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Yamaha 2006 YZFR6V Service Manual

Other manuals for 2006 YZFR6V: Service Manual, Owner's Manual

Summary of 2006 YZFR6V

  • Page 1

    Service manual yzfr6v(c) lit-11616-19-78 2c0-28197-10

  • Page 2

    Eas20050 yzfr6v(c) service manual ©2005 by yamaha motor corporation, u.S.A. First edition, december 2005 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-19-78.

  • Page 3

    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

    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

    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 6: 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 7: General Information

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

  • Page 8: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped on the right side of the steering head pipe. Eas20150 model label the model label “1” is affixed to the frame under the passenger seat. This information will be needed t...

  • Page 9: 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 10: Features

    Features 1-3 et2c01019 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 11: Features

    Features 1-4 et2c01026 ycc-t (yamaha chip controlled throttle) mechanism characteristics yamaha developed the ycc-t system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but yamaha has developed a fast- er, more compact...

  • Page 12: Features

    Features 1-5 ycc-t system outline 1 1 4 5 8 10 11 12 9 6 7 13 14 15 16 17 18 2 2 3 1. Throttle position sensor (for throttle cable pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. Ecu (engine control unit) 5. Etv main cpu (32 bit) 6. Etv sub cpu (16 bit) 7. Fi cpu...

  • Page 13: Features

    Features 1-6 ycc-t control outline 15 m 18 17 16 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Throttle position sensor (for throttle cable pulley) 2. Throttle position sensor (for throttle valves) 3. Crankshaft position sensor 4. Speed sensor 5. Coolant temperature sensor 6. Neutral switch 7. Atmospheric ...

  • Page 14: Features

    Features 1-7 et2c01020 instrument functions multi-function meter unit warning ew2c01003 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a tac...

  • Page 15: Features

    Features 1-8 to set the clock: 1. Push the “select” button and “reset” but- ton together for at least two seconds. 2. When the hour digits start flashing, push the “reset” button to set the hours. 3. Push the “select” button, and the minute digits will start flashing. 4. Push the “reset” button to s...

  • Page 16: Features

    Features 1-9 caution: ec2c01021 do not operate the engine if it is overheated. Air intake temperature display the air intake temperature display indicates the temperature of the air drawn into the air filter case. Push the “reset” button to switch the coolant temperature display to the air intake te...

  • Page 17: Features

    Features 1-10 to adjust the brightness of the multi-function meter displays and tachometer: 1. Turn the key to “off”. 2. Push and hold the “select” button. 3. Turn the key to “on”, and then release the “select” button after five seconds. 4. Push the “reset” button to select the de- sired brightness ...

  • Page 18: Important Information

    Important information 1-11 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 1-14. 3. When disasse...

  • Page 19: Important Information

    Important information 1-12 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 20: Checking The Connections

    Checking the connections 1-13 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 21: Special Tools

    Special tools 1-14 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 22: Special Tools

    Special tools 1-15 oil filter wrench 90890-01426 yu-38411 3-11 oil pressure gauge set 90890-03120 3-13 oil pressure adapter h 90890-03139 3-13 steering nut wrench 90890-01403 spanner wrench yu-33975 3-27, 4-58 fork spring compressor 90890-01441 ym-01441 4-47, 4-52 rod holder 90890-01434 damper rod h...

  • Page 23: Special Tools

    Special tools 1-16 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-51, 4-52 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-51, 4-52 ring nut wrench 90890-01268 spanner wrench yu-01268 4-58 ring nut wrench 90890-01507 ym-01507 4-67...

  • Page 24: Special Tools

    Special tools 1-17 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym-04108 5-19, 5-24 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-21 valve guide installer (ø4.5) 90890-04117 valve guide installer (4.5 mm) ym-04117 5-21 valve gu...

  • Page 25: Special Tools

    Special tools 1-18 universal clutch holder 90890-04086 ym-91042 5-41, 5-45 thickness gauge 90890-03180 feeler gauge set yu-26900-9 5-41 piston pin puller set 90890-01304 piston pin puller yu-01304 5-60 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-3 radiator cap tester adapt...

  • Page 26: Special Tools

    Special tools 1-19 pressure gauge 90890-03153 pressure gauge yu-03153 7-12 fuel pressure adapter 90890-03176 ym-03176 7-12 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-13 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-92 tool name/tool no. I...

  • Page 27: Specifications

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

  • Page 28: General Specifications

    General specifications 2-1 eas20280 general specifications model model 2c05/2c08 (usa) 2c06 (california) dimensions overall length 2040 mm (80.3 in) overall width 700 mm (27.6 in) overall height 1100 mm (43.3 in) seat height 850 mm (33.5 in) wheelbase 1380 mm (54.3 in) ground clearance 130 mm (5.12 ...

