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Yamaha 2006 FJR1300A Service Manual

Summary of 2006 FJR1300A

  • Page 1

    2006 service manual fjr1300a(v) 3p6-28197-e0

  • Page 2

    Eas20040 fjr1300a(v) 2006 service manual ©2006 by yamaha motor co., ltd. First edition, january 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

    Eas20070 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4: How to Use This Manual

    Eas20090 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5: Symbols

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 lt new t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool ...

  • Page 7: Table of Contents

    Eas20110 table of contents general information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 electrical system 8 troubleshooting 9.

  • Page 9: General Information

    1 general information identification ............................................................................................ 1-1 vehicle identification number ..................................................... 1-1 model label......................................................................

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas20150 model label the model label “1” is affixed to the frame. This information will be needed to order spare parts..

  • Page 11: Features

    Features 1-2 eas20170 features et2c01025 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sy...

  • Page 12: Features

    Features 1-3 et3p61042 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 13: Features

    Features 1-4 et3p61050 outline of the unified brake system the yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle usin...

  • Page 14: Features

    Features 1-5 brake pedal input force and braking force at each wheel metering valve this valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level. Only the rear brake caliper is operated when there is an ext...

  • Page 15: Features

    Features 1-6 abs layout abs the operation of the yamaha abs brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. However, part of the front brake is operated together with rear brake. When wheel ...

  • Page 16: Features

    Features 1-7 • slip ratio: when the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula. 0%: there is ...

  • Page 17: Features

    Features 1-8 the difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ...

  • Page 18: Features

    Features 1-9 warning ewa13870 the abs controls only the tendency of the wheel to lock caused by applying the brakes. The abs cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine braking, even if the abs is operating. Electronic abs features the yamaha abs (anti-lo...

  • Page 19: Features

    Features 1-10 abs block diagram et3p61051 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel speed and transmit the rotation signal to the abs ecu. Each wheel sensor is composed of a permanent magnet and a coil. The wheel sensors are installed in the sen...

  • Page 20: Features

    Features 1-11 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off, so that the rider can check if the abs warning light is disconnected and check...

  • Page 21: Features

    Features 1-12 when the abs is activated, the flow control valve regulates the flow of brake fluid to the brake and the solenoid valve decreases and increases the brake fluid pressure. 1. When the brakes are operated normally, the solenoid valve “2” is closed, the spool “3” of the flow control valve ...

  • Page 22: Features

    Features 1-13 abs ecu (electronic control unit) the abs ecu “1” controls the abs and is installed under the storage compartment. To protect the abs ecu from water damage, it is protected by a cover “2”. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front...

  • Page 23: Features

    Features 1-14 the necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit and abs motor relay. Abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diag...

  • Page 24: Features

    Features 1-15 abs motor relay the abs motor relay “1” controls the power supply of the hydraulic unit and is located beside the hy- draulic unit. Composition and operation the abs motor relay is activated by signals transmitted from the abs ecu and the abs motor oper- ates when the abs starts to red...

  • Page 25: Features

    Features 1-16 et3p61052 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. 12 14 1 11 10 2 3 4 5 6 7 8 9 13 1. Abs ecu 2. Pump motor monitor 3. Power supp...

  • Page 26: Features

    Features 1-17 normal braking (abs not activated) when the abs is not activated, port d “11” of the solenoid valve is closed because a control signal has not been transmitted from the abs ecu and port a “7” and port b “9” of the flow control valve are open. Therefore, when the brake lever is squeezed...

  • Page 27: Features

    Features 1-18 emergency braking (abs activated) 1. Depressurized state when the front wheel is about to lock, port d “11” of the solenoid valve is opened by the “depressur- ization” signal transmitted from the abs ecu. When this occurs, the spool of the flow control valve compresses the return sprin...

  • Page 28: Features

    Features 1-19 2. Pressurized state port d “11” is closed by the “pressurization” signal transmitted from the abs ecu. Before this oc- curs, the spool of the flow control valve has compressed the return spring and closed port b “9”. Brake fluid that has entered through port a “7” is further restricte...

  • Page 29: Features

    Features 1-20 et3p61053 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the meter assembly. Instances when the abs warning light comes on 1. The abs warning light comes on when the main switch...

  • Page 30: Features

    Features 1-21 3. The abs warning light comes on while riding. If the abs warning light comes on while riding, a malfunction has been detected in the abs. The abs hydraulic control will not be performed. The abs will have recourse to manual braking if this occurs. 4. The abs warning light flashes whi...

  • Page 31: Features

    Features 1-22 et3p61054 abs warning light and operation abs warning light • when the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off. • the abs warning light comes on while the start switch is being pushed. • if the abs warning light comes on while riding, ...

  • Page 32: Features

    Features 1-23 • depending on the road conditions, the braking distance may be longer compared to that of vehicles not equipped with abs. Therefore, ride at a safe speed and keep a safe distance between yourself and other vehicles. • the braking of the vehicle, even in the worst case, is principally ...

  • Page 33: Features

    Features 1-24 et3p61043 instrument functions speedometer the speedometer shows the riding speed. When the key is turned to “on”, the speedome- ter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit. Tachometer the electric tachometer allows ...

  • Page 34: Features

    Features 1-25 odometer and tripmeter modes pushing the “select” button switches the dis- play between the odometer mode “odo” and the tripmeter modes “trip 1” and “trip 2” in the following order: odo → trip 1 → trip 2 → odo note: when selecting “trip 1” or “trip 2”, the display flashes for five seco...

  • Page 35: Features

    Features 1-26 coolant temperature meter with the key in the “on” position, the coolant temperature meter indicates the temperature of the coolant. When the key is turned to “on”, all of the display segments of the coolant tempera- ture meter will appear one after the other and then disappear in orde...

  • Page 36: Features

    Features 1-27 instantaneous fuel consumption mode the instantaneous fuel consumption display can be set to either “km/l” or “l/100 km”. • when the display is set to “km/l”, the dis- tance that can be traveled on 1.0 l of fuel un- der the current riding conditions is shown. • when the display is set ...

  • Page 37: Features

    Features 1-28 note: 1. • if the ambient temperature falls below -9 °c, a lower temperature than -9 °c will not be dis- played. • if the ambient temperature climbs above 50 °c, a higher temperature than 50 °c will not be dis- played. • the accuracy of the temperature reading may be affected when ridi...

  • Page 38: Features

    Features 1-29 note: if the multi-function display indicates fault code 52, this could be caused by transponder interfer- ence. If this fault code appears, try the following. 1. Use the code re-registering key to start the engine. Note: make sure there are no other immobilizer keys close to the main ...

  • Page 39: Important Information

    Important information 1-30 eas20180 important information eas20190 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 equip- ment. Refer to “special tools” on page 1-33. 3. When disasse...

  • Page 40: Important Information

    Important information 1-31 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if...

  • Page 41: Checking The Connections

    Checking the connections 1-32 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 42: Special Tools

    Special tools 1-33 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 43: Special Tools

    Special tools 1-34 compression gauge 90890-03081 engine compression tester yu-33223 3-11 oil filter wrench 90890-01426 yu-38411 3-13 oil pressure gauge set 90890-03120 3-14 oil pressure adapter b 90890-03124 3-14 steering nut wrench 90890-01403 spanner wrench yu-33975 3-26, 4-77 damper rod holder 90...

  • Page 44: Special Tools

    Special tools 1-35 coupling gear/middle shaft tool 90890-01229 gear holder ym-01229 4-95, 4-98 bearing retainer wrench 90890-04050 pinion bearing retainer & remover ym-04050 4-95, 4-98 fork seal driver weight 90890-01184 4-100 fork seal driver attachment 90890-01186 replacement 27 mm ym-a9409-1 4-10...

  • Page 45: Special Tools

    Special tools 1-36 valve spring compressor attachment 90890-04114 valve spring compressor adapter 19.5 mm ym-04114 5-22, 5-27 valve guide remover (ø5) 90890-04097 valve guide remover (5.0 mm) ym-04097 5-23 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-23 valve guid...

  • Page 46: Special Tools

    Special tools 1-37 thickness gauge 90890-03180 feeler gauge set yu-26900-9 5-49 bearing retainer wrench 90890-04137 middle drive shaft bearing retainer wrench ym-04137 5-67, 5-69 damper spring compressor 90890-04090 5-67, 5-68 bearing retainer wrench 90890-04140 middle drive shaft bearing retainer w...

  • Page 47: Special Tools

    Special tools 1-38 weight 90890-01084 yu-01083-3 5-99 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-3 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 middle ...

  • Page 48: Special Tools

    Special tools 1-39 fuel pressure adapter 90890-03176 ym-03176 7-7 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-8 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-162 tool name/tool no. Illustration reference pages.

  • Page 49: Specifications

    2 specifications general specifications ........................................................................ 2-1 engine specifications ............................................................................ 2-2 chassis specifications ............................................................

  • Page 50: General Specifications

    General specifications 2-1 eas20280 general specifications model model 3p61 (europe except (b) and (f)) (za) 3p62 (b) (f) 3p63 (aus) dimensions overall length 2230 mm (87.8 in) overall width 750 mm (29.5 in) overall height 1450 mm (57.1 in) seat height 800 mm (31.5 in) wheelbase 1545 mm (60.8 in) gr...

  • Page 51: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 1298.0 cm³ (79.20 cu.In) cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) compression ratio 10.80 :1 standard compression press...

  • Page 52: Engine Specifications

    Engine specifications 2-3 coolant reservoir capacity (up to the maximum level mark) 0.25 l (0.26 us qt) (0.22 imp.Qt) radiator cap opening pressure 93.3–122.7 kpa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) valve relief pressure 4.9 kpa (0.7 psi) (0.05 kgf/cm²) thermostat model/manufacturer 4fm/nippon therm...

  • Page 53: Engine Specifications

    Engine specifications 2-4 limit 24.897 mm (0.9802 in) camshaft runout limit 0.030 mm (0.0012 in) timing chain model/number of links 92rh2015/136 tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.15–0.22 mm (0.0059–0.0087 in) exhaust 0.18–0.25 mm (0.0071–0.009...

  • Page 54: Engine Specifications

    Engine specifications 2-5 valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (exhaust) 0.020–0.047 mm (0.0008–0.0019 in) limit 0.105 mm (0.0041 in) valve stem runout 0.010 mm (0.0004 in) cylinder head valve se...

  • Page 55: Engine Specifications

    Engine specifications 2-6 height h 5.0 mm (0.20 in) offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) limit 19.045 mm (0.7498 in) piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) limit 18.971 mm (0.7469 in) pist...

  • Page 56: Engine Specifications

    Engine specifications 2-7 connecting rod oil clearance (using plastigauge ® ) 0.031–0.048 mm (0.0012–0.0019 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow 6.Pink small end inside diameter 19.005–19.018 mm (0.7482–0.7487 in) crankshaft width a 61.60–63.20 mm (2.425–2.488 in) width b 3...

  • Page 57: Engine Specifications

    Engine specifications 2-8 5th 26/28 (0.929) main axle runout limit 0.08 mm (0.0032 in) drive axle runout limit 0.08 mm (0.0032 in) shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.100 mm (0.0039 in) air filter air filter element dry element fuel p...

  • Page 58: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 26.00° trail 109.0 mm (4.29 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 135.0 mm (5.31 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel ...

  • Page 59: Chassis Specifications

    Chassis specifications 2-10 front disc brake disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) brake disc thickness limit 4.0 mm (0.16 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 5.5 mm (0.22 in) limit 0.5 mm (0.02 in) brake pad lining thic...

  • Page 60: Chassis Specifications

    Chassis specifications 2-11 optional spring available no recommended oil suspension oil m1 or ohlins r & t43 quantity 696.0 cm³ (23.53 us oz) (24.55 imp.Oz) level 92.0 mm (3.62 in) rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorb...

  • Page 61: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition timing (b.T.D.C.) 5.0°/1050 r/min engine control unit model/manufacturer fua0008/mitsubishi (europe except (b) and (f)) (za) (...

  • Page 62: Electrical Specifications

    Electrical specifications 2-13 license plate light 12 v, 5.0 w × 1 meter lighting led indicator light neutral indicator light led turn signal indicator light led oil level warning light led high beam indicator light led engine trouble warning light led abs warning light led immobilizer system indica...

  • Page 63: Electrical Specifications

    Electrical specifications 2-14 starting circuit cut-off relay model/manufacturer g8r-30y-v3/omron coil resistance 180.0 Ω headlight relay model/manufacturer acm33211 m05/matsushita coil resistance 96.0 Ω radiator fan model/manufacturer 3p6/denso running rpm 4250 r/min fan motor relay model/manufactu...

  • Page 64: Tightening Torques

    Tightening torques 2-15 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 65: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 4 13 nm (1.3 m·kg, 9.4 ft·lb) cylinder head bolt m10 10 see note. Cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft cap bolt m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder...

  • Page 66: Tightening Torques

    Tightening torques 2-17 oil pump housing cover bolt m6 3 12 nm (1.2 m·kg, 8.7 ft·lb) oil level switch bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) throttle body joint clamp screw m4 8 3 nm (0.3 m·kg, 2.2 ft·lb) air filter case joint clamp screw m4 4 4 nm (0.4 m·kg, 2.9 ft·lb) air filter case and rear lower...

  • Page 67: Tightening Torques

    Tightening torques 2-18 clutch spring bolt m6 6 8 nm (0.8 m·kg, 5.8 ft·lb) clutch release cylinder bolt m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) clutch hose union bolt m10 1 30 nm (3.0 m·kg, 22 ft·lb) bleed screw (clutch release cylin- der) m8 1 6 nm (0.6 m·kg, 4.3 ft·lb) main axle assembly screw m6 3 12 nm...

  • Page 68: Tightening Torques

    Tightening torques 2-19 note: cylinder head bolt tighten the cylinder head bolts to 25 nm (2.5 m·kg 18 ft·lb) in the proper tightening sequence, loosen and retighten the bolts to 25 nm (2.5 m·kg 18 ft·lb) in the proper tightening sequence, and then tighten them further to reach the specified angle 1...

  • Page 69: Tightening Torques

    Tightening torques 2-20 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolts (right front lower side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolts (right front upper side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolts (left fron...

  • Page 70: Tightening Torques

    Tightening torques 2-21 lower ring nut (final tightening torque) m30 1 18 nm (1.8 m·kg, 13 ft·lb) see note. Handlebar bolt m8 2 23 nm (2.3 m·kg, 17 ft·lb) handlebar nut m12 2 65 nm (6.5 m·kg, 47 ft·lb) clutch master cylinder holder bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) front brake master cylinder ho...

  • Page 71: Tightening Torques

    Tightening torques 2-22 t-bar bolt m10 3 37 nm (3.7 m·kg, 27 ft·lb) rear fender bolt m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) rear fender nut m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) front wheel axle bolt m14 1 91 nm (9.1 m·kg, 66 ft·lb) see note. Front wheel axle pinch bolt m8 4 21 nm (2.1 m·kg, 15 ft·lb) front brak...

  • Page 72: Tightening Torques

    Tightening torques 2-23 note: lower ring nut 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 nm (1.8 m·kg, 13 ft·lb) with a torque wrench. Note: front wheel axle pi...

  • Page 73: Tightening Torques

    Tightening torques 2-24 1 2 3 4.

  • Page 74: 2-25

    Lubrication points and lubricant types 2-25 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobes camshaft journals balanc...

