking performance/ faulty front fork legs trbl shtg eas00856 overcooling cooling system thermostat sthermostat stays open eas00857 poor braking performance sworn brake pad sworn brake disc sair in hydraulic brake system sleaking brake fluid sfaulty brake caliper kit sfaulty br...

  • Page 469: Trbl

    9-6 unstable handling/ faulty lighting or signaling system trbl shtg tire(s) suneven tire pressures (front and rear) sincorrect tire pressure suneven tire wear wheel(s) sincorrect wheel balance sdeformed cast wheel sdamaged wheel bearing sbent or loose wheel axle sexcessive wheel runout frame sbent ...

  • Page 470

    62 auxiliary light 63 rear brake light switch 64 tail / brake light 65 headlight 66 rear turn signal light (left) 67 rear turn signal light (right) 68 front turn signal light (left) 69 front turn signal light (right) 70 radiator fan motor fuse 71 radiator fan relay 72 radiator fan motor color code b...

  • Page 471

    62 rear turn signal light (left) 63 rear turn signal light (right) 64 front turn signal light (left) 65 front turn signal light (right) 66 radiator fan motor fuse 67 radiator fan relay 68 radiator fan motor color code b black . . . . . . . Br brown . . . . . . Ch chocolate . . . . . Dg dark green . ...

  • Page 474

    R b dg lg br b y ch g l on off p r l b off on off on hi lo off on r n l dg y b ch br g y l b y b b b b b b b b b b b/y l/y off po on off run off on b l gy g/w g/w l/y l/b l/w l/w r/w l/b l/r dg lg br b y ch g l l/b l/r y/l b/w r/g l/r br/r l/r r/w g/y br/r l/y w w w w gy g/w r/w r/g l/g l w/b b/l b/...

  • Page 475

    Tdm900p 2002 wiring diagram (oce).