  • Page 29: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid-cooled 4-stroke, dohc displacement 599 cm³ (36.55 cu.In) cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in) compression ratio 12.8 :1 standard compression pressure ...

  • Page 30: 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 107.9–137.3 kpa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) thermostat valve opening temperature 71 °c (159.8 °f) valve full open temperature 85 °c (185 °f) val...

  • Page 31: Engine Specifications

    Engine specifications 2-4 exhaust b 25.082–25.182 mm (0.9875–0.9914 in) limit 25.032 mm (0.9855 in) camshaft runout limit 0.030 mm (0.0012 in) timing chain model/number of links 98xrh2015/118 tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.12–0.19 mm (0.004...

  • Page 32: Engine Specifications

    Engine specifications 2-5 valve margin thickness d (intake) 0.90–1.10 mm (0.0354–0.0433 in) limit 0.8 mm (0.03 in) valve margin thickness d (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) limit 1.0 mm (0.04 in) valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) limit 4.460 mm (0.1756 in) valve...

  • Page 33: Engine Specifications

    Engine specifications 2-6 spring tilt (intake) 2.5°/1.6 mm spring tilt (exhaust) 2.5°/1.6 mm winding direction (intake) clockwise winding direction (exhaust) clockwise cylinder bore 67.000–67.010 mm (2.6378–2.6382 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.050 mm (0.0020 in) piston pi...

  • Page 34: Engine Specifications

    Engine specifications 2-7 2nd ring ring type taper dimensions (b × t) 0.80 × 2.50 mm (0.03 × 0.10 in) end gap (installed) 0.70–0.80 mm (0.0276–0.0315 in) limit 1.00 mm (0.0394 in) ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) oil ring dimensions (b × t) 1.50 × 2.00 mm (0.06 × 0.08 in) end ga...

  • Page 35: Engine Specifications

    Engine specifications 2-8 plate quantity 8 pcs warpage limit 0.10 mm (0.0039 in) clutch spring free length 55.00 mm (2.17 in) minimum length 54.00 mm (2.13 in) spring quantity 6 pcs transmission transmission type constant mesh 6-speed primary reduction system spur gear primary reduction ratio 85/41 ...

  • Page 36: Engine Specifications

    Engine specifications 2-9 fuel injection sensor crankshaft position sensor resistance 248–372 Ω at 20 °c (68 °f) cylinder identification sensor output voltage (on) less than 0.8 v cylinder identification sensor output voltage (off) more than 4.8 v intake air pressure sensor output voltage 3.15–4.15 ...

  • Page 37: Chassis Specifications

    Chassis specifications 2-10 eas20300 chassis specifications chassis frame type diamond caster angle 24.00° trail 97.0 mm (3.82 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel ...

  • Page 38: Chassis Specifications

    Chassis specifications 2-11 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) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) master cylinder inside diamete...

  • Page 39: Chassis Specifications

    Chassis specifications 2-12 spring free length 163.5 mm (6.44 in) installed length 152.5 mm (6.00 in) spring rate k1 98.00 n/mm (559.58 lb/in) (9.99 kgf/mm) spring stroke k1 0.0–60.0 mm (0.00–2.36 in) optional spring available no enclosed gas/air pressure (std) 1200 kpa (170.7 psi) (12.0 kgf/cm²) sw...

  • Page 40: Electrical Specifications

    Electrical specifications 2-13 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) advancer type throttle position sensor and electrical ignition timing (b.T.D.C.) 10.0°/1300 r/min engine control unit model/manufacture...

  • Page 41: Electrical Specifications

    Electrical specifications 2-14 high beam indicator light led fuel level warning light led coolant temperature warning light led engine trouble warning light led shift timing indicator light led electric starting system system type constant mesh starter motor model/manufacturer sm14/mitsuba power out...

  • Page 42: Electrical Specifications

    Electrical specifications 2-15 fuel pump relay model/manufacturer g8r-30y-v4/omron fan motor relay model/manufacturer acm33211m05/matsushita fuses main fuse 50.0 a headlight fuse 15.0 a signaling system fuse 10.0 a ignition fuse 15.0 a radiator fan fuse 15.0 a × 2 fuel injection system fuse 15.0 a b...

  • Page 43: Tightening Torques

    Tightening torques 2-16 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 44: Tightening Torques

    Tightening torques 2-17 eas20340 engine tightening torques item thread size q’ty tightening torque remarks camshaft cap bolt (intake and exhaust) m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder head stud bolt (exhaust pipe assembly) m8 8 15 nm (1.5 m·kg, 11 ft·lb) cylinder head nut (1st) m10 8 25 nm (2.5...