  • Page 75: 2-26

    Lubrication points and lubricant types 2-26 cylinder head cover mating surface three bond 1541 ® cylinder head cover gasket yamaha bond no.1215 (three bond no.1215 ® ) crankcase mating surface yamaha bond no.1215 (three bond no.1215 ® ) crankshaft position sensor lead grommet yamaha bond no.1215 (th...

  • Page 76: 2-27

    Lubrication points and lubricant types 2-27 eas20380 chassis lubrication point lubricant steering bearings and upper bearing cover lip lower bearing dust seal lip front wheel oil seal lips (right and left) rear wheel oil seal lips rear wheel drive hub oil seal rear wheel drive hub mating surface rea...

  • Page 77: 2-28

    Lubrication points and lubricant types 2-28.

  • Page 78: 2-29

    Lubrication system chart and diagrams 2-29 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 15 14 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9.

  • Page 79: 2-30

    Lubrication system chart and diagrams 2-30 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12. Main axle 13. Oil pipe 14. Drive axle 15. Middle drive...

  • Page 80: 2-31

    Lubrication system chart and diagrams 2-31 eas20410 lubrication diagrams 5 6 7 1 2 3 4.

  • Page 81: 2-32

    Lubrication system chart and diagrams 2-32 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle.

  • Page 82: 2-33

    Lubrication system chart and diagrams 2-33 1 3 2.

  • Page 83: 2-34

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Drive axle 3. Oil delivery pipe 1.

  • Page 84: 2-35

    Lubrication system chart and diagrams 2-35 6 5 4 3 2 1.

  • Page 85: 2-36

    Lubrication system chart and diagrams 2-36 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump.

  • Page 86: 2-37

    Lubrication system chart and diagrams 2-37 1 2 3 4 5 6 7 8 9.

  • Page 87: 2-38

    Lubrication system chart and diagrams 2-38 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly.

  • Page 88: 2-39

    Lubrication system chart and diagrams 2-39 4 5 3 2 1 9 8 6 7.

  • Page 89: 2-40

    Lubrication system chart and diagrams 2-40 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump.

  • Page 90: Cooling System Diagrams

    Cooling system diagrams 2-41 eas20420 cooling system diagrams a c d b b d a 6 5 15 6 7 8 9 9 10 1 2 3 4 12 11 16 17 18 19 13 14 5 c.

  • Page 91: Cooling System Diagrams

    Cooling system diagrams 2-42 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Plunger control unit hose 1 4. Plunger control unit hose 2 5. Oil cooler outlet hose 6. Radiator 7. Coolant reservoir breather hose 8. Thermostat inlet pipe 2 9. Coolant reservoir hose 10. Radiator inlet hose 11. T...

  • Page 92: Cooling System Diagrams

    Cooling system diagrams 2-43 a a 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12.

  • Page 93: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10. Water pump 11. Water jacket joint 12. Water...

  • Page 94: Cable Routing

    Cable routing 2-45 eas20430 cable routing b-b a a b b a b c d e f g g h h i j k l m 1 1 1 2 2 2 2 3 3 3 4 4 4 5 5 5 6 7 8 9 11 11 12 12 10 11 12 13 14 15 16 17 18 19 20 20 20 21 21 21 1 2 3 m.

  • Page 95: Cable Routing

    Cable routing 2-46 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Right handlebar switch lead 3. Clutch hose 4. Left handlebar switch lead 5. Main switch lead 6. Immobilizer unit lead 7. Left horn (low) 8. Brake hose (hydraulic unit to left front brake caliper) 9. Front wheel senso...

  • Page 96: Cable Routing

    Cable routing 2-47 b-b c-c d-d a-a e e a a b c d b c d a b c e i j k l 1 1 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 19 20 21 22 23 24 25 26 27 27 28 29 29 30 31 32 33 34 35 36 37 38 d f g m n p 27 29 29 18 o h.

  • Page 97: Cable Routing

    Cable routing 2-48 1. O 2 sensor lead 2. Engine idling speed adjusting cable 3. Starter motor lead 4. Air deflector 5. Wire harness 6. Spark plug lead #4 7. Spark plug lead #1 8. Cylinders-#1/#4 ignition coil 9. Cylinders-#2/#3 ignition coil 10. Starter relay 11. Starter relay lead 12. Fuse box 2 13...

  • Page 98: Cable Routing

    Cable routing 2-49 a b c d e 1 1 2 3 4 5 6 7 8 9 11 10 12.

  • Page 99: Cable Routing

    Cable routing 2-50 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Hydraulic unit 5. Brake hose (front brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to proportioning valve) 7. Brake hose (hydraulic unit to metering valve) 8. Brake h...

  • Page 100: Cable Routing

    Cable routing 2-51 a b c 1 2 3 4 6 5 7 8 9 10 11 12.

  • Page 101: Cable Routing

    Cable routing 2-52 1. Auxiliary dc jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Left radiator fan 8. Coolant reservoir breather hose 9. Left horn (low) 10. Left horn (low) leads 11. Thermostat assembly breather...

  • Page 102: Cable Routing

    Cable routing 2-53 a-a b c c b a a a b c d f e h i j k l m n o p q r s t u v 1 2 6 6 8 14 14 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 g 6 7 3 5 4.

  • Page 103: Cable Routing

    Cable routing 2-54 1. Grip warmer couplers (for optional grip warmers) 2. Handlebar switch couplers 3. Right handlebar switch lead 4. Immobilizer unit lead 5. Main switch lead 6. Clutch hose 7. Left handlebar switch lead 8. Stator coil lead 9. Air filter case breather hose 10. Gear position switch l...

  • Page 104: Cable Routing

    Cable routing 2-55 a-a b-b c c b b a a a b c e d f g h i j k 2 2 1 1 4 4 4 5 5 5 6 7 8 9 10 11 12 13 3 3 3 14 15 16 17 16 17 18 19 20 21 22.

  • Page 105: Cable Routing

    Cable routing 2-56 1. Wire harness 2. Ecu (engine control unit) 3. Abs ecu (electronic control unit) 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Hydraulic unit breather hose 10. Stator coil lead 11. Rear shock abso...

  • Page 106: Cable Routing

    Cable routing 2-57 c b h a d e f g i i j k l m n o p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 31.

  • Page 107: Cable Routing

    Cable routing 2-58 1. Spark plug lead #1 2. Spark plug lead #2 3. Clutch hose 4. Front wheel sensor lead 5. Immobilizer unit lead 6. Main switch lead 7. Throttle cable (accelerator cable) 8. Throttle cable (decelerator cable) 9. Brake hose (hydraulic unit to front brake calipers) 10. Brake hose (met...

  • Page 108: Cable Routing

    Cable routing 2-59 d a b b c e 1 2 3 4.

  • Page 109: Cable Routing

    Cable routing 2-60 1. License plate light lead 2. Tail/brake light assembly lead 3. Seat lock cable 4. Intake air temperature sensor a. Route the tail/brake light assembly lead and license plate light lead between the rib and the u- lock holder on the rear fender, making sure that the leads are not ...

  • Page 110: Cable Routing

    Cable routing 2-61 a a a b c d e p f h i j k l m n q r 1 2 3 4 5 6 9 10 11 13 14 15 16 g 7 8 o 12.

  • Page 111: Cable Routing

    Cable routing 2-62 1. Windshield drive unit 2. Relay unit 3. Thermistor 4. Windshield drive unit lead 5. Meter assembly lead 6. Headlight relay (dimmer) 7. Left headlight beam adjusting cable 8. Left auxiliary light lead 9. Left headlight lead 10. Lean angle sensor 11. Right headlight lead 12. Right...

  • Page 112: Cable Routing

    Cable routing 2-63 c-c a b a b c c a b j c d f g g i 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 e h 11.

  • Page 113: Cable Routing

    Cable routing 2-64 1. Hydraulic unit 2. Proportioning valve 3. Brake hose (proportioning valve to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to metering valve) 6. Brake hose (hydraulic unit to front brake calipers) 7. Brake hose (fr...

  • Page 114: Cable Routing

    Cable routing 2-65.

  • Page 115

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance and lubrication chart ...................

  • Page 116

    Chassis ....................................................................................................... 3-21 adjusting the front disc brake ................................................ 3-21 adjusting the rear disc brake .................................................. 3-21 checking the...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-2 eau17670 note: • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake and clutch service • regularly check and, if necessary, correct the brake and clutch fluid levels. • every two years replace the internal componen...

  • Page 120: Engine

    Engine 3-3 eas20470 engine eas20490 adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead ce...

  • Page 121: Engine

    Engine 3-4 • measure the valve clearance in the following sequence. D. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft clockwise as specified in the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Remove: • camshafts...

  • Page 122: Engine

    Engine 3-5 example: if the valve pad is marked “155”, the pad thickness is 1.55 mm (0.061 in). D. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: 1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 1.58 mm (0.062 ...

  • Page 123: Engine

    Engine 3-6 2. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • t-bar refer to “general chassis” on page 4-1. 3. Remove: • caps “1” 4. Install: • vacuum gauge “1” • digital tachometer 5. Install: • fuel tank 6. Start the engine and let it wa...

  • Page 124: Engine

    Engine 3-7 9. Measure: • engine idling speed out of specification → adjust. Make sure that the vacuum pressure is within specification. 10.Stop the engine and remove the measuring equipment. 11.Adjust: • throttle cable free play refer to “adjusting the throttle ca- ble free play” on page 3-8. 12.Ins...

  • Page 125: Engine

    Engine 3-8 note: the co adjustment volume appears on the odometer/tripmeter/fuel reserve tripmeter lcd. • to decrease the co adjustment volume, press the “reset” button. • to increase the co adjustment volume, press the “select” button. 8. Simultaneously press the “select” and “reset” buttons to ret...

  • Page 126: Engine

    Engine 3-9 2. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • t-bar refer to “general chassis” on page 4-1. 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ throttle body side a. Loosen the locknut “1...

  • Page 127: Engine

    Engine 3-10 • insulator “2” abnormal color → replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: • spark plug gap “a” (with a wire thickness gauge) out of specification → regap. 8. Install: • spark plug note: befor...

  • Page 128: Engine

    Engine 3-11 b. Check that pointer “a” on the pickup rotor cov- er is within the firing range “b” on the pickup rotor. Incorrect firing range → check the ignition system. Note: the ignition timing is not adjustable. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Tighten: • timing mark accessing...

  • Page 129: Engine

    Engine 3-12 c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → eliminate. D. If the compression pressure is below the min- imum specification, pour a teaspoonful of en- gine oil into the s...

  • Page 130: Engine

    Engine 3-13 eas20780 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: • engine oil filler cap “1” • engine oil drain bolt “2” (along with the gasket) 4. Drain: • engine oil (completel...

  • Page 131: Engine

    Engine 3-14 b. Slightly loosen the engine oil check bolt “1”. C. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. D. Check the engine oil passages, the oil filter...

  • Page 132: Engine

    Engine 3-15 eas20860 adjusting the clutch lever 1. Adjust: • clutch lever position (distance “a” from the handlebar grip to the clutch lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the clutch lever forward, turn the adjusting dial “1” until the clutch lever is in the desi...

  • Page 133: Engine

    Engine 3-16 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Add the recommended clutch fluid to the proper level. B. Install the clutch master cylinder reservoir di- aphragm. C. Connect a clear plastic hose “1” tightly to the bleed screw “2”. D. Place the other end of the hose into a con- taine...

  • Page 134: Engine

    Engine 3-17 3. Install: • throttle body refer to “throttle bodies” on page 7-4. • air filter case refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • rider seat refer to “general chassis” on page 4-1. Eas21030 checking the fuel line 1. Remove: • rider seat refer t...

  • Page 135: Engine

    Engine 3-18 • gasket “3” exhaust gas leaks → replace. 3. Check: • tightening torque • exhaust pipe assembly nuts “4” • exhaust pipe assembly bolts “5” • exhaust pipe assembly and muffler bolts “6” • muffler bolts “7” 4. Install: • side cowlings refer to “general chassis” on page 4-1. Eas21110 checki...

  • Page 136: Engine

    Engine 3-19 • water pump outlet hose “10” cracks/damage → replace. Refer to “radiator” on page 6-1, “oil cooler” on page 6-4, “thermostat” on page 6-6 and “water pump” on page 6-10. 3. Install: • exhaust pipe assembly refer to “engine removal” on page 5-1. Eas21130 changing the coolant 1. Remove: • ...

  • Page 137: Engine

    Engine 3-20 7. Drain: • coolant (from the coolant reservoir) 8. Install: • coolant reservoir 9. Connect: • radiator outlet hose 10.Install: • coolant drain bolt (water pump) (along with the copper washer ) 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling no...

  • Page 138: Chassis

    Chassis 3-21 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake 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 lev...

  • Page 139: Chassis

    Chassis 3-22 air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. Caution: eca13510 after adjusting the brake pedal position, make sure there is no brake drag. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • rear bra...

  • Page 140: Chassis

    Chassis 3-23 1. Operate the brake. 2. Check: • front brake pad wear indicator grooves “1” almost disap- peared → replace the brake pads as a set. Refer to “front brake” on page 4-25. Eas21260 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake....

  • Page 141: Chassis

    Chassis 3-24 • 1st step: front brake calipers • 2nd step: right front brake caliper (unified brake system) • 3rd step: rear brake caliper warning ew3p61010 bleed the abs whenever: • the system is disassembled. • a brake hose is loosened, disconnected, or replaced. • the brake fluid level is very low...

  • Page 142: Chassis

    Chassis 3-25 caution: ec3p61029 make sure that the main switch is turned to “off” before checking the operation of the hydraulic unit. K. After operating the abs, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper level with the recomm...

  • Page 143: Chassis

    Chassis 3-26 4. Install: • final gear oil filler bolt eas21470 changing the final gear oil 1. Place a container under the final gear case. 2. Remove: • final gear oil filler bolt “1” • final gear oil drain bolt “2” completely drain the final gear case of its oil. 3. Check: • final gear oil drain bol...

  • Page 144: Chassis

    Chassis 3-27 c. Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding i...

  • Page 145: Chassis

    Chassis 3-28 e. Install the handlebar bolts “3” and nuts “2” temporarily. F. Tighten the handlebar bolts and nuts. Note: first tighten the bolts, then tighten the nuts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21530 checking the front fork 1. Stand the vehicle on a level surface. Warning...

  • Page 146: Chassis

    Chassis 3-29 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting knob “1” in direction “a” or “b”. ▲▲▲ ▲ ▲...

  • Page 147: Chassis

    Chassis 3-30 1. Adjust: • spring preload ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Move the adjusting lever “1” in direction “a” or “b”. B. Adjust the adjusting lever to “hard” or “soft”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping caution: eca13590 never go beyond t...

  • Page 148: Chassis

    Chassis 3-31 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ to close a side panel a. Remove the quick fastener screws “1”. B. Push the side panel to the closed position, and then install the quick fastener screws “1”. Note: make sure that the side...

  • Page 149: Chassis

    Chassis 3-32 c. Insert the projection “c” on the front of the rid- er seat into seat holder (for high position) “3” as shown. D. Align the high position projection “d” on the bottom of the rider seat with the “h” position slot “e”, and then push the rear of the seat down to lock it in place as shown...

  • Page 150: Chassis

    Chassis 3-33 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the ant...

  • Page 151: Chassis

    Chassis 3-34 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a t...