  • Page 45: Tightening Torques

    Tightening torques 2-18 upper air filter case to lower air filter case bolt m5 9 2 nm (0.2 m·kg, 1.4 ft·lb) upper air filter case joint bolt m5 6 4 nm (0.4 m·kg, 2.9 ft·lb) secondary injector fuel rail m6 2 5 nm (0.5 m·kg, 3.6 ft·lb) locknut (throttle cable) m6 2 5 nm (0.5 m·kg, 3.6 ft·lb) exhaust p...

  • Page 46: Tightening Torques

    Tightening torques 2-19 note: connecting rod nut tighten the connecting rod nuts to 15 nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 175°–185°. Note: crankcase bolt 1. First, tighten the bolts to approximately 20 nm (2.0 m·kg, 14 ft·lb) with a torque wrench. 2. ...

  • Page 47: Tightening Torques

    Tightening torques 2-20 cylinder head tightening sequence: crankcase tightening sequence: 8 6 2 4 10 9 3 1 5 7 12 11 2 6 9 8 1 4 3 5 7 10 13 25 26 14 20 12 21 11 15 19 18 16 28 27 17 24 23 22.

  • Page 48: Tightening Torques

    Tightening torques 2-21 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (front right side) m10 2 45 nm (4.5 m·kg, 32 ft·lb) engine mounting bolt (front left side) m10 2 45 nm (4.5 m·kg, 32 ft·lb) engine mounting nut (rear upper side) m12 1 68 ...

  • Page 49: Tightening Torques

    Tightening torques 2-22 lower bracket pinch bolt m8 4 23 nm (2.3 m·kg, 17 ft·lb) see note horn and front brake hose joint bolt m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) front brake hose guide bolt m5 1 7 nm (0.7 m·kg, 5.1 ft·lb) lower bracket and front brake hose joint bracket bolt m6 2 10 nm (1.0 m·kg, 7.2 ...

  • Page 50: Tightening Torques

    Tightening torques 2-23 note: front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 nm (9.1 m·kg, 66 ft·lb) without performing temporary tightening. 2. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”,...

  • Page 51: Tightening Torques

    Tightening torques 2-24 4. In the order pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. 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 wrenc...

  • Page 52

    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 surface piston pins connecting rod bolts and nuts crankshaft journals generator rotor bolt and washer camshaft...

  • Page 53

    Lubrication points and lubricant types 2-26 crankshaft position sensor lead grommet yamaha bond no.1215 (three bond no.1215 ® ) stator coil lead grommet yamaha bond no.1215 (three bond no.1215 ® ) lubrication point lubricant.

  • Page 54

    Lubrication points and lubricant types 2-27 eas20380 chassis lubrication point lubricant steering bearings and upper bearing cover lip lower bearing dust seal lip tube guide (throttle grip) inner surface and throttle cables brake lever pivoting point and metal-to-metal moving parts clutch cable end ...

  • Page 55

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

  • Page 56

    Lubrication system chart and diagrams 2-30 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main gallery 7. Oil nozzle 8. Timing chain tensioner 9. Intake camshaft 10. Exhaust camshaft 11. Oil pipe 12. Main axle 13. Shift fork 14. Drive axle.

  • Page 57

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

  • Page 58

    Lubrication system chart and diagrams 2-32 1. Ventilation chamber cover 2. Relief valve 3. Ventilation chamber oil drain pipe 4. Oil cooler.

  • Page 59

    Lubrication system chart and diagrams 2-33 1 2 3 4 8 7 6 5.

  • Page 60

    Lubrication system chart and diagrams 2-34 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Oil check bolt 5. Oil strainer 6. Ventilation chamber oil drain pipe 7. Oil pipe 8. Oil pump.

  • Page 61

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

  • Page 62

    Lubrication system chart and diagrams 2-36 1. Oil cooler 2. Oil filter 3. Oil pipe 4. Oil pump 5. Oil strainer.

  • Page 63

    Lubrication system chart and diagrams 2-37 1 5 4 3 2.

  • Page 64

    Lubrication system chart and diagrams 2-38 1. Main axle 2. Oil pump 3. Oil pipe 4. Ventilation chamber oil drain pipe 5. Relief valve.

  • Page 65

    Lubrication system chart and diagrams 2-39 3 1 2 5 4.

  • Page 66

    Lubrication system chart and diagrams 2-40 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle.

  • Page 67

    Lubrication system chart and diagrams 2-41 1 3 2.

  • Page 68

    Lubrication system chart and diagrams 2-42 1. Oil pipe 2. Main axle 3. Drive axle.

  • Page 69: Cooling System Diagrams

    Cooling system diagrams 2-43 eas20420 cooling system diagrams 1 2 3 4.

  • Page 70: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Radiator inlet hose 2. Radiator inlet pipe 3. Thermostat outlet hose 4. Radiator.

  • Page 71: Cooling System Diagrams

    Cooling system diagrams 2-45 a a 2 1 3 4 5 6 7 8 6 13 8 9 15 14 9 10 11 12.

  • Page 72: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Water pump breather hose 2. Coolant reservoir hose 3. Coolant reservoir 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Radiator outlet pipe 8. Water jacket joint inlet hose 9. Water pump outlet pipe 10. Water pump inlet hose 11. Water pump outlet hos...

  • Page 73: Cable Routing

    Cable routing 2-47 eas20430 cable routing a a a b c d e f g h i j 1 2 3 4 5 6 7 8 8 9 10 10 11 11 13 14 15 16 17 18 12.

  • Page 74: Cable Routing

    Cable routing 2-48 1. Front brake light switch lead 2. Front brake fluid reservoir hose 3. Right handlebar switch lead 4. Clutch cable 5. Main switch lead 6. Left handlebar switch lead 7. Clutch switch lead 8. Horn lead 9. Front brake hose 10. Throttle cable (decelerator cable) 11. Throttle cable (a...

  • Page 75: Cable Routing

    Cable routing 2-49 1 2 3 3 4 4 4 5 5 6 7 8 9 10 11 12 13 14 14 15 15 16 15 16 17 18 19 19 20 20 21 21 22 23 24 25 26 27 a b p c d e f g h i k j l m n o 60˚ a-a b-b d-d c a a b b d d c q.

  • Page 76: Cable Routing

    Cable routing 2-50 1. Exup servo motor lead 2. Crankshaft position sensor lead 3. Ignition coil lead 4. Wire harness 5. Right radiator fan motor lead 6. Front brake fluid reservoir hose 7. Right handlebar switch lead 8. Throttle cable (accelerator cable) 9. Throttle cable (decelerator cable) 10. Fro...

  • Page 77: Cable Routing

    Cable routing 2-51 c c b b-b c-c a a b b a c m n d h i j k l 1 2 3 4 5 6 6 7 7 8 10 11 12 13 9 8 14 6 7 13 14 e f g.

  • Page 78: Cable Routing

    Cable routing 2-52 1. Main switch lead 2. Left handlebar switch lead 3. Left radiator fan motor lead 4. Wire harness 5. Radiator inlet pipe 6. Fuel tank breather hose (except for california) 7. Sidestand switch lead 8. Ac magneto lead 9. Front left turn signal/position light lead 10. Main switch lea...

  • Page 79: Cable Routing

    Cable routing 2-53 a-a a b b a a b c d e f g h i j k l m n o e p e q w x r v u t s s 1 2 3 4 5 7 6 7 6 8 8 9 10 10 11 11 12 13 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28 29 30 31 32 32 45˚ 135˚ b-b.

  • Page 80: Cable Routing

    Cable routing 2-54 1. Front right turn signal/position light lead 2. Right radiator fan motor lead 3. Throttle position sensor (for throttle valves) lead 4. Throttle servo motor lead 5. Throttle position sensor (for throttle cable pulley) lead 6. Ignition coil lead 7. Crankshaft position sensor lead...

  • Page 81: Cable Routing

    Cable routing 2-55 a 3 1 2 3 c b.

  • Page 82: Cable Routing

    Cable routing 2-56 1. Throttle cable (decelerator cable) 2. Throttle cable (accelerator cable) 3. Front brake hose a. Pass the throttle cables between the front fork and the front brake hose. B. When installing the guide on the lower bracket, be sure to pass the front brake hose through it. C. Faste...

  • Page 83: Cable Routing

    Cable routing 2-57 4 5 7 8 9 11 13 14 12 10 15 16 11 16 6 a c e b d 5 6 10 12 16 1 2 3.

  • Page 84: Cable Routing

    Cable routing 2-58 1. Canister purge hose (throttle body-#4 to 3-way joint) (for california only) 2. Canister purge hose (3-way joint to canister) (for california only) 3. Fuel tank breather hose (fuel tank to rollover valve) (for california only) 4. Fuel tank breather hose (fuel tank to hose joint)...

  • Page 85: Cable Routing

    Cable routing 2-59 f f c c e e d d a a g g b b a b c e f d g h i j k 1 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 12 16 1 2 2 3 3 5 6 7 6 7 9 10 13 14 15 17 l 1 14 17 13 10 15 a-a b-b c-c d-d e-e f-f g-g.