  • Page 152: Chassis

    Chassis 3-35 eas21720 lubricating the sidestand lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Eas21730 lubricating the centerstand lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Eas21740 lubricating the rear suspension lubricate the ...

  • Page 153: Electrical System

    Electrical system 3-36 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-145. Eas21770 checking the fuses refer to “electrical components” on page 8-145. Eas21790 replacing the headlight bulbs the following procedure applies to both of t...

  • Page 154: Electrical System

    Electrical system 3-37 right headlight ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ direction “a” headlight beam moves to the left. Direction “b” headlight beam moves to the right. Direction “a” headlight beam moves to the right. Direction “b” headlight beam moves to the left. 1 b a b a.

  • Page 155: Chassis

    4 chassis general chassis....................................................................................... 4-1 removing the side panels .............................................................. 4-7 installing the front cowling left inner panel 2 ................ 4-7 installing the front c...

  • Page 156

    Rear brake ............................................................................................... 4-37 introduction ..................................................................................... 4-43 checking the rear brake disc.................................................... 4-4...

  • Page 157

    Swingarm................................................................................................... 4-83 removing the swingarm................................................................ 4-85 checking the swingarm ................................................................ 4-85 inst...

  • Page 158: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats and covers order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 1 3 grab bar 1 4 left rear cowling 1 5 right rear cowling 1 6 center rear cowling 1 7 left side cover 1 8 right side cover 1 9 rider seat height position ...

  • Page 159: General Chassis

    General chassis 4-2 removing the front cowling assembly order job/parts to remove q’ty remarks open the accessory box lid. 1 left side panel 1 2 left side cowling 1 3 front left turn signal light coupler 1 disconnect. 4 right side panel 1 5 right side cowling 1 6 front right turn signal light couple...

  • Page 160: General Chassis

    General chassis 4-3 17 handlebar switch coupler 2 disconnect. 18 front cowling wire harness coupler 5 disconnect. 19 horn connector 4 disconnect. 20 front cowling assembly 1 for installation, reverse the removal proce- dure. Removing the front cowling assembly order job/parts to remove q’ty remarks ...

  • Page 161: General Chassis

    General chassis 4-4 disassembling the front cowling assembly order job/parts to remove q’ty remarks front cowling assembly refer to “removing the front cowling assem- bly”. 1 windshield outer bracket 1 2 windshield 1 3 windshield upper inner bracket 1 4 windshield lower inner bracket 1 5 rearview mi...

  • Page 162: General Chassis

    General chassis 4-5 removing the headlight assembly order job/parts to remove q’ty remarks front cowling refer to “disassembling the front cowling assembly”. 1 headlight assembly 1 for installation, reverse the removal proce- dure. 1.

  • Page 163: General Chassis

    General chassis 4-6 removing the windshield drive unit, meter assembly, and relays order job/parts to remove q’ty remarks front cowling stay refer to “disassembling the front cowling assembly”. 1 windshield drive unit coupler 2 disconnect. 2 windshield drive unit side rail 2 3 windshield drive unit ...

  • Page 164: General Chassis

    General chassis 4-7 et3p61037 removing the side panels 1. Remove: • side panel “1” note: to release a pin on the side panel “1” from its corresponding hinge on the side cowling “2”, push the end “a” of the hinge with a flathead screwdriver. Et3p61038 installing the front cowling left inner panel 2 1...

  • Page 165: General Chassis

    General chassis 4-8 i. Insert the adjusting knob shaft into the hole in inner panel 2, making sure to align the projec- tion “a” on the shaft's sleeve with the slot “b” in the panel, and then install the nut. J. Install the headlight beam adjusting knob “4”. K. Install the hexagon socket bolts and t...

  • Page 166: General Chassis

    General chassis 4-9 b a 1 2.

  • Page 167: General Chassis

    General chassis 4-10 removing the t-bar order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 t-bar 1 2 heat protector 1 for installation, reverse the removal proce- dure. 1 2 t r . . 37 nm (3.7 m • kg, 27 ft • ib) t r...

  • Page 168: General Chassis

    General chassis 4-11 removing the air filter case order job/parts to remove q’ty remarks left side cover/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air shroud 1 2 air duct 1 3 air filter case cover 1 4 air filter element 1 5 tool kit 1 6 ecu coupler 1...

  • Page 169: General Chassis

    General chassis 4-12 15 air filter case joint assembly 1 16 air filter case 1 17 air filter case breather hose 2 18 filter assembly 1 for installation, reverse the removal proce- dure. Removing the air filter case order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . ...

  • Page 170: Front Wheel

    Front wheel 4-13 eas21880 front wheel removing the front wheel, brake discs, wheel sensor, and sensor housing order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 front fender 1 2 front wheel sensor coupler 1 di...

  • Page 171: Front Wheel

    Front wheel 4-14 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 172: Front Wheel

    Front wheel 4-15 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • front wheel sensor • front brake calipers caution: ec3p61020 • be sure not to contact the sensor elect...

  • Page 173: Front Wheel

    Front wheel 4-16 4. Check: • wheel bearings front wheel turns roughly or is loose → re- place the wheel bearings. • oil seals damage/wear → replace. Eas22010 maintenance of the front wheel sensor and sensor rotor caution: ec3p61031 • handle the abs components with care since they have been accuratel...

  • Page 174: Front Wheel

    Front wheel 4-17 eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: ec3p61021 do not contact the wheel bearing inner race “1” or b...

  • Page 175: Front Wheel

    Front wheel 4-18 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • front wheel static balance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ...

  • Page 176: Front Wheel

    Front wheel 4-19 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 nm (9.1 m·kg, 66 ft·lb). B. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to...

  • Page 177: Rear Wheel

    Rear wheel 4-20 eas22030 rear wheel removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks storage compartment refer to “general chassis” on page 4-1. 1 rear wheel sensor coupler 1 disconnect. 2 rear wheel sensor 1 3 rear wheel axle pinch bolt 1 ...

  • Page 178: Rear Wheel

    Rear wheel 4-21 disassembling the rear wheel order job/parts to remove q’ty remarks 1 dust cover 1 2 rear wheel drive hub 1 3 dust seal 1 4 wheel bearing 1 5 rear wheel drive hub damper 6 6 oil seal 1 7 circlip 1 8 wheel bearing 1 9 spacer 1 10 spacer 1 11 oil seal 1 12 bearing 1 for assembly, rever...

  • Page 179: Rear Wheel

    Rear wheel 4-22 eas22050 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on the centerstand so that the rear wheel is elevated. 2. Remove: • rear wheel sensor • rear ...

  • Page 180: Rear Wheel

    Rear wheel 4-23 2. Install: • wheel bearings • oil seals refer to “assembling the front wheel” on page 4-17. Eas22150 adjusting the rear wheel static balance note: • after replacing the tire, wheel, or both, the rear wheel static balance should be adjusted. • adjust the rear wheel static balance wit...

  • Page 181: Rear Wheel

    Rear wheel 4-24 5. Tighten: • brake torque rod nuts • rear wheel axle nut • rear wheel axle pinch bolt 6. Install: • rear wheel sensor caution: eca14500 to route the rear wheel sensor lead, refer to “cable routing” on page 2-45. Note: when installing the rear wheel sensor, check the rear wheel senso...

  • Page 182: Front Brake

    Front brake 4-25 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 front brake caliper 1 3 brake pad bolt 2 4 brake pad spring 2 5 front brake pad 4 for installation, ...

  • Page 183: Front Brake

    Front brake 4-26 * apply silicon grease removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-23. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm hold- er 1...

  • Page 184: Front Brake

    Front brake 4-27 * apply silicon grease disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 185: Front Brake

    Front brake 4-28 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-23. 1 brake hose holder 1 2 brake hose union bolt 1 3 coppe...

  • Page 186: Front Brake

    Front brake 4-29 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad bolt 2 2 brake pad spring 2 3 front brake pad 4 4 brake caliper piston 4 5 brake caliper piston seal 8 6 bleed screw 1 7 ble...

  • Page 187: Front Brake

    Front brake 4-30 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 188: Front Brake

    Front brake 4-31 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. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 189: Front Brake

    Front brake 4-32 3. Lubricate: • brake pad bolts caution: eca14150 • do not allow grease to contact the brake pads. • remove any excess grease. 4. Install: • brake pad bolts • brake caliper 5. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper...

  • Page 190: Front Brake

    Front brake 4-33 warning ewa13560 • cover the brake caliper pistons with a rag. Be careful not to get injured when the pis- tons are expelled from the brake caliper. • never try to pry out the brake caliper pis- tons. B. Remove the brake caliper piston seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 191: Front Brake

    Front brake 4-34 caution: eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper. 2. Remove: • brake caliper 3. Install: • brake pads • brake pad springs • brake pad bolts • brake caliper • brake hose holder re...

  • Page 192: Front Brake

    Front brake 4-35 eas22490 removing the front brake master cylinder note: before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • brake hose union bolt “1” • copper washers “2” • brake hose (front brake master cylinder to hydraulic unit) “3”...

  • Page 193: Front Brake

    Front brake 4-36 warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-45. Caution: ec3p61025 when installing the brake hose onto the brake master cylinder, make sure the brake pipe “a” touches the projection “b” on the brake m...

  • Page 194: Rear Brake

    Rear brake 4-37 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 rear brake caliper 1 3 brake pad shim 2 4 rear brake pad 2 5 brake pad spring 2 for installation, reverse the removal proce- dure..

  • Page 195: Rear Brake

    Rear brake 4-38 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-23. Right side cover/storage compartment refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 brake flui...

  • Page 196: Rear Brake

    Rear brake 4-39 12 rear brake master cylinder 1 for installation, reverse the removal proce- dure. Removing the rear brake master cylinder order job/parts to remove q’ty remarks 1 2 3 4 5 6 7 9 10 11 8 12 t r . . 28 nm (2.8 m • kg, 20 ft • ib) new new t r . . 28 nm (2.8 m • kg, 20 ft • ib) t r . . 3...

  • Page 197: Rear Brake

    Rear brake 4-40 * apply silicon grease disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder push rod 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 198: Rear Brake

    Rear brake 4-41 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-23. 1 brake hose union bolt 1 2 copper washer 2 3 brake hose (proportioning valve to rear brake caliper) 1 4 rear brake caliper bol...

  • Page 199: Rear Brake

    Rear brake 4-42 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 brake pad shim 2 3 rear brake pad 2 4 brake pad spring 2 5 rear brake caliper bracket 1 6 brake caliper piston 1 7 brake caliper piston seal 2 8 bleed screw 1 for assembly, rever...

  • Page 200: Rear Brake

    Rear brake 4-43 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 201: Rear Brake

    Rear brake 4-44 note: always install new brake pads, brake pad shims, and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw ...

  • Page 202: Rear Brake

    Rear brake 4-45 eas22600 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston seals “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. Warning ...

  • Page 203: Rear Brake

    Rear brake 4-46 • rear wheel axle nut note: • do not install the brake pads, brake pad shims, and brake pad springs. • align the slot “a” of the rear wheel sensor hous- ing “1” with the projection “b” of the rear brake caliper bracket “2”, and then assemble them. • after assembling the rear wheel se...

  • Page 204: Rear Brake

    Rear brake 4-47 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...

  • Page 205: Rear Brake

    Rear brake 4-48 eas22740 installing the rear brake master cylinder 1. Install: • copper washers • brake hose (rear brake master cylinder to hy- draulic unit) “1” • rear brake hose union bolt “2” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cab...

  • Page 206: Rear Brake

    Rear brake 4-49 7. Adjust: • brake pedal position refer to “adjusting the rear disc brake” on page 3-21. 8. Adjust: • rear brake light operation timing refer to “adjusting the rear brake light switch” on page 3-23..

  • Page 207: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-50 eas22760 abs (anti-lock brake system) et3p61060 abs components chart 1 4 5 6 7 9,10 11 12 2 3 a a 16 18 13 4 8 14 15 17 15 2 3 1 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (hydraulic unit to front brake calipers) 3. Brake hose (front b...

  • Page 208: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-51 removing the rear fender assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Abs ecu/abs motor relay refer to “abs (anti-lock brake sys- tem)” on page 8-111. Brake fluid drain. Refer to “bleeding the hydraulic brak...

  • Page 209: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-52 removing the hydraulic unit order job/parts to remove q’ty remarks 1 brake hose union bolt/copper washer 1/2 2 brake hose (front brake master cylinder to hy- draulic unit) 1 disconnect. 3 brake hose union bolt/copper washer 1/2 4 brake hose (rear brake master cylind...

  • Page 210: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-53 15 brake hose (metering valve to right front brake caliper) 1 disconnect. 16 metering valve 1 17 brake hose (proportioning valve to rear brake caliper) 1 18 proportioning valve 1 for installation, reverse the removal proce- dure. Removing the hydraulic unit order jo...

  • Page 211: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-54 et3p61055 removing the hydraulic unit caution: eca14510 do not remove the hydraulic unit to check the resistance of the solenoid valves and the abs motor for continuity. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing ...

  • Page 212: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 et3p61057 checking the proportioning valve and metering valve 1. Check: • proportioning valve cracks/damage → replace the proportioning valve. • metering valve cracks/damage → replace the metering valve et3p61058 installing the hydraulic unit proceed in the reverse ...

  • Page 213: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-56 • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the s...

  • Page 214: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-57 6. Turn the main switch to “on” while operating the brake lever and the brake pedal simulta- neously. Note: this check cannot be performed unless both the brake lever and the brake pedal are operated si- multaneously when the main switch is turned to “on”. 7. Check:...

  • Page 215: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-58 • if the pulse is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hy- draulic unit. • if the operation of the hydraulic unit is normal, delete all of the malfunction codes. Hydraulic unit operation test...

  • Page 216: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-59 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. 10.A reaction-force pulsating action is generated in the brake lever “1” 0.5 second after the brake lever and the brake pedal are operated simultaneously and continues...

  • Page 217: Handlebars

    Handlebars 4-60 eas22850 handlebars removing the left handlebar order job/parts to remove q’ty remarks 1 clutch switch coupler 1 disconnect. 2 clutch master cylinder holder 1 3 clutch master cylinder assembly 1 4 left handlebar 1 5 lead holder 1 6 left handlebar switch 1 7 grip end 1 8 handlebar gri...

  • Page 218: Handlebars

    Handlebars 4-61 removing the right handlebar order job/parts to remove q’ty remarks 1 front brake light switch connector 2 disconnect. 2 front brake master cylinder holder 1 3 front brake master cylinder assembly 1 4 grip end 1 5 throttle cable housing 2 6 throttle cable 2 disconnect. 7 throttle gri...

  • Page 219: Handlebars

    Handlebars 4-62 eas22870 removing the handlebars 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the handlebar grip, and gradually...

  • Page 220: Handlebars

    Handlebars 4-63 • left handlebar note: fit the projections on each handlebar into the holes in the upper bracket, making sure that the handlebars are installed in the same position. 6. Install: • handlebar bolts “1” (temporarily) • handlebar nuts “2” (temporarily) 7. Tighten: • handlebar bolts • han...

  • Page 221: Handlebars

    Handlebars 4-64 note: • install the clutch master cylinder holder with the “up” mark facing up • align the mating surfaces of the clutch master cylinder holder with the punch mark “a” on the left handlebar. • first, tighten the upper bolt, then the lower bolt. 11.Adjust: • throttle cable free play r...