  • Page 86: Cable Routing

    Cable routing 2-60 1. Negative battery lead 2. Main fuse leads 3. Lean angle sensor lead 4. Ecu (engine control unit) 5. Tail/brake light lead 6. Turn signal light lead (right and left side) 7. License plate light lead 8. Seat lock cable 9. Fuse box lead 10. Sidestand switch lead 11. Positive batter...

  • Page 87

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction....................................................................................... 3-1 periodic maintenance chart for the emission control system.....

  • Page 88

    Lubricating the pedals................................................................. 3-34 lubricating the sidestand .......................................................... 3-34 lubricating the rear suspension ............................................ 3-34 electrical system ....................

  • Page 89: 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 90: Periodic Maintenance

    Periodic maintenance 3-2 5 * brake hoses • check for cracks or damage. √ √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for dam- age. • replace if necessary. √ √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. ...

  • Page 91: Periodic Maintenance

    Periodic maintenance 3-3 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Eau17650 note: • air filter • this mod...

  • Page 92: Engine

    Engine 3-4 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 93: Engine

    Engine 3-5 • 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. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remove: • camshafts...

  • Page 94: Engine

    Engine 3-6 c. Check the thickness of the current valve pad. Note: the thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touch- es the valve lifter. Example: if the valve pad is marked “155”, the pad thickness is 1.55 mm (0.061 in). D. Calculate the sum of the va...

  • Page 95: Engine

    Engine 3-7 1. Stand the vehicle on a level surface. Note: place the vehicle on a suitable stand. 2. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. 3. Remove: • caps “1” 4. Install: • vacuum gauge “1” • digital tachometer 5. Install: • fuel ...

  • Page 96: Engine

    Engine 3-8 b. Turn all of the bypass air screws in fully. C. Using the throttle body with the lowest vacu- um pressure as the standard, turn out the by- pass air screws of the other throttle bodies to adjust them. Note: • do not turn out the bypass air screw of the throttle body with the lowest vacu...

  • Page 97: Engine

    Engine 3-9 1. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • air filter case refer to “air filter case” on page 7-5. • canister (for california only) refer to “throttle bodies” on page 7-8. • air induction system solenoid refer to “air in...

  • Page 98: Engine

    Engine 3-10 • radiator refer to “radiator” on page 6-1. 4. Remove: • ignition coils • spark plugs caution: eca13340 before removing the spark plugs, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinders. 5. Install: • compressi...

  • Page 99: Engine

    Engine 3-11 4. Check: • engine oil level the engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → add the recommended engine oil to the proper level. Note: • before checking the engine oil level, wait a few minutes until the oil has...

  • Page 100: Engine

    Engine 3-12 d. Lubricate the o-ring “1” of the new oil filter cartridge with a thin coat of engine oil. Caution: ec2c01006 make sure the o-ring “1” is positioned cor- rectly in the groove of the oil filter cartridge. E. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrenc...

  • Page 101: Engine

    Engine 3-13 2. Start the engine, warm it up for several min- utes, and then turn it off. Caution: eca13410 when the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the eng...

  • Page 102: Engine

    Engine 3-14 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified clutch lever free play is obtained. Note: if the specified clutch lever free play cannot be obtained on the handlebar side of the cable, use the adj...

  • Page 103: Engine

    Engine 3-15 eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • air filter case refer to “air filter case” o...

  • Page 104: Engine

    Engine 3-16 eas21080 checking the exhaust system the following procedure applies to all of the ex- haust pipe assembly and gaskets. 1. Remove: • side cowlings • bottom cowlings refer to “general chassis” on page 4-1. 2. Check: • exhaust pipe assembly “1” • muffler “2” cracks/damage → replace. • gask...

  • Page 105: Engine

    Engine 3-17 2. Check: • exup system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to “fuel injection system” on page 8-33. B. Set the engine stop switch to “ ”. C. Check that the exup valve operates prope...

  • Page 106: Engine

    Engine 3-18 f. Repeat steps (2) and (3). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Install: • exup valve pulley cover eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Check: •...

  • Page 107: Engine

    Engine 3-19 3. Install: • exhaust pipe assembly refer to “engine removal” on page 5-1. • bottom cowlings • side cowlings refer to “general chassis” on page 4-1. Eas21130 changing the coolant 1. Remove: • right side panel • right upper side cowling • right lower side cowling • right bottom cowling re...

  • Page 108: Engine

    Engine 3-20 8. Install: • coolant reservoir 9. Connect: • water pump inlet 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 notes for coolant coolant is potentially harmful a...