  • Page 222: Front Fork

    Front fork 4-65 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front cowling assembly refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-13. 1 battery holder 1 2...

  • Page 223: Front Fork

    Front fork 4-66 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 nut 1 4 damper adjusting rod 1 5 spacer 1 6 washer 1 7 fork spring 1 8 dust seal 1 9 oil seal clip 1 10 oil seal 1 11 was...

  • Page 224: Front Fork

    Front fork 4-67 17 inner tube 1 18 outer tube bushing 1 1 d = 52 mm (2.05 in), l = 12 mm (0.47 in) 19 outer tube bushing 2 1 d = 51 mm (2.01 in), l = 15 mm (0.59 in) 20 inner tube bushing 1 21 outer tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the front fork legs order job...

  • Page 225: Front Fork

    Front fork 4-68 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 226: Front Fork

    Front fork 4-69 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull up the inner tube completely, fill it with oil up to the top, and then install the cap bolt. Note: do not install the fork spring. B. Place the front fork leg in a press and gradu- ally apply pressure to remove the oil seal. C...

  • Page 227: Front Fork

    Front fork 4-70 3. Check: • damper rod assembly damage/wear → replace. Obstruction → blow out all of the oil passag- es with compressed air. • oil flow stopper damage → replace. Caution: eca14200 • the front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construct...

  • Page 228: Front Fork

    Front fork 4-71 4. Install: • outer tube bushing 2 (d = 51 mm (2.01 in), l = 15 mm (0.59 in)) “1” (with the slide metal installer “2” and fork seal driver “3”) 5. Install: • outer tube bushing 1 (d = 52 mm (2.05 in), l = 12 mm (0.47 in)) “1” • washer “2” (with the fork seal driver “3”) 6. Install: •...

  • Page 229: Front Fork

    Front fork 4-72 8. Install: • dust seal “1” (with the fork seal driver “2”) 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) caution: eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disasse...

  • Page 230: Front Fork

    Front fork 4-73 note: install the fork spring so that the end “a” shown in the illustration is facing up. 15.Install: • nut “1” • damper adjusting rod “2” • cap bolt “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the nut “1” and finger tighten it. B. Install the damper adjusting ro...

  • Page 231: Front Fork

    Front fork 4-74 3. Adjust: • spring preload • rebound damping • compression damping refer to “adjusting the front fork legs” on page 3-28..

  • Page 232: Steering Head

    Steering head 4-75 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Handlebars refer to “handlebars” on page 4-60. Front fork legs refer to “front fork” on pag...

  • Page 233: Steering Head

    Steering head 4-76 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 upper bearing cover 1 16 upper bearing inner race 1 17 upper bearing 1 18 lower bearing 1 19 dust seal 1 20 lower bearing inner race 1 21 upper bearing outer race 1 22 lower bearing outer race 1 for installation, reverse...

  • Page 234: Steering Head

    Steering head 4-77 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 235: Steering Head

    Steering head 4-78 • lock washer “4” refer to “checking and adjusting the steering head” on page 3-26. 3. Install: • upper bracket • steering stem nut note: temporarily tighten the steering stem nut. 4. Install: • front fork legs refer to “front fork” on page 4-65. Note: temporarily tighten the uppe...

  • Page 236: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-79 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-20. Mufflers/exhaust pipe assembly refer to “eng...

  • Page 237: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-80 11 relay arm 1 12 spacer 1 13 spacer 1 14 spacer 1 15 oil seal 6 16 bearing 2 17 bearing 2 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order job/parts to remove q’ty remarks new new new new t r . . 7 nm (0.7 m • kg, 5...

  • Page 238: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-81 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 239: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-82 • rear shock absorber gas leaks/oil leaks → replace the rear shock absorber assembly. • spring damage/wear → replace the rear shock ab- sorber assembly. • bushing damage/wear → replace the rear shock ab- sorber assembly. • spacer damage/scratches → replace. • bolts ...

  • Page 240: Swingarm

    Swingarm 4-83 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-20. Rear shock absorber assembly/connecting arms refer to “rear shock absorber as- sembly” on page 4-79. Final drive assembly/universal joint refer to “shaft drive”...

  • Page 241: Swingarm

    Swingarm 4-84 13 spacer 1 14 oil seal 1 15 circlip 1 16 bearing 1 17 spacer 1 18 bearing 1 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 28 nm (2.8...

  • Page 242: Swingarm

    Swingarm 4-85 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swinga...

  • Page 243: Swingarm

    Swingarm 4-86 3. Tighten: • pivot shaft • pivot shaft locknut • pivot shaft nut 3. Swingarm 4. Connecting arm a. Left side b. Right side t r . . Pivot shaft 23 nm (2.3 m·kg, 17 ft·lb) t r . . Pivot shaft locknut 115 nm (11.5 m·kg, 85 ft·lb) t r . . Pivot shaft nut 125 nm (12.5 m·kg, 90 ft·lb) 1 3 a ...

  • Page 244: Shaft Drive

    Shaft drive 4-87 eas23550 shaft drive removing the final drive assembly order job/parts to remove q’ty remarks final gear oil drain. Refer to “changing the engine oil” on page 3-13. Rear wheel refer to “rear wheel” on page 4-20. 1 final drive assembly 1 for installation, reverse the removal proce- d...

  • Page 245: Shaft Drive

    Shaft drive 4-88 removing the universal joint order job/parts to remove q’ty remarks 1 shift arm 1 2 left footrest assembly 1 3 sidestand switch coupler 1 disconnect. 4 sidestand 1 5 drive shaft dust cover 1 6 universal joint dust cover 1 7 universal joint 1 for installation, reverse the removal pro...

  • Page 246: Shaft Drive

    Shaft drive 4-89 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 circlip 2 2 oil seal 1 3 drive shaft 1 4 spring 1 5 ring gear bearing housing 1 6 dust cover 1 7 oil seal 1 8 stopper bolt 1 left-hand threads 9 stopper bolt shim(s) 10 ring gear shim(s) 11 ring gear 1 1...

  • Page 247: Shaft Drive

    Shaft drive 4-90 * apply shaft drive gear oil (part no.: 9079e-sh001-00) 18 final drive pinion gear 1 19 bearing 1 20 final drive pinion gear shim(s) 21 final drive pinion gear bearing 1 22 ring gear bearing 1 23 oil seal 1 24 collar 1 25 final gear case 1 for assembly, reverse the disassembly pro- ...

  • Page 248: Shaft Drive

    Shaft drive 4-91 eas23560 troubleshooting note: causes a, b and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual. I...

  • Page 249: Shaft Drive

    Shaft drive 4-92 no → yes ↓ yes → no ↓ eas23570 checking the final drive oil for contamination and checking the shaft drive for leaks 1. Drain: • final gear oil (from the final gear case) refer to “changing the final gear oil” on page 3-26. 2. Check: • final gear oil large amount of metal particles ...

  • Page 250: Shaft Drive

    Shaft drive 4-93 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install a bolt “1” of the specified size, into the final gear oil drain hole. B. Finger tighten the bolt until it stops the ring gear from moving. Note: do not overtighten the bolt. C. Install the final gear backlash band “2” and ...

  • Page 251: Shaft Drive

    Shaft drive 4-94 b. If it is necessary to increase the final gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. C. If it is necessary to reduce the final gear back- lash by more than 0.2 mm, increase the thrust washe...

  • Page 252: Shaft Drive

    Shaft drive 4-95 • apply loctite ® onto the stopper bolt. 4. Measure: • ring-gear-to-stopper-bolt clearance note: if the ring-gear-to-stopper-bolt clearance is out of specification, repeat the above procedure. Eas23620 disassembling the final drive assembly 1. Remove: • ring gear bearing housing bol...

  • Page 253: Shaft Drive

    Shaft drive 4-96 eas23630 removing and installing the bearings 1. Check: • bearings damage → replace. 2. Remove: • collar “1” • oil seal “2” • bearing “3” (with an appropriate press tool “4” and an ap- propriate support for the final gear case) 3. Remove: • bearing “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 254: Shaft Drive

    Shaft drive 4-97 b. To find final drive pinion gear shim thickness “a”, use the following formula: where: a = 84 b = a numeral on the final gear case, to be di- vided by 100 and added to “83”. Example: if the final drive pinion gear is marked “+01” and the final gear case is marked “50”: therefore, ...

  • Page 255: Shaft Drive

    Shaft drive 4-98 f = the ring gear bearing thickness constant. Example: if the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “- 05”, and “f” is 13.00: therefore, the calculated ring gear shim thickness is 0.41 mm. Shim sizes are supplied in the...

  • Page 256: Shaft Drive

    Shaft drive 4-99 4. Stake the coupling gear nut “1” at a cutout “a” in the final drive pinion gear. 5. Install: • ring gear bearing housing (along with the ring gear, but without the thrust washer) 6. Adjust: • final gear backlash refer to “measuring the final gear backlash” on page 4-92 and “adjust...

  • Page 257: Shaft Drive

    Shaft drive 4-100 eas23660 installing the drive shaft and final drive assembly 1. Lubricate: • drive shaft spline (final drive pinion gear side) 2. Lubricate: • drive shaft spline (universal joint side) 3. Install: • oil seal “1” • washer “2” (with the fork seal driver weight “3” and fork seal drive...

  • Page 258: Shaft Drive

    Shaft drive 4-101.

  • Page 259: Engine

    5 engine engine removal ........................................................................................ 5-1 removing the engine ........................................................................ 5-6 installing the engine....................................................................

  • Page 260

    Clutch ........................................................................................................ 5-41 removing the clutch ..................................................................... 5-48 checking the friction plates..................................................... 5-48 c...

  • Page 261

    Crankcase ................................................................................................ 5-74 disassembling the crankcase.................................................... 5-78 checking the crankcase .............................................................. 5-78 checking the...

  • Page 262: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the exhaust pipe assembly order job/parts to remove q’ty remarks left side cowling/right side cowling/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3...

  • Page 263: Engine Removal

    Engine removal 5-2 disconnecting the leads and hoses order job/parts to remove q’ty remarks front fender refer to “front wheel” on page 4-13. Air filter case refer to “general chassis” on page 4-1. Throttle bodies refer to “throttle bodies” on page 7-4. Air cut-off valve/reed valves refer to “air in...

  • Page 264: Engine Removal

    Engine removal 5-3 5 oil level switch coupler 1 disconnect. 6 crankshaft position sensor coupler 1 disconnect. 7 gear position switch coupler 1 disconnect. 8 ground lead 1 disconnect. 9 spark plug cap 4 for installation, reverse the removal proce- dure. Disconnecting the leads and hoses order job/pa...

  • Page 265: Engine Removal

    Engine removal 5-4 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the engine. 1 brake pedal 1 2 engine mounting bolt (left rear side) 2 3 engine bracket bolt (left rear side) 1 4 engine bracket (left rear side) 1 5 engine bracket bolt (top) 4 6 engine m...

  • Page 266: Engine Removal

    Engine removal 5-5 16 spacer bolt 1 loosen. 17 engine mounting bolt (rear lower side) 1 18 spacer 1 19 engine mounting bolt (rear upper side) 1 20 engine 1 for installation, reverse the removal proce- dure. Removing the engine order job/parts to remove q’ty remarks t r . . 32 nm (3.2 m • kg, 23 ft •...

  • Page 267: Engine Removal

    Engine removal 5-6 et3p61023 removing the engine 1. Loosen: • spacer bolt note: loosen the spacer bolt with the pivot shaft wrench “1” and pivot shaft wrench adapter “2”. Eas23720 installing the engine 1. Install: • engine note: when mounting the engine to the frame, be sure to align the splines on ...

  • Page 268: Engine Removal

    Engine removal 5-7 6. Tighten: • engine mounting nut (rear upper side) “14” note: lubricate the engine mounting nut (rear upper side) threads with engine oil. 7. Tighten: • engine mounting bolt (left front lower side) “6” • engine mounting bolt (right front upper side) “8” • engine mounting bolt (ri...

  • Page 269: Engine Removal

    Engine removal 5-8 note: do not fully tighten the bolts. 14.Tighten: • engine bracket bolt (left rear side) “2” 15.Tighten: • engine mounting bolts (left rear side) “3” 16.Install: • brake pedal “1” note: align the punch mark “a” on the brake pedal with the punch mark “b” on the brake pedal pivot sh...

  • Page 270: Camshafts

    Camshafts 5-9 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Air cut-off valve/reed valves refer to “air induction system” on page 7-9. 1 spark plug 4 2 cylinder identification sensor 1 3 cylinder ...

  • Page 271: Camshafts

    Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-34. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft cap 4 4 exhaust camshaft cap 4 ...

  • Page 272: Camshafts

    Camshafts 5-11 eas23810 removing the camshafts 1. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick-...

  • Page 273: Camshafts

    Camshafts 5-12 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: • camshaft runout out of specification → replace. 4. Me...

  • Page 274: Camshafts

    Camshafts 5-13 note: • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the plastigauge ® . D. Remove the camshaft caps and then mea- sure the width of ...

  • Page 275: Camshafts

    Camshafts 5-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24010 installing the camshafts 1. Install: • exhaust camshaft sprocket • intake camshaft sprocket note: • while holding the camshaft sprockets with the rotor holding tool “1”, tighten the camshaft sprocket bolts. • make sure that th...

  • Page 276: Camshafts

    Camshafts 5-15 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • exhaust camshaft caps • intake camshaft caps note: • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “e”, “e1”, “e2”, “e3”: exhaust “i”, “i1”, “i2”, “i3”: inta...

  • Page 277: Camshafts

    Camshafts 5-16 d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Turn: • crankshaft (several turns clockwise) 8. Check: • “t” mark make sure the “t” mark “a” on t...

  • Page 278: Camshafts

    Camshafts 5-17.

  • Page 279: Cylinder Head

    Cylinder head 5-18 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Camshafts refer to “camshafts” on page 5-9. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the removal proce- ...

  • Page 280: Cylinder Head

    Cylinder head 5-19 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts note: • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: • co...

  • Page 281: Cylinder Head

    Cylinder head 5-20 e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Warning ew3p61014 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a...

  • Page 282: Valves and Valve Springs

    Valves and valve springs 5-21 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-18. 1 valve lifter 16 2 valve pad 16 3 valve cotter 32 4 upper spring seat 16 5 intake valve spring 8 6 exhaus...

  • Page 283: Valves and Valve Springs

    Valves and valve springs 5-22 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lif...

  • Page 284: Valves and Valve Springs

    Valves and valve springs 5-23 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼...

  • Page 285: Valves and Valve Springs

    Valves and valve springs 5-24 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness ...

  • Page 286: Valves and Valve Springs

    Valves and valve springs 5-25 4. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ...

  • Page 287: Valves and Valve Springs

    Valves and valve springs 5-26 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve ...

  • Page 288: Valves and Valve Springs

    Valves and valve springs 5-27 4. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • upper spring seat “5” (into the cylinder head) note: • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 5....

  • Page 289: Generator and Starter Clutch

    Generator and starter clutch 5-28 eas24480 generator and starter clutch removing the generator rotor and starter clutch order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the ...

  • Page 290: Generator and Starter Clutch

    Generator and starter clutch 5-29 10 starter clutch 1 for installation, reverse the removal proce- dure. Removing the generator rotor and starter clutch order job/parts to remove q’ty remarks.