  • Page 109: Chassis

    Chassis 3-21 eas21140 chassis eas21150 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Push the brake lever forward. B. Turn the adjusting knob “1” in direction “a” or “b” u...

  • Page 110: Chassis

    Chassis 3-22 caution: ec2c01009 after adjusting the installed rear master cyl- inder length, make sure there is no brake drag. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch” on page 3-23. Eas21240 checking the b...

  • Page 111: Chassis

    Chassis 3-23 1. Operate the brake. 2. Check: • rear brake pad wear limit “a” reached → replace the brake pads as a set. Refer to “rear brake” on page 4-29. Eas21280 checking the front brake hoses the following procedure applies to all of the brake hoses and brake hose holders. 1. Check: • brake hose...

  • Page 112: Chassis

    Chassis 3-24 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21360 bleeding the hydraulic brake system warning ewa13100 bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake ope...

  • Page 113: Chassis

    Chassis 3-25 k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid level” on page 3-22. Warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas213...

  • Page 114: Chassis

    Chassis 3-26 note: measure the drive chain slack halfway between the drive axle and the rear wheel axle. 3. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle nut “1”. B. Loosen both locknuts “2”. C. Turn both adjusting bolts “3” in direction “a” o...

  • Page 115: Chassis

    Chassis 3-27 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer “1”, upper ring nut “2”, and rubber washer “3”. B. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”. Note: set the torque wrench at a r...

  • Page 116: Chassis

    Chassis 3-28 d. Hold the spring gauge at a 90° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. E. Repeat the above procedure on the opposite handlebar. F. If the steering head tension is out of specifica- tion (both handlebars should...

  • Page 117: 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 screw “1” in direction “a” or “b”. ▲▲▲ ▲ ...

  • Page 118: Chassis

    Chassis 3-30 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • compression damping (slow compression damping) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21610 adjusting th...

  • Page 119: Chassis

    Chassis 3-31 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲ ▲ ...

  • Page 120: Chassis

    Chassis 3-32 2. Adjust: • compression damping (slow compression damping) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21650 checking the tires the following procedure applies to both of...

  • Page 121: Chassis

    Chassis 3-33 warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden deflation. • when using a tube tire, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. • to avoid ...

  • Page 122: Chassis

    Chassis 3-34 warning ewa13260 never attempt to make any repairs to the wheel. Note: after a tire or wheel has been changed or re- placed, always balance the wheel. Eas21690 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Warning ewa13270 da...

  • Page 123: Electrical System

    Electrical system 3-35 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-77. Eas21770 checking the fuses refer to “electrical components” on page 8-77. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 124: Electrical System

    Electrical system 3-36 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • headlight beam (horizontally) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a. Left headlight b. Right ...

  • Page 125: Chassis

    4 chassis general chassis ...................................................................................... 4-1 front wheel .............................................................................................. 4-4 removing the front wheel ..................................................

  • Page 126

    Rear brake............................................................................................... 4-29 introduction..................................................................................... 4-34 checking the rear brake disc ................................................... 4-34 ...

  • Page 127

    Chain drive ............................................................................................... 4-70 removing the drive chain ............................................................ 4-71 checking the drive chain ............................................................. 4-71 chec...

  • Page 128: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 rider seat 1 2 passenger seat 1 3 fuel tank bracket 1 4 negative battery lead 1 disconnect. 5 positive battery lead 1 disconnect. 6 battery band 1 7 battery 1 for installation, reverse...

  • Page 129: General Chassis

    General chassis 4-2 removing the tail/brake light assembly order job/parts to remove q’ty remarks rider seat/passenger seat refer to “general chassis” on page 4-1. 1 owner’s tool kit 1 2 rear upper cowling 1 3 rear right turn signal light coupler 1 disconnect. 4 rear left turn signal light coupler 1...

  • Page 130: General Chassis

    General chassis 4-3 removing the side cowlings and front cowling assembly order job/parts to remove q’ty remarks 1 side panel 2 2 upper side cowling 2 3 lower side cowling 2 4 front turn signal/position light coupler 2 disconnect. 5 bottom cowling 2 6 bottom cowling inner panel 2 7 air intake duct 2...

  • Page 131: Front Wheel

    Front wheel 4-4 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 left reflector assembly 1 2 right reflector assembly 1 3 left front brake hose holder 1 4 right fron...

  • Page 132: Front Wheel

    Front wheel 4-5 13 front brake disc 2 for installation, reverse the removal proce- dure. Removing the front wheel and brake discs order job/parts to remove q’ty remarks.