  • Page 291: Generator and Starter Clutch

    Generator and starter clutch 5-30 removing the stator coil assembly order job/parts to remove q’ty remarks 1 stator coil assembly lead holder 1 2 stator coil assembly 1 for installation, reverse the removal proce- dure..

  • Page 292: Generator and Starter Clutch

    Generator and starter clutch 5-31 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer note: while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff key cau...

  • Page 293: Generator and Starter Clutch

    Generator and starter clutch 5-32 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24600 installing the starter clutch 1. Install: • starter clutch • starter clutch bolts “1” note: while holding the generator rotor with the sheave holder, tighten the starter clutch bolts. Eas24500 installing the...

  • Page 294: Generator and Starter Clutch

    Generator and starter clutch 5-33 note: tighten the generator cover bolts in stages and in a crisscross pattern..

  • Page 295: Pickup Rotor

    Pickup rotor 5-34 eas24520 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks side cowlings/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Generator cover refer to “generator and starter clutch” on page 5-28. 1 pickup ro...

  • Page 296: Pickup Rotor

    Pickup rotor 5-35 eas24530 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3” note: while holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. Eas24540 installing the pickup rotor 1. Install: • pickup rotor “1” • washer •...

  • Page 297: Pickup Rotor

    Pickup rotor 5-36 4. Install: • pickup rotor cover gasket • pickup rotor cover note: tighten the pickup rotor cover bolts in stages and in a crisscross pattern. T r . . Pickup rotor cover bolt 12 nm (1.2 m·kg, 8.7 ft·lb) new.

  • Page 298: Electric Starter

    Electric starter 5-37 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure..

  • Page 299: Electric Starter

    Electric starter 5-38 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 brush 2 4 brush seat (along with brushes) 1 5 washer 1 6 lock washer 1 7 oil seal 1 8 bearing 1 9 starter motor rear cover 1 10 collar 1 11 o-ring 2 12 starter moto...

  • Page 300: Electric Starter

    Electric starter 5-39 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “1” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 301: Electric Starter

    Electric starter 5-40 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” note: align the slot “a” on the brush seat with the tab “b” in the starter motor...

  • Page 302: Clutch

    Clutch 5-41 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-13. 1 clutch cover 1 2 clutch cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 303: Clutch

    Clutch 5-42 removing the clutch order job/parts to remove q’ty remarks rear balancer refer to “balancers” on page 5-103. 1 oil guide plate 1 2 clutch spring plate retainer 1 3 clutch spring plate 1 4 clutch spring plate seat 1 5 pressure plate 1 6 short clutch push rod 1 7 ball 1 8 long clutch push ...

  • Page 304: Clutch

    Clutch 5-43 17 thrust washer 1 18 spacer 1 19 clutch housing 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks 19 18 17 16 14 15 12 11 10 9 8 7 6 5 4 3 2 1 13 (6) new new lt t r . . 90 nm (9.0 m • kg, 65 ft • ib) t r . . 10 nm (1.0 m • kg...

  • Page 305: Clutch

    Clutch 5-44 * apply silicon grease removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. 1 clutch master cylinder reservoir cap 1 2 clutch master cylinder reservoir diaphragm holder 1 3 clutch mast...

  • Page 306: Clutch

    Clutch 5-45 * apply silicon grease disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 washer 1 5 clutch master cylinder kit 1 6 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure...

  • Page 307: Clutch

    Clutch 5-46 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. 1 clutch hose union bolt 1 2 copper washer 2 3 clutch hose 1 disconnect. 4 clutch release cylinder 1 5 dowel pin 2 6 plate 1 for i...

  • Page 308: Clutch

    Clutch 5-47 disassembling the clutch release cylinder order job/parts to remove q’ty remarks 1 clutch release cylinder piston 1 2 clutch release cylinder spring 1 3 clutch release cylinder piston seal 1 4 bleed screw 1 5 clutch release cylinder body 1 for assembly, reverse the disassembly pro- cedur...

  • Page 309: Clutch

    Clutch 5-48 eas25080 removing the clutch 1. Remove: • clutch cover “1” note: loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • rear balancer weight refer to “balancers” on page 5-103. 3. Remove: • c...

  • Page 310: Clutch

    Clutch 5-49 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 311: Clutch

    Clutch 5-50 eas25170 checking the pressure plate 1. Check: • pressure plate cracks/damage → replace. • bearing damage/wear → replace. Eas25190 checking the clutch push rods 1. Check: • o-ring • short clutch push rod • long clutch push rod • ball cracks/damage/wear → replace the defec- tive part(s). ...

  • Page 312: Clutch

    Clutch 5-51 • lock washer “2” • clutch boss nut “3” note: • install the clutch boss nut with its large inner di- ameter side facing inward as shown in the illus- tration. • while holding the clutch boss with the univer- sal clutch holder “4”, tighten the clutch boss nut. 4. Bend the lock washer tab ...

  • Page 313: Clutch

    Clutch 5-52 • if any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly. • never use solvents on internal clutch com- ponents. • use only clean or new clutch fluid for clean- ing clu...

  • Page 314: Clutch

    Clutch 5-53 2. Install: • copper washers “1” • clutch hose “2” • clutch hose union bolt “3” warning ew3p61017 proper clutch hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-45. Caution: ec3p61034 when installing the clutch hose onto the clutch master c...

  • Page 315: Clutch

    Clutch 5-54 et3p61024 removing the clutch release cylinder 1. Remove: • clutch hose union bolt “1” • copper washers “2” • clutch hose “3” note: put the end of the clutch hose into a container and pump out the clutch fluid carefully. Eas25330 checking the clutch release cylinder 1. Check: • clutch re...

  • Page 316: Clutch

    Clutch 5-55 warning ewa13370 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful c...

  • Page 317: Shift Shaft

    Shift shaft 5-56 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-41. 1 oil baffle plate 1 1 2 shift arm 1 3 circlip 1 4 shift shaft 1 5 shift shaft spring 1 6 spacer 1 7 stopper lever spring 1 8 stopper...

  • Page 318: Shift Shaft

    Shift shaft 5-57 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • shift lever sp...

  • Page 319: Oil Pump

    Oil pump 5-58 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-13. Throttle bodies refer to “throttle bodies” on page 7-4. Exhaust pipe assembly refer to “engine removal” on page 5-1. Sidestand r...

  • Page 320: Oil Pump

    Oil pump 5-59 11 relief valve assembly 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks.

  • Page 321: Oil Pump

    Oil pump 5-60 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump driven sprocket 1 8 oil pump housing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 322: Oil Pump

    Oil pump 5-61 eas24960 checking the oil pump 1. Check: • oil pump driven sprocket • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-ho...

  • Page 323: Oil Pump

    Oil pump 5-62 1. Check: • oil delivery pipes damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer ...

  • Page 324: Middle Gear

    Middle gear 5-63 eas25710 middle gear removing the middle gear order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Oil pan/oil pump refer to “oil pump” on page 5-58. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 325: Middle Gear

    Middle gear 5-64 15 spacer 1 16 middle driven gear 1 17 bearing retainer 1 18 bearing 1 19 middle drive pinion gear shim 20 bearing 1 for installation, reverse the removal proce- dure. Removing the middle gear order job/parts to remove q’ty remarks.

  • Page 326: Middle Gear

    Middle gear 5-65 disassembling the middle drive shaft assembly order job/parts to remove q’ty remarks 1 spring retainer 2 2 spring seat 1 3 damper spring 1 4 damper driven cam 1 5 damper drive cam 1 6 middle drive shaft 1 for assembly, reverse the disassembly pro- cedure..

  • Page 327: Middle Gear

    Middle gear 5-66 disassembling the middle driven shaft assembly order job/parts to remove q’ty remarks 1 oil seal 1 2 middle driven pinion gear nut 1 3 middle driven shaft 1 4 middle driven pinion gear 1 5 bearing retainer 1 6 bearing 1 7 middle driven shaft bearing housing 1 for assembly, reverse t...

  • Page 328: Middle Gear

    Middle gear 5-67 eas25730 removing the middle drive shaft assembly 1. Remove: • middle drive pinion gear nut “1” • lock washer “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Straighten the lock washer tab. B. Loosen the middle drive pinion gear nut. Note: while holding the middle drive sha...

  • Page 329: Middle Gear

    Middle gear 5-68 c. Remove the middle driven pinion gear nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Remove: • bearing retainer ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the middle driven shaft bearing housing onto the lower crankcase. B. Straighten the t...

  • Page 330: Middle Gear

    Middle gear 5-69 d. Lock the threads with a drift punch. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Tighten: • middle driven pinion gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle driven pinion gear nut to specification. Note: secure the middle driven shaft...

  • Page 331: Middle Gear

    Middle gear 5-70 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle drive pinion gear nut to specification. Note: • lubricate the nut threads with engine oil. • install the middle drive pinion gear nut with its large inner diameter side facing inward as shown in the illustration...

  • Page 332: Middle Gear

    Middle gear 5-71 eas25880 measuring the middle gear backlash 1. Measure: • middle gear backlash out of specification → refer to “adjusting the middle gear backlash” on page 5-71. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the middle drive shaft “1”. B. Install the gear lash measuremen...

  • Page 333: Middle Gear

    Middle gear 5-72 6. Measure: • crankcase-to-middle-driven-shaft-bearing- housing clearance (with a thickness gauge) 7. Select: • middle driven pinion gear shim(s) “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Shims can only be selected in 0.05 mm incre- ments, therefore round off to the h...

  • Page 334: Middle Gear

    Middle gear 5-73 “a”= 65.00 “b”= 18.94 “c”= a numeral on the lower crankcase, to be divided by 100 and added to “84” example: “a” is 65.00 “b” is 18.94 if the lower crankcase is marked “45” “c” is 84.45 (i.E., 84.00 + 0.45 = 84.45) “a” = 84.45 - 65.00 - 18.94 = 0.51 round off to the hundredths digit...

  • Page 335: Crankcase

    Crankcase 5-74 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-18. Starter clutch refer to “generator and starter clutch” on page 5-28. Pickup rotor refer to “pickup roto...

  • Page 336: Crankcase

    Crankcase 5-75 9 lower crankcase 1 10 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 1st 20 n...

  • Page 337: Crankcase

    Crankcase 5-76 removing the oil baffle plate and bearings order job/parts to remove q’ty remarks connecting rod refer to “connecting rods and pis- tons” on page 5-82. Crankshaft/crankshaft journal bearings refer to “crankshaft” on page 5-90. Transmission refer to “transmission” on page 5-94. 1 oil b...

  • Page 338: Crankcase

    Crankcase 5-77 13 lower crankcase 1 for installation, reverse the removal proce- dure. Removing the oil baffle plate and bearings order job/parts to remove q’ty remarks 10 ls ls 2 lt lt lt lt lt lt 4 8 3 lt 5 7 6 12 1 9 13 t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • i...

  • Page 339: Crankcase

    Crankcase 5-78 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numeri...

  • Page 340: Crankcase

    Crankcase 5-79 2. Apply: • sealant (onto the crankcase mating surfaces and oil baffle plate 2) note: do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2–3 mm (0.08–0.12 in) of the crankshaft journal bearings. 3. Instal...

  • Page 341: Crankcase

    Crankcase 5-80 7. Tighten: • crankcase bolts (m9 × 115 mm) “1”–“10” warning ew3p61013 replace the bolts with new ones. Note: the tightening procedure of crankcase bolts “1”– “10” is angle controlled, therefore tighten the bolts using the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 342: Crankcase

    Crankcase 5-81 note: tighten the crankcase bolts in the proper tight- ening sequence as shown. T r . . Crankcase bolt “11”, “12” 24 nm (2.4 m·kg, 17 ft·lb) crankcase bolt “13”, “14” 12 nm (1.2 m·kg, 8.7 ft·lb) crankcase bolt “15”–“31” 10 nm (1.0 m·kg, 7.2 ft·lb) 13 21 18 15 16 17 20 19 22 14 24 29 3...

  • Page 343: Connecting Rods and Pistons

    Connecting rods and pistons 5-82 et3p61027 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston 4...

  • Page 344: Connecting Rods and Pistons

    Connecting rods and pistons 5-83 eas26030 removing the connecting rods and pistons the following procedure applies to all of the con- necting rods and pistons. 1. Remove: • connecting rod cap “1” note: identify the position of each connecting rod so that it can be reinstalled in its original place. ...

  • Page 345: Connecting Rods and Pistons

    Connecting rods and pistons 5-84 note: measure cylinder bore “c” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. B. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure...

  • Page 346: Connecting Rods and Pistons

    Connecting rods and pistons 5-85 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If th...

  • Page 347: Connecting Rods and Pistons

    Connecting rods and pistons 5-86 et3p61028 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following procedure applies to all of the connecting rods. Caut...

  • Page 348: Connecting Rods and Pistons

    Connecting rods and pistons 5-87 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Select: • big end bearings (p 1 –p 4 ) note: • the numbers “a” stamped into the crankshaft web and the numbers “b” on the connecting rods are used to determine the replacement big end bearing sizes. • p 1 –p 4 refe...

  • Page 349: Connecting Rods and Pistons

    Connecting rods and pistons 5-88 • reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3. Offset: • piston ring end gaps 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) 5. Lubricate: • bolt threads • nut seats (with t...

  • Page 350: Connecting Rods and Pistons

    Connecting rods and pistons 5-89 8. Tighten: • connecting rod nuts “1” warning ew3p61019 replace the connecting rod bolts and nuts with new ones. Note: tighten the connecting rod nuts using the follow- ing procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the connecting rod nut...

  • Page 351: Crankshaft

    Crankshaft 5-90 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. Front balancer weight refer to “balancers” on page 5-103. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-82. 1 crankshaft ...

  • Page 352: Crankshaft

    Crankshaft 5-91 eas26040 removing the crankshaft journal bearings 1. Remove: • crankshaft journal upper bearings (from the upper crankcase) • crankshaft journal lower bearings (from the lower crankcase) note: identify the position of each crankshaft journal bearing so that it can be reinstalled in i...

  • Page 353: Crankshaft

    Crankshaft 5-92 e. Install the crankshaft journal lower bearings “3” into the lower crankcase and assemble the crankcase halves. Note: • align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d” in the lower crankcase. • do not move the crankshaft until the clearance ...

  • Page 354: Crankshaft

    Crankshaft 5-93 note: • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • be sure to install each crankshaft journal bear- ing in its original place..

  • Page 355: Transmission

    Transmission 5-94 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. Stopper lever refer to “shift shaft” on page 5-56. 1 drive axle assembly 1 2 bearing 1 3 washer 1 4 be...

  • Page 356: Transmission

    Transmission 5-95 13 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 357: Transmission

    Transmission 5-96 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 5th pinion gear 1 5 toothed spacer 1 6 toothed washer 2 7 circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 collar 1 11 main...

  • Page 358: Transmission

    Transmission 5-97 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 middle drive gear 1 2 washer 1 3 2nd wheel gear 1 4 collar 1 5 washer 1 6 5th wheel gear 1 7 circlip 2 8 toothed washer 2 9 3rd wheel gear 1 10 toothed spacer 1 11 toothed lock washer 1 12 toothed lock w...

  • Page 359: Transmission

    Transmission 5-98 18 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 e m m m m m m 5 new new.

  • Page 360: Transmission

    Transmission 5-99 eas26250 removing the transmission 1. Remove: • main axle assembly note: remove the main axle assembly with the slide hammer bolts “1” and weight. Eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • ...