  • Page 133: Front Wheel

    Front wheel 4-6 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 134: Front Wheel

    Front wheel 4-7 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. Note: place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • r...

  • Page 135: Front Wheel

    Front wheel 4-8 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: ec2c01010 do not contact the wheel bearing inner race “1” or ba...

  • Page 136: Front Wheel

    Front wheel 4-9 b. Turn the front wheel 90° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • fro...

  • Page 137: Front Wheel

    Front wheel 4-10 caution: ec2c01015 before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. Note: lubricate the front wheel axle bolt mating surfac- es with lithium-soap-based grease. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 138: Rear Wheel

    Rear wheel 4-11 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the rear wheel is elevated. 1 rear brake caliper 1 2 drive chain adjusting locknut 2 loosen. 3 drive chain adjusting bolt 2 loosen. 4 rear wheel axle...

  • Page 139: Rear Wheel

    Rear wheel 4-12 removing the rear brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sprocket 1 3 collar 1 4 dust cover 1 5 oil seal 1 6 bearing 1 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 dust cover 1 10 collar 1 for installat...

  • Page 140: Rear Wheel

    Rear wheel 4-13 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 141: Rear Wheel

    Rear wheel 4-14 eas22040 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 a suitable stand so that the rear wheel is elevated. 2. Remove: • rear brake caliper “1” n...

  • Page 142: Rear Wheel

    Rear wheel 4-15 2. Replace: • rear wheel sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. B. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. C. Install the new rear wheel spro...

  • Page 143: Rear Wheel

    Rear wheel 4-16 4. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-25. 5. Install: • rear brake caliper warning ewa13500 make sure the brake hose is routed properly. Drive chain slack 35.0–45.0 mm (1.38–1.77 in) t r . . Rear brake caliper bolt (m12) 27 nm (2.7 m·kg, ...

  • Page 144: Front Brake

    Front brake 4-17 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 reflector assembly 1 2 brake hose holder 1 3 front brake caliper 1 4 brake pad clip 2 5 brake pad pin 1 6 brake pad spring...

  • Page 145: Front Brake

    Front brake 4-18 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 brake fluid reservoir cap holder 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid...

  • Page 146: Front Brake

    Front brake 4-19 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 bleed screw 1 3 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. Ls 1 3 2 1 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) new new.

  • Page 147: Front Brake

    Front brake 4-20 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” on page 3-24. 1 reflector assembly 1 2 brake hose holder 1 3 front brake ho...

  • Page 148: Front Brake

    Front brake 4-21 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 front brake pad 2 5 brake caliper piston 4 6 brake caliper piston seal 8 7 b...

  • Page 149: Front Brake

    Front brake 4-22 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 150: Front Brake

    Front brake 4-23 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 151: Front Brake

    Front brake 4-24 refer to “checking the brake fluid level” on page 3-22. 5. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-24. Eas22300 removing the front brake calipers the following procedure applies to bot...

  • Page 152: Front Brake

    Front brake 4-25 • brake caliper cylinders “2” scratches/wear → replace the brake caliper assembly. • brake caliper body “3” cracks/damage → replace the brake caliper assembly. • brake fluid delivery passages (brake caliper body) obstruction → blow out with compressed air. Warning ewa13600 whenever ...

  • Page 153: Front Brake

    Front brake 4-26 • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • when refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lowe...

  • Page 154: Front Brake

    Front brake 4-27 eas22540 installing the front brake master cylinder 1. Install: • front brake master cylinder “1” • front brake master cylinder holder “2” note: • install the brake master cylinder holder with the “up” mark “a” facing up. • align the mating surfaces of the brake master cylinder hold...

  • Page 155: Front Brake

    Front brake 4-28 6. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-24. A.

  • Page 156: Rear Brake

    Rear brake 4-29 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad shim 2 5 brake pad insulator 2 6 rear brake pad 2 7 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 157: Rear Brake

    Rear brake 4-30 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 brake fluid reservoir bracket 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid rese...

  • Page 158: Rear Brake

    Rear brake 4-31 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake hose joint 1 3 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. New new new ls 2 1 3.

  • Page 159: Rear Brake

    Rear brake 4-32 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 rear brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 rear brake caliper 1 5 brake pad spring 1 for installation, re...

  • Page 160: Rear Brake

    Rear brake 4-33 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad shim 2 4 brake pad insulator 2 5 rear brake pad 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston seal 2 9 bleed screw 1 for assembly, reverse...

  • Page 161: Rear Brake

    Rear brake 4-34 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 162: Rear Brake

    Rear brake 4-35 • brake pad spring note: always install new brake pads, brake pad insu- lators, brake pad shims, and a brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into a...