  • Page 361: Transmission

    Transmission 5-100 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replac...

  • Page 362: Transmission

    Transmission 5-101 3. Install: • 2nd pinion gear “1” note: install the 2nd pinion gear with its chamfered side facing inward as shown in the illustration. Eas26350 installing the transmission 1. Install: • main axle assembly “1” • main axle bearing housing bolts note: • when installing the main axle...

  • Page 363: Transmission

    Transmission 5-102 note: • the bearing pin “1” must face towards the rear of the upper crankcase. • make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • transmission rough movement → repair. Note: oil each gear, shaft, and bearing thoroughly. 1 2.

  • Page 364: Balancers

    Balancers 5-103 et3p61031 balancers removing the front balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. 1 front balancer lever 1 2 front balancer shaft 1 3 washer 2 4 bearing 2 5 front balancer gear 1 6 damper 4 7 front balancer weight 1 for inst...

  • Page 365: Balancers

    Balancers 5-104 removing the rear balancer order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-34. Clutch cover refer to “clutch” on page 5-41. 1 rear balancer cover 1 2 rear balancer cover gasket 1 3 rea...

  • Page 366: Balancers

    Balancers 5-105 eas26120 checking the balancers 1. Check: • front balancer gear damage/wear → replace the front balancer gear and crankshaft. • rear balancer gear damage/wear → replace the rear balancer gear and clutch housing. 2. Check: • balancer shafts cracks/damage/wear → replace the balanc- er ...

  • Page 367: Balancers

    Balancers 5-106 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • front balancer lever “1” • front balancer lever bolt “2” note: • apply locking agent (loctite ® ) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • front balancer sha...

  • Page 368: Balancers

    Balancers 5-107 2. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick- up rotor with the crankcase ma...

  • Page 369: Balancers

    Balancers 5-108 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • rear balancer lever “1” • rear balancer lever bolt “2” note: • apply locking agent (loctite ® ) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • rear balancer shaft ...

  • Page 370: Balancers

    Balancers 5-109.

  • Page 371: Cooling System

    6 cooling system radiator ...................................................................................................... 6-1 checking the radiator.................................................................... 6-3 installing the radiator.....................................................

  • Page 372: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-19. Throttle bodies refer to “throttle bodies” on page 7-4. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant reservoir breather hose 1 4 coolant r...

  • Page 373: Radiator

    Radiator 6-2 14 left radiator fan motor coupler 1 disconnect. 15 right radiator fan motor coupler 1 disconnect. 16 radiator 1 17 radiator cover 1 18 left radiator fan motor 1 19 right radiator fan motor 1 20 radiator bracket 1 21 air deflector 1 for installation, reverse the removal proce- dure. Rem...

  • Page 374: Radiator

    Radiator 6-3 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Note: straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage...

  • Page 375: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-13. Coolant drain. Refer to “changing the coolant” on page 3-19. Radiator refer to “radiator” on page 6-1. Exhaust pipe assembly refer to “...

  • Page 376: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose • water pump outlet hose • water pump outlet pipe • water jacket joint inlet hose cracks/damage/wear → replace. Eas26430 installing the oil coole...

  • Page 377: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-19. Throttle bodies refer to “throttle bodies” on page 7-4. 1 radiator cap 1 2 coolant reservoir hose 1 disconnect. 3 radiator inlet hos...

  • Page 378: Thermostat

    Thermostat 6-7 13 thermostat inlet pipe 1 1 for installation, reverse the removal proce- dure. Removing the thermostat assembly order job/parts to remove q’ty remarks t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 7 nm (...

  • Page 379: Thermostat

    Thermostat 6-8 eas26450 checking the thermostat 1. Check: • thermostat does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” ...

  • Page 380: Thermostat

    Thermostat 6-9 5. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3..

  • Page 381: Water Pump

    Water pump 6-10 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Right side cowling refer to “general chassis” on page 4-1. Coolant drain. Refe...

  • Page 382: Water Pump

    Water pump 6-11 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump housing cover 1 2 o-ring 1 3 circlip 1 4 impeller shaft 1 5 rubber damper holder 1 6 rubber damper 1 7 water pump seal 1 8 oil seal 1 9 bearing 2 10 water pump housing 1 for assembly, reverse the disasse...

  • Page 383: Water Pump

    Water pump 6-12 eas26510 disassembling the water pump 1. Remove: • rubber damper holder “1” • rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) note: do not scratch the impeller shaft. 2. Remove: • water pump seal “1” note: remove the water pump seal from the inside of the wa...

  • Page 384: Water Pump

    Water pump 6-13 3. Install: • rubber damper “1” • rubber damper holder “2” note: before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: eca14090 make sure the rubber damper an...

  • Page 385: Water Pump

    Water pump 6-14 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-19. 3. Check: • cooling system leaks → repair or replace any faulty part. 4. Measure: • radiator cap opening pressure below the specified pressure → replace th...

  • Page 386: Water Pump

    Water pump 6-15.

  • Page 387: Fuel System

    7 fuel system fuel tank..................................................................................................... 7-1 removing the fuel tank .................................................................. 7-2 removing the fuel pump .........................................................

  • Page 388: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. 1 fuel tank panel 1 2 fuel sender coupler 1 disconnect. 3 fuel pump coupler 1 disconnect. 4 fuel tank breather hose 1 5 fuel tank overflow hose 1 6 fuel h...

  • Page 389: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose warning ew3p61012 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out whe...

  • Page 390: Fuel Tank

    Fuel tank 7-3 • to install the fuel hose onto the fuel rail, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown. 2. Install: • fuel hose (fuel pump side) • fuel hose holder caution: ec3p61008 when installing the fuel hose, make sure that it is securely...

  • Page 391: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. T-bar/air filter case refer to “general chassis” on page 4-1. Air cut-off valve refer to “air induction system” on page 7-9. Coolant drain. Ref...

  • Page 392: Throttle Bodies

    Throttle bodies 7-5 10 plunger control unit hose 2 1 disconnect. 11 throttle body joint 4 for installation, reverse the removal proce- dure. Removing the throttle bodies order job/parts to remove q’ty remarks t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) 5 5 5 5 11 11...

  • Page 393: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor coupler 1 disconnect. 3 cylinder-#1 injector coupler 1 disconnect. 4 cylinder-#2 injector coupler 1 disconnect. 5 cylinder-#3 injector coupl...

  • Page 394: Throttle Bodies

    Throttle bodies 7-7 eas26980 checking the injectors 1. Check: • injectors damage → replace. Eas26990 checking the throttle bodies 1. Check: • throttle bodies cracks/damage → replace the throttle bod- ies as a set. 2. Check: • fuel passages obstructions → clean. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 395: Throttle Bodies

    Throttle bodies 7-8 c. Turn the main switch to “on”. D. Measure the throttle position sensor voltage. E. Adjust the throttle position sensor angle so that the voltage is within the specified range. F. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “...

  • Page 396: Air Induction System

    Air induction system 7-9 eas27040 air induction system 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6.

  • Page 397: Air Induction System

    Air induction system 7-10 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5. Air cut-off valve 6. Air induction system hose (3-way joi...

  • Page 398: Air Induction System

    Air induction system 7-11 removing the air cut-off valve order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. T-bar refer to “general chassis” on page 4-1. 1 air induction system solenoid coupler 1 disconnect. 2 air induction system hose (air filter case joint assembly ...

  • Page 399: Air Induction System

    Air induction system 7-12 removing the reed valves order job/parts to remove q’ty remarks thermostat inlet pipe 1 refer to “thermostat” on page 6-6. 1 reed valve cover (cylinder-#1) 1 2 reed valve cover (cylinders-#2/#3) 1 3 reed valve cover (cylinder-#4) 1 4 reed valve assembly 4 5 reed valve plate...

  • Page 400: Air Induction System

    Air induction system 7-13 eas27050 checking the pressure regulator 1. Check: • pressure regulator damage → replace. Eas27060 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing ...

  • Page 401: Electrical System

    8 electrical system ignition system ......................................................................................... 8-1 circuit diagram (1/2).......................................................................... 8-1 circuit diagram (2/2)....................................................

  • Page 402

    Windshield drive system..................................................................... 8-87 circuit diagram (1/2)........................................................................ 8-87 circuit diagram (2/2)........................................................................ 8-89 trou...

  • Page 403

    Electrical components.................................................................... 8-145 checking the switches ............................................................... 8-149 checking the bulbs and bulb sockets ................................. 8-152 checking the fuses ....................

  • Page 404: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b /w b /w b /w ...

  • Page 405: Ignition System

    Ignition system 8-2 1. Main switch 7. Main fuse 8. Battery 13.Gear position switch 14.Coupler 1 (wire harness–front cowling wire harness) 17.Coupler 2 (wire harness–front cowling wire harness) 31.Coupler 3 (wire harness–front cowling wire harness) 32.Sidestand switch 33.Cylinders-#1/#4 ignition coil...

  • Page 406: Ignition System

    Ignition system 8-3 et3p61001 circuit diagram (2/2) front cowling wire harness b b b b ch b b dg dg ch b b p p br p br 77 78 96 96 97 98 g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b b b l/ r b b b b b ( gray ) ( gray ) ( gray ...

  • Page 407: Ignition System

    Ignition system 8-4 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 69.Engine stop switch 79.Relay unit 95.Lean angle sensor.

  • Page 408: Ignition System

    Ignition system 8-5 et3p61002 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the gear position ...

  • Page 409: Ignition System

    Ignition system 8-6 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ...

  • Page 410: Ignition System

    Ignition system 8-7 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-149. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-149. Replace the r...

  • Page 411: Ignition System

    Ignition system 8-8.

  • Page 412: Electric Starting System

    Electric starting system 8-9 eas27160 electric starting system eas27170 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w ...

  • Page 413: Electric Starting System

    Electric starting system 8-10 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 13.Gear position switch 17.Coupler 2 (wire harness – front cowling wire harness) 31.Coupler 3 (wire harness – front cowling wire harness) 32.Sidestand switch 52.Coupler 5 (wire harness – front cowl...

  • Page 414: Electric Starting System

    Electric starting system 8-11 et3p61003 circuit diagram (2/2) front cowling wire harness g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b b b l/ r b b b b b ( gray ) ( gray ) ( gray ) b /l b /w ( gray ) ly /ly /wb /y g /ww /ly /gl...

  • Page 415: Electric Starting System

    Electric starting system 8-12 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 69.Engine stop switch 70.Start switch 73.Clutch switch 79.Relay unit 80.Starting circuit cut-off relay.

  • Page 416: Electric Starting System

    Electric starting system 8-13 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is turned “on” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is ...

  • Page 417: Electric Starting System

    Electric starting system 8-14 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the ...

  • Page 418: Electric Starting System

    Electric starting system 8-15 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-149. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-149. Rep...

  • Page 419: Electric Starting System

    Electric starting system 8-16.

  • Page 420: Charging System

    Charging system 8-17 eas27200 charging system eas27210 circuit diagram r br/l br/r r bb r/w r/g b/w y/l g/b b/r br/b br/b br/b l/y l l/y l/y l b b r lg/w b b g/w r/l y/w b/y b/r y/w b/y l g/r l/w p l/w p w/l r r r b b b b b b b/w r r/l l/w r/w r b w w g/l r/b bb b1 bb4 bb3 bb2 bb1 l/r br/r g/y r/w b...

  • Page 421: Charging System

    Charging system 8-18 2. Rectifier/regulator 3. Ac magneto 7. Main fuse 8. Battery.

  • Page 422: Charging System

    Charging system 8-19 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Front cowling right inner panel 1 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page 8-153...

  • Page 423: Charging System

    Charging system 8-20

  • Page 424: Lighting System

    Lighting system 8-21 eas27240 lighting system eas27250 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b w /l w /g w /y b /w b /w b /w r /l r /l r /b...

  • Page 425: Lighting System

    Lighting system 8-22 1. Main switch 7. Main fuse 8. Battery 26.License plate light 28.Tail/brake light 31.Coupler 3 (wire harness–front cowling wire harness) 41.Ecu (engine control unit) 52.Coupler 5 (wire harness–front cowling wire harness) 53.Headlight relay (on/off) 54.Hazard lighting fuse 56.Hea...

  • Page 426: Lighting System

    Lighting system 8-23 et3p61004 circuit diagram (2/2) front cowling wire harness b b b b ch b b dg dg ch b b dg br /g ch b p p br p br 77 78 96 96 97 98 g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b b b l/ r b b b b b ( gray ) (...

  • Page 427: Lighting System

    Lighting system 8-24 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 74.Pass switch 75.Dimmer switch 90.Meter light 91.High beam indicator light 99.Headlight relay (dimmer) 101.Auxiliary light 102.Headlight.

  • Page 428: Lighting System

    Lighting system 8-25 eas27260 troubleshooting any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng →...

  • Page 429: Lighting System

    Lighting system 8-26 ng → ok ↓ ng → ok ↓ 8. Check the headlight relay (dimmer). Refer to “checking the re- lays” on page 8-157. Replace the headlight relay (dimmer). 9. Check the entire lighting system wiring. Refer to “circuit diagram (1/2)” on page 8-21 and “circuit dia- gram (2/2)” on page 8-23. ...

  • Page 430: Signaling System

    Signaling system 8-27 eas27270 signaling system eas27280 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b /w b /w b ...

  • Page 431: Signaling System

    Signaling system 8-28 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 13.Gear position switch 14.Coupler 1 (wire harness – front cowling wire harness) 16.Fuel sender 17.Coupler 2 (wire harness – front cowling wire harness) 19.Abs ecu (electronic control unit) 21.Rear wheel sensor 24.Rear brak...

  • Page 432: Signaling System

    Signaling system 8-29 et3p61005 circuit diagram (2/2) front cowling wire harness 49 31 14 17 52 67 68 69 71 72 73 74 75 76 79 70 81 82 83 84 85 86 88 89 80 91 92 93 94 95 99 90 101 101 102 102 103 104 100 b b b b ch b b dg dg ch b b b p br p br 77 78 96 96 97 98 g y b g y b b br /y ( black ) br /b b...

  • Page 433: Signaling System

    Signaling system 8-30 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 49.Coupler 4 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 65....

  • Page 434: Signaling System

    Signaling system 8-31 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. • the fuel meter fails to come on. • the speedometer fails to operate. Note: • before troubleshooting, remove the following part(s): 1. F...

  • Page 435: Signaling System

    Signaling system 8-32 ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Check the horns. Refer to “checking the horns” on page 8-165. Replace the horn(s). 3. Check the entire signaling system wiring. Refer to “circuit diagram (1/2)” on pa...

  • Page 436: Signaling System

    Signaling system 8-33 the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the turn signal light bulbs and sockets. Refer to “checking the bulbs and bulb ...

  • Page 437: Signaling System

    Signaling system 8-34 ng → ok ↓ the shift indicator fails to come on. Ng → ok ↓ ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter fails to come on. Ng → ok ↓ 3. Check the entire signaling system wiring. Refer to “circuit diagram (1/2)” on page 8-27 and “circu...

  • Page 438: Signaling System

    Signaling system 8-35 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ note: repair or replace if there is an open or short circuit. • between rear wheel sensor and abs ecu coupler. (white–white) (black–black) • between abs ecu coupler and ecu coupler. (white/yellow–white/yellow) • be...

  • Page 439: Signaling System

    Signaling system 8-36.

  • Page 440: Cooling System

    Cooling system 8-37 eas27300 cooling system eas27310 circuit diagram r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b /w b /w b /w r /l r ...

  • Page 441: Cooling System

    Cooling system 8-38 1. Main switch 7. Main fuse 8. Battery 41.Ecu (engine control unit) 44.Coolant temperature sensor 57.Ignition fuse 60.Radiator fan motor relay 61.Left radiator fan motor fuse 62.Left radiator fan motor 63.Right radiator fan motor fuse 64.Right radiator fan motor.

  • Page 442: Cooling System

    Cooling system 8-39 eas27320 troubleshooting the radiator fan motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, ...

  • Page 443: Cooling System

    Cooling system 8-40

  • Page 444: Fuel Injection System

    Fuel injection system 8-41 eas27330 fuel injection system eas27340 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b ...

  • Page 445: Fuel Injection System

    Fuel injection system 8-42 1. Main switch 4. Abs ecu fuse 5. Fuel injection system fuse 7. Main fuse 8. Battery 13.Gear position switch 14.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel pump 17.Coupler 2 (wire harness–front cowling wire harness) 19.Abs ecu (electronic control unit) 21.R...

  • Page 446: Fuel Injection System

    Fuel injection system 8-43 et3p61006 circuit diagram (2/2) front cowling wire harness dg ch dg br /g ch b p p br p br 77 78 96 96 g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b b b l/ r b b b b b ( gray ) ( gray ) ( gray ) b /l ...

  • Page 447: Fuel Injection System

    Fuel injection system 8-44 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 69.Engine stop switch 74.Pass switch 75.Dimmer switch...

  • Page 448: Fuel Injection System

    Fuel injection system 8-45 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 449: Fuel Injection System

    Fuel injection system 8-46 eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the ...

  • Page 450: Fuel Injection System

    Fuel injection system 8-47 22 intake air tempera- ture sensor (open or short circuit) intake air temperature sensor: open or short circuit detected. Able able 24 o 2 sensor (inactive) no normal signal is received from the o 2 sensor. Able able 30 lean angle sensor latch up detected. No normal signal...

  • Page 451: Fuel Injection System

    Fuel injection system 8-48 communication error with the meter eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on ...

  • Page 452: Fuel Injection System

    Fuel injection system 8-49 5. Erase the malfunction history in the diagnos- tic mode. Refer to “sensor operation table (diagnostic code no. 62)”. Note: turning the main switch to “off” will not erase the malfunction history. The engine operation is not normal but the engine trouble warning light doe...

  • Page 453: Fuel Injection System

    Fuel injection system 8-50 7. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the trip lcd. • actuator operation set the engine stop switch to “ ” to operate the actuator. Note: if the engine stop switch is se...

  • Page 454: Fuel Injection System

    Fuel injection system 8-51 19 a break or disconnection of the black/red lead of the ecu is detected. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in ecu. • defective relay unit (diode). 20 21 coolant temperature sen- sor: open or short...

  • Page 455: Fuel Injection System

    Fuel injection system 8-52 33 malfunction detected in the primary wire of the cylin- ders-#1/#4 ignition coil. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in cylinders-#1/#4 ignition coil. • malfunction in ecu. 30 34 malfunction detec...

  • Page 456: Fuel Injection System

    Fuel injection system 8-53 sensor operation table er-2 no signals are received from the ecu within the specified duration. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in meter assembly. • malfunction in ecu. — er-3 data from the ecu c...

  • Page 457: Fuel Injection System

    Fuel injection system 8-54 08 lean angle sensor remove the lean angle sensor and incline it more than 65 degrees. • upright 0.4–1.4 • overturned 3.7–4.4 09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery ...

  • Page 458: Fuel Injection System

    Fuel injection system 8-55 *1 if it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference). Actuator operation table 62 malfunction history code erasure • no history 0 — • history exists • displays the total number of malfunc...

  • Page 459: Fuel Injection System

    Fuel injection system 8-56 eas27450 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 460: Fuel Injection System

    Fuel injection system 8-57 fault code no.: code number displayed on the meter when the engine failed to work normally. Refer to “self-diagnostic function table”. Diagnostic code no.: diagnostic code number to be used when the diagnostic mode is operated. Refer to “diagnostic mode” on page 8-49. Faul...

  • Page 461: Fuel Injection System

    Fuel injection system 8-58 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor check for lo...

  • Page 462: Fuel Injection System

    Fuel injection system 8-59 fault code no. 13 symptom intake air pressure sensor: open or short circuit detected. Diagnostic code no. 03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor coupler...

  • Page 463: Fuel Injection System

    Fuel injection system 8-60 fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. Che...

  • Page 464: Fuel Injection System

    Fuel injection system 8-61 fault code no. 16 symptom stuck throttle position sensor is detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. Check for loosene...

  • Page 465: Fuel Injection System

    Fuel injection system 8-62 fault code no. 19 symptom a break or disconnection of the black/red lead of the ecu is detected. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness ecu coupler • front ...

  • Page 466: Fuel Injection System

    Fuel injection system 8-63 fault code no. 21 symptom coolant temperature sensor: open or short circuit detect- ed. Diagnostic code no. 06 coolant temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of coolant tempera- ture s...

  • Page 467: Fuel Injection System

    Fuel injection system 8-64 fault code no. 22 symptom intake air temperature sensor: open or short circuit de- tected. Diagnostic code no. 05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of intake air tem- p...

  • Page 468: Fuel Injection System

    Fuel injection system 8-65 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of o 2 sensor check for looseness or pinching. Starting the en- ...

  • Page 469: Fuel Injection System

    Fuel injection system 8-66 fault code no. 30 symptom latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the veh...

  • Page 470: Fuel Injection System

    Fuel injection system 8-67 fault code no. 31 symptom the amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance j...

  • Page 471: Fuel Injection System

    Fuel injection system 8-68 5 the fuel pressure is too low. • compare the fuel pressures at idle and with throttle open. • about the same → normal • too low → refer to the following table. • check the fuel pump. • replace if defective. Refer to “checking the fuel pump body” on page 7-2. • check the d...

  • Page 472: Fuel Injection System

    Fuel injection system 8-69 fault code no. 32 symptom the amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (rich air-fuel ratio). Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance j...

  • Page 473: Fuel Injection System

    Fuel injection system 8-70 5 the fuel pressure is too high. • compare the fuel pressures at idle and with throttle open. About the same → normal too high → refer to the follow- ing table. • checking the pressure regula- tor. • replace if defective. Refer to “checking the fuel pressure” on page 7-7. ...

  • Page 474: Fuel Injection System

    Fuel injection system 8-71 fault code no. 33 symptom malfunction detected in the primary wire of the cylinders- #1/#4 ignition coil. Diagnostic code no. 30 cylinders-#1/#4 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders-#...

  • Page 475: Fuel Injection System

    Fuel injection system 8-72 fault code no. 34 symptom malfunction detected in the primary wire of the cylinders- #2/#3 ignition coil. Diagnostic code no. 31 cylinders-#2/#3 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders-#...

  • Page 476: Fuel Injection System

    Fuel injection system 8-73 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • wire harness ecu coupler...

  • Page 477: Fuel Injection System

    Fuel injection system 8-74 fault code no. 42 symptom a. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. Diagnostic code no. A 07 rear wheel sensor b 21 gear position switch (neutral circuit) order ite...

  • Page 478: Fuel Injection System

    Fuel injection system 8-75 b-1 connections • gear position switch coupler • wire harness ecu coupler • front cowling wire harness coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coup...

  • Page 479: Fuel Injection System

    Fuel injection system 8-76 fault code no. 43 symptom the ecu is unable to monitor the battery voltage (an open or short circuit in the line to the ecu). Diagnostic code no. 09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • r...

  • Page 480: Fuel Injection System

    Fuel injection system 8-77 fault code no. 44 symptom an error is detected while reading or writing on eeprom (co adjustment value). Diagnostic code no. 60 eeprom fault cylinder no. Order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in ecu. • set the ...

  • Page 481: Fuel Injection System

    Fuel injection system 8-78 fault code no. 46 symptom power supply to the fuel injection system is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness ecu coupler • check the coupler for any pins that ...

  • Page 482: Fuel Injection System

    Fuel injection system 8-79 fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • meter assembly coupler • wire harness ecu coupler • front cowling wire harness c...

  • Page 483: Fuel Injection System

    Fuel injection system 8-80 fault code no. Er-3 symptom data from the ecu cannot be received correctly. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • meter assembly coupler • wire harness ecu coupler • front cowling wire...

  • Page 484: Fuel Pump System

    Fuel pump system 8-81 eas27550 fuel pump system eas27560 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b /w b /w b ...

  • Page 485: Fuel Pump System

    Fuel pump system 8-82 1. Main switch 5. Fuel injection system fuse 7. Main fuse 8. Battery 15.Fuel pump 17.Coupler 2 (wire harness–front cowling wire harness) 41.Ecu (engine control unit) 52.Coupler 5 (wire harness–front cowling wire harness) 57.Ignition fuse.

  • Page 486: Fuel Pump System

    Fuel pump system 8-83 et3p61007 circuit diagram (2/2) front cowling wire harness b b b b ch b b dg dg ch b b dg br /g ch b p p br p br 77 78 96 96 97 98 g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b b b l/ r b b b b b ( gray ) ...

  • Page 487: Fuel Pump System

    Fuel pump system 8-84 17.Coupler 2 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 69.Engine stop switch 79.Relay unit 81.Fuel pump relay.

  • Page 488: Fuel Pump System

    Fuel pump system 8-85 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, a...

  • Page 489: Fuel Pump System

    Fuel pump system 8-86.

  • Page 490: Windshield Drive System

    Windshield drive system 8-87 eas27610 windshield drive system eas27620 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /...

  • Page 491: Windshield Drive System

    Windshield drive system 8-88 1. Main switch 6. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 7. Main fuse 8. Battery 17.Coupler 2 (wire harness – front cowling wire harness) 52.Coupler 5 (wire harness – front cowling wire harness) 55.Signaling system fuse.

  • Page 492: Windshield Drive System

    Windshield drive system 8-89 et3p61008 circuit diagram (2/2) front cowling wire harness b b b b ch b b dg ch b b dg br /g ch b p p br p br 77 78 96 96 97 98 g y b g y b b br /y ( black ) br /b b ( black ) r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b l/ r b b b b b b b ( gra...

  • Page 493: Windshield Drive System

    Windshield drive system 8-90 17.Coupler 2 (front cowling wire harness – wire harness) 52.Coupler 5 (front cowling wire harness – wire harness) 76.Windshield position switch 105.Windshield drive unit.

  • Page 494: Windshield Drive System

    Windshield drive system 8-91 eas27630 troubleshooting the windshield fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, signaling system, and back...

  • Page 495: Windshield Drive System

    Windshield drive system 8-92.

  • Page 496: Accessory Box System

    Accessory box system 8-93 et3p61009 accessory box system et3p61010 circuit diagram (1/2) r br/l br/r r bb r/w r/g b/w y/l g/b br/b br/b br/b l/y l l/y l/y l b b r lg/w b b g/w r/l r r r b b b b b b b/w r r/l l/w r/w r b w w g/l r/b bb b1 bb4 bb3 bb2 bb1 l/r br/r g/y r/w br/l br/l br/l l/r br r/y r/y...

  • Page 497: Accessory Box System

    Accessory box system 8-94 1. Main switch 7. Main fuse 8. Battery 52.Coupler 5 (wire harness–front cowling wire harness) 55.Signaling system fuse.

  • Page 498: Accessory Box System

    Accessory box system 8-95 et3p61011 circuit diagram (2/2) front cowling wire harness g y b g y b r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b l/ r b b b ( gray ) ( gray ) ( gray ) b /l b /w ( gray ) ly /ly /wb /y g /ww /ly /gl /w pb /rg /bg /r b /yy /wy /ll l/ w g /r y /gw ...

  • Page 499: Accessory Box System

    Accessory box system 8-96 52.Coupler 5 (front cowling wire harness–wire harness) 82.Accessory box solenoid.

  • Page 500: Accessory Box System

    Accessory box system 8-97 et3p61012 troubleshooting the accessory box fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and signaling system) refer to “checking the fus...

  • Page 501: Accessory Box System

    Accessory box system 8-98.

  • Page 502: Immobilizer System

    Immobilizer system 8-99 eas27640 immobilizer system eas27650 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r /w w /g w /y b /w b /...

  • Page 503: Immobilizer System

    Immobilizer system 8-100 1. Main switch 6. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 7. Main fuse 8. Battery 12.Immobilizer unit 14.Coupler 1 (wire harness–front cowling wire harness) 17.Coupler 2 (wire harness–front cowling wire harness) 31.Coupler 3 (wire harne...

  • Page 504: Immobilizer System

    Immobilizer system 8-101 et3p61013 circuit diagram (2/2) front cowling wire harness b b b b ch b b dg dg ch b b dg br /g ch b p p br p br 77 78 96 96 97 98 r br r /wg /l l/ w r /y r /b l/ r br /b l/ r b l/ r b b b b b l/ y r /b b /r r /lr /g g /y sb b /y r /g sb lg b sb /w br r /b b /r b /r r /b b b...

  • Page 505: Immobilizer System

    Immobilizer system 8-102 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 86.Immobilizer system indicator light 87.Multi-function...

  • Page 506: Immobilizer System

    Immobilizer system 8-103 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 507: Immobilizer System

    Immobilizer system 8-104 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with...

  • Page 508: Immobilizer System

    Immobilizer system 8-105 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a stand...

  • Page 509: Immobilizer System

    Immobilizer system 8-106 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost st...

  • Page 510: Immobilizer System

    Immobilizer system 8-107 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number is indicated in the lcd display of the meter assembly and the immobilizer system indicator light flashes at the same time. The patter...

  • Page 511: Immobilizer System

    Immobilizer system 8-108 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 52 immobilizer unit codes between the key and immobilizer unit do n...

  • Page 512: Immobilizer System

    Immobilizer system 8-109 a. Light on b. Light off.

  • Page 513: Immobilizer System

    Immobilizer system 8-110

  • Page 514: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-111 eas28790 abs (anti-lock brake system) eas27730 circuit diagram (1/2) r br /l br /r r bb r /w r /g b /w y /l g /b b /r b br /b br /b br /b br /b l /y l l /y l/ y l b b r lg /w b b g /w r /l b /w b3 l /g b l /r b b dg ch y /g l /r g /y br /b br r /b r /w r /w w /l r ...

  • Page 515: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-112 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 9. Abs motor fuse 10.Starter relay 14.Coupler 1 (wire harness–front cowling wire harness) 17.Coupler 2 (wire harness–front cowling wire harness) 18.Abs test coupler 19.Abs ecu (electronic control unit) 20.Front...

  • Page 516: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-113 et3p61021 circuit diagram (2/2) front cowling wire harness g y b g y b r br r /wg /l l/ w r /y r /b l/ r br /b g /l y l/ b g (black) b l/ r b l/ r b b b ( gray ) ( gray ) ( gray ) b /l b /w ( gray ) ly /ly /wb /y g /ww /ly /gl /w pb /rg /bg /r b /yy /wy /ll l/ w g ...

  • Page 517: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-114 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 31.Coupler 3 (front cowling wire harness–wire harness) 52.Coupler 5 (front cowling wire harness–wire harness) 68.Front brake light switch 69.Engine stop sw...

  • Page 518: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-115 eas27740 abs components chart 4 5 6 7 8 9 10 11,12 13 14 1 2 3 a a 15 16 5 7 1. Abs test coupler 2. Abs warning light 3. Abs ecu fuse 4. Abs motor fuse 5. Abs motor relay 6. Abs ecu (electronic control unit) 7. Hydraulic unit (hu) 8. Rear wheel sensor 9. Rear wheel...

  • Page 519: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-116.

  • Page 520: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-117 eas27750 abs coupler location chart 4 r/w w/g w/l w/y r/w r/w 2 b g/r lg sb 3 r/l r/b r/w w/b w w w/b br/b w/l br/w b b b/w g/r g/y w/y lg r/b b w/g w/l w/y r/l y/g sb b2 l/w r/w 7 8 9 w b gy w 1 10 ch dg r/g b/w g/r sb b/l b/w w g/b b/r l/w y/w p b/y r/w g/w y/l s...

  • Page 521: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-118 1. Meter assembly coupler 2. Abs test coupler 3. Abs motor relay coupler 4. Hydraulic unit solenoid coupler 5. Abs motor coupler 6. Rear wheel sensor coupler 7. Abs ecu coupler 8. Wire harness–abs wire harness coupler 9. Front wheel sensor coupler 10. Wire harness–...

  • Page 522: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-119 eas27760 abs ecu and abs motor relay removing the abs ecu and abs motor relay order job/parts to remove q’ty remarks rear side cover refer to “general chassis” on page 4-1. Storage compartment refer to “general chassis” on page 4-1. 1 abs ecu cover 1 2 abs ecu coup...

  • Page 523: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-120 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the abs ecu. • terminals “2” of the abs ecu couplers connection defective, contaminated, come- off → correct or clean. Note: if the abs ecu co...

  • Page 524: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-121 b. Check the solenoid valve insulation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • abs motor continuity no continuity → replace the hydraulic unit. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the abs...

  • Page 525: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-122 self-diagnosis and servicing the abs ecu has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the abs ecu also stores the mal- function history. In case malfunct...

  • Page 526: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-123 eas27810 basic process for troubleshooting check the fuse. Check the wire harness, connectors, and couplers. Check the main switch. Check the brake switch circuits. Check the battery. Check the meter assembly. For details, use the mal- function codes listed from [c...

  • Page 527: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-124 note: do not delete the malfunction codes during the troubleshooting procedures. Be sure to delete the codes when the service is finished. Warning ew3p61011 when maintenance or checks have been performed on components related to the abs, be sure to perform a final ...

  • Page 528: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 1. The malfunction code “1” is displayed on the multi-function display (example: malfunction code 11). 2. The abs warning light flashes every 0.5 second for more than 6 seconds. The abs warning light flashes every 0.5 second if a malfunction code for a past malfunc...

  • Page 529: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 as an example, a “10 digits/1 digit pattern” of the tester reading is shown below. A b 5 6 7 8 9 9 3 2 4 1 10 11 11 1. Abs test coupler 2. Lock plate 3. Protective cap 4. Ground terminal (black) 5. T/c terminal (sky blue) 6. T/f terminal (light green) 7. Abs warnin...

  • Page 530: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 eas27840 [c-1] only the abs warning light fails to come on when the main switch is turned to “on” disconnect the abs ecu couplers and meter assembly coupler, and then connect the test coupler adapter to the abs test coupler. 1. Check for continuity between the whit...

  • Page 531: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128 et3p61066 [c-4] the abs warning light flashes with the engine off, check the front and rear brake light switches. Check that the rear brake light switch is adjusted properly, and then check if the brake light comes on when the front or rear brake is applied. 1. The...

  • Page 532: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 et3p61068 [c-6] the abs warning light remains on 1. The battery voltage is low. • check the condition of the battery. Refer to “checking and charging the battery” on page 8-154. • if the battery voltage is low, clean the battery terminals and recharge it, or replac...

  • Page 533: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 information for the malfunction codes from the abs ecu, for both past and present malfunctions, is contained in the following table. Refer to the following table for troubleshooting. Note: record all of the malfunction codes displayed and inspect the check points. ...

  • Page 534: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 21 hydraulic unit solenoid circuit is broken or short-circuited. • abs wire harness (abs cir- cuit) • hydraulic unit solenoid cou- pler • hydraulic unit solenoids malfunction code 21 (see page 8-135.) 23 front or rear brake light switch is defec- tive. • improper a...

  • Page 535: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 * malfunction code 11 is indicated if the rear wheel rotates for longer than about 20 seconds with the front wheel stopped (e.G., when the vehicle is on the centerstand). 32 abs ecu circuit is broken or short-cir- cuited. • wire harness and abs wire harness (abs ci...

  • Page 536: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 note: malfunction codes 15 (front wheel) and 16 (rear wheel) are indicated if a defective connection is detect- ed in the front or rear wheel sensor when the vehicle is not being ridden. Malfunction code 11 (front wheel sensor signal is not received properly.) turn...

  • Page 537: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 • abs ecu coupler terminal is disconnected. Refer to “maintenance of the abs ecu” on page 8-120. 2. The abs warning light comes on for 2.0 seconds, then goes off. A. With the rear wheel stopped, the front wheel was rotated at a speed faster than about 11 km/h. This...

  • Page 538: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 2. Teeth surfaces of the sensor rotors are defective. • check if there are flaws on the surfaces of the sensor rotor teeth. Also, check for any foreign mate- rials. Refer to “maintenance of the front wheel sensor and sensor rotor” on page 4-16, “installing the fron...

  • Page 539: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 • check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal. Malfunction code 23 (front or rear brake light switch is defective.) 1. Wire harness, abs wire harness, and front cowling wire harness • check the entire anti-lock bra...

  • Page 540: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 malfunction code 24 (brake light is defective.) 1. Wire harness and abs wire harness • check the entire anti-lock brake system wiring. Refer to “circuit diagram (1/2)” on page 8-111 and “circuit diagram (2/2)” on page 8-113. 2. Brake light relay • check the brake l...

  • Page 541: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138 2. Brake master cylinder and brake caliper • check that the brake fluid pressure is correctly transmitted to the brake calipers when the brake lever is operated and that the pressure decreases when the lever is released. 3. Brake fluid • visually check the brake fl...

  • Page 542: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 6. Hydraulic unit if the malfunction is not corrected after checking items (1) to (5), replace the hydraulic unit. Be sure to connect the brake hoses and couplers correctly and securely. Check the hydraulic unit operation. Refer to “hydraulic unit operation tests” ...

  • Page 543: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 • if the brake hoses (to the proportioning valve and the metering valve) are switched during assembly, the brakes will continue to operate as normal. However, the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be rever...

  • Page 544: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 2. Abs motor relay • check if the abs motor relay operates correctly. Refer to “maintenance of the abs motor relay” on page 8-120. 3. Wire harness and abs wire harness • remove the abs motor relay and abs motor fuse, and then check for continuity between the red/bl...

  • Page 545: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 3. Abs ecu • if the malfunction is not corrected after checking items (1) to (2), replace the abs ecu. Malfunction code 51 (front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hyd...

  • Page 546: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-143 5. The multi-function display switches to the odometer/tripmeter/fuel reserve tripmeter display and the abs warning light flashes in 0.5 second-intervals while the malfunction codes are being deleted. 6. Turn the main switch to “off”. 7. Turn the main switch to “on...

  • Page 547: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-144 b. Check for continuity between the abs ecu and the start switch lead. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Check: • abs ecu voltage out of specification → replace the right han- dlebar switch. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Co...

  • Page 548: Electrical Components

    Electrical components 8-145 eas27970 electrical components 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17.

  • Page 549: Electrical Components

    Electrical components 8-146 1. Windshield drive unit 2. Battery 3. Starter relay 4. Abs motor fuse 5. Front brake light switch 6. Clutch switch 7. Fuse box 2 8. Fuse box 1 9. Right radiator fan motor 10. Left radiator fan motor 11. Gear position switch 12. Sidestand switch 13. Oil level switch 14. R...

  • Page 550: Electrical Components

    Electrical components 8-147 1 17 16 18 19 3 2 4 5 6 7 8 9 10 11 12 13 14 15.

  • Page 551: Electrical Components

    Electrical components 8-148 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. Abs motor relay 6. Hydraulic unit 7. Ecu (engine control unit) 8. Abs (ecu) 9. Cylinder identification sensor 10. O 2 sensor 11. Crankshaft position...

  • Page 552: Electrical Components

    Electrical components 8-149 eas27980 checking the switches 1 r br/l br/r on off p br/l br/r r 2 (brown) b b 3 p b lg sb br/w l/b ch dg b/y y r/y l/y lg b sb up down 13 dg br/w ch 14 b p 10 12 r/y y r/y l/b 11 b br/w ch dg r/b r/w g/y l/w br 8 l/w b r/w r/b 9 ch dg br/w 7 b/y l/y (black) 6 (blue) b b...

  • Page 553: Electrical Components

    Electrical components 8-150 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Gear position switch 5. Sidestand switch 6. Clutch switch 7. Hazard switch 8. Start switch 9. Engine stop switch 10. Horn switch 11. Dimmer switch 12. Pass switch 13. Windshield position switch 14. T...

  • Page 554: Electrical Components

    Electrical components 8-151 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the prob...

  • Page 555: Electrical Components

    Electrical components 8-152 eas27990 checking the bulbs and bulb sockets note: do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or...

  • Page 556: Electrical Components

    Electrical components 8-153 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in...

  • Page 557: Electrical Components

    Electrical components 8-154 warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possib...

  • Page 558: Electrical Components

    Electrical components 8-155 note: • the charge state of an mf battery can be checked by measuring its open-circuit voltage (i.E., the voltage when the positive battery ter- minal is disconnected). • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charg...

  • Page 559: Electrical Components

    Electrical components 8-156 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Note: voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to...

  • Page 560: Electrical Components

    Electrical components 8-157 10.Install: • front cowling right inner panel 1 refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. 1. Disconnect the relay from the wire...

  • Page 561: Electrical Components

    Electrical components 8-158 headlight relay (on/off) headlight relay (dimmer) first step: second step: brake light relay first step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive tester ...

  • Page 562: Electrical Components

    Electrical components 8-159 second step: radiator fan motor relay et3p61059 checking the abs motor relay 1. Remove: • abs motor relay 2. Check: • abs motor relay resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the ...

  • Page 563: Electrical Components

    Electrical components 8-160 et3p61014 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must be repaired. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 564: Electrical Components

    Electrical components 8-161 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no ...

  • Page 565: Electrical Components

    Electrical components 8-162 c. Measure the primary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. ...

  • Page 566: Electrical Components

    Electrical components 8-163 2. Check: • crankshaft position sensor resistance out of specification → replace the crank- shaft position sensor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler as shown. B. Measure the ...

  • Page 567: Electrical Components

    Electrical components 8-164 b. Check the starter motor operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the stator coil. ▼▼▼ ▼ ...

  • Page 568: Electrical Components

    Electrical components 8-165 eas28180 checking the horns the following procedure applies to both of the horns. 1. Check: • horn resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the horn connectors from the horn terminals. B. Connect the pocket...

  • Page 569: Electrical Components

    Electrical components 8-166 b. Measure the oil level switch resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28220 checking the fuel sender 1. Disconnect: • fuel pump coupler • fuel sender coupler (from the wire harness) 2. Remove: • fuel tank 3. Remove: • fuel pump (from the fuel ta...

  • Page 570: Electrical Components

    Electrical components 8-167 eas28260 checking the coolant temperature sensor 1. Remove: • coolant temperature sensor warning ewa14130 • handle the coolant temperature sensor with special care. • never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is d...

  • Page 571: Electrical Components

    Electrical components 8-168 eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the air induction system solenoid coupler from the wire harness. B. Con...

  • Page 572: Electrical Components

    Electrical components 8-169 b. Turn the main switch to “on”. C. Measure the intake air pressure sensor out- put voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28420 checking the intake air temperature sensor 1. Remove: • intake air temperature sensor (from the air filter case) warning...

  • Page 573: Electrical Components

    Electrical components 8-170 c. Measure the accessory box solenoid resis- tance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ b br 1 2.

  • Page 574: Electrical Components

    Electrical components 8-171.

  • Page 575: Troubleshooting

    9 troubleshooting troubleshooting..................................................................................... 9-1 general information ....................................................................... 9-1 starting failures...................................................................

  • Page 576: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ...

  • Page 577: Troubleshooting

    Troubleshooting 9-2 • improperly adjusted engine idling speed (throttle stop screw) • improper throttle cable free play • flooded throttle body • faulty air induction system electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spa...

  • Page 578: Troubleshooting

    Troubleshooting 9-3 • match marks not aligned 2. Engine oil • incorrect oil level • incorrect oil viscosity (high) • deteriorated oil eas28600 overheating engine 1. Clogged coolant passages • cylinder head and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil visco...

  • Page 579: Troubleshooting

    Troubleshooting 9-4 • damaged ball bearing or bearing race 2. Front fork leg(s) • uneven oil levels (both front fork legs) • unevenly tensioned fork spring (both front fork legs) • broken fork spring • bent or damaged inner tube • bent or damaged outer tube 3. Swingarm • worn bearing or bushing • be...

  • Page 580: Wiring Diagram

    Eas28740 wiring diagram fjr1300a(v) 2006 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Abs ecu fuse 5. Fuel injection system fuse 6. Backup fuse (odometer, clock, immobilizer system, and wind- shield drive system) 7. Main fuse 8. Battery 9. Abs motor fuse 10. Starter relay 11. Starter motor...

  • Page 582

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 583

    Fjr1300a(v) 2006 wiring diagram (1/2) fjr1300a(v) 2006 schÉma de cblage (1/2) fjr1300a(v) 2006 schaltplan (1/2) fjr1300a(v) 2006 schema elettrico (1/2) fjr1300a(v) 2006 diagrama elÉctrico (1/2) r br/l br/r r bb r/w r/g b/w y/l g/b b/r b br/b br/b br/b br/b l/y l l/y l/y l b b r lg/w b b g/w r/l b/w ...

  • Page 584

    Fjr1300a(v) 2006 wiring diagram (2/2) front cowling wire harness fjr1300a(v) 2006 schÉma de cblage (2/2) faisceau de fils au carénage avant fjr1300a(v) 2006 schaltplan (2/2) frontverkleidungs-kabelbaum fjr1300a(v) 2006 schema elettrico (2/2) cablaggio elettrico del cupolino fjr1300a(v) 2006 diagrama...

  • Page 585

    Fjr1300a(v) 2006 wiring diagram (1/2) fjr1300a(v) 2006 schÉma de cblage (1/2) fjr1300a(v) 2006 schaltplan (1/2) fjr1300a(v) 2006 schema elettrico (1/2) fjr1300a(v) 2006 diagrama elÉctrico (1/2) on off p (gray) (gray) (blue) (blue) (blue) (blue) (gray) (black) (dark green) c c b c a a a a a a a c c c...

  • Page 586

    Fjr1300a(v) 2006 wiring diagram (2/2) front cowling wire harness fjr1300a(v) 2006 schÉma de cblage (2/2) faisceau de fils au carénage avant fjr1300a(v) 2006 schaltplan (2/2) frontverkleidungs-kabelbaum fjr1300a(v) 2006 schema elettrico (2/2) cablaggio elettrico del cupolino fjr1300a(v) 2006 diagrama...