  • Page 163: Rear Brake

    Rear brake 4-36 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. Warning ewa13550 • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled fro...

  • Page 164: Rear Brake

    Rear brake 4-37 eas22670 installing the rear brake caliper 1. Install: • rear brake caliper “1” (temporarily) • copper washers • rear brake hose “2” • rear brake hose union bolt “3” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” o...

  • Page 165: Rear Brake

    Rear brake 4-38 eas22700 removing the rear brake master cylinder note: before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • rear brake hose union bolt “1” • copper washers “2” • rear brake hose “3” note: to collect any remaining brake flu...

  • Page 166: Rear Brake

    Rear brake 4-39 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 167: Handlebars

    Handlebars 4-40 eas22850 handlebars removing the handlebars order job/parts to remove q’ty remarks left side panel/left upper side cowling refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Canister (for califor...

  • Page 168: Handlebars

    Handlebars 4-41 11 front brake light switch connector 2 disconnect. 12 right handlebar switch/bracket 1/1 13 front brake master cylinder holder 1 14 front brake master cylinder assembly 1 15 handlebar bolt 2 16 upper bracket pinch bolt 2 loosen. 17 steering stem nut 1 18 rectifier/regulator holder 1...

  • Page 169: Handlebars

    Handlebars 4-42 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 170: Handlebars

    Handlebars 4-43 note: there should be 1–3 mm (0.04–0.12 in) of clear- ance “a” between the throttle grip and the right grip end. 6. Install: • clutch lever assembly “1” note: align the mating surfaces of the clutch lever as- sembly with the punch mark “a” on the left han- dlebar. 7. Install: • left ...

  • Page 171: Front Fork

    Front fork 4-44 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. Side panels refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-4. 1 front fender 1 2 upper bracket...

  • Page 172: Front Fork

    Front fork 4-45 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 washer 1 4 damper adjusting rod 1 5 nut 1 6 spacer 1 7 fork spring 1 8 spring seat 1 9 outer tube 1 10 dust seal 1 11 oil...

  • Page 173: Front Fork

    Front fork 4-46 15 inner tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the front fork legs order job/parts to remove q’ty remarks t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) 1 2 new 3 5 6 7 8 9 13 12 1...

  • Page 174: Front Fork

    Front fork 4-47 eas22970 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 175: Front Fork

    Front fork 4-48 note: loosen the nut using a proper tool that has a thickness of 3 mm (0.12 in) or less. D. Remove the cap bolt. E. Remove the rod holder and fork spring com- pressor. F. Remove the nut and spacer. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Drain: • fork oil note: stroke th...

  • Page 176: Front Fork

    Front fork 4-49 3. Check: • damper rod damage/wear → replace. Obstruction → blow out all of the oil passag- es with compressed air. • damper adjusting rod bends/damage → replace. Caution: eca14200 • the front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construc...

  • Page 177: Front Fork

    Front fork 4-50 caution: ec2c01012 make sure the numbered side of the oil seal faces bottom side. Note: • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the inner tube with fork oil. • before installing the oil seal, cover the top ...

  • Page 178: Front Fork

    Front fork 4-51 10.Fully compress the front fork leg. 11.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 disassembling and assembling ...

  • Page 179: Front Fork

    Front fork 4-52 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the rod puller attachment. B. Install the spring seat. C. Install the fork spring. Note: install the spring with the smaller pitch “a” facing up “a”. D. Install the spacer. E. Install the nut. F. Reinstall the rod puller att...

  • Page 180: Front Fork

    Front fork 4-53 n. Remove the rod holder and fork spring com- pressor. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 16.Install: • cap bolt (to the outer tube) note: temporarily tighten the cap bolt. Eas23050 installing the front fork legs the following procedure applies to both of the front for...

  • Page 181: Front Fork

    Front fork 4-54 • fasten the front brake hose to the right front fork leg with the plastic locking tie. 6. Adjust: • spring preload • rebound damping • compression damping refer to “adjusting the front fork legs” on page 3-28. 1 2.

  • Page 182: Steering Head

    Steering head 4-55 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. Front fork legs refer to “front fork” on page 4-44. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air fil...

  • Page 183: Steering Head

    Steering head 4-56 10 lower bracket cover 1 11 front brake hose joint bracket 1 12 steering stem nut 1 13 upper bracket 1 14 lock washer 1 15 upper ring nut 1 16 rubber washer 1 17 lower ring nut 1 18 lower bracket 1 19 upper bearing cover 1 20 upper bearing inner race 1 21 upper bearing 1 22 lower ...

  • Page 184: Steering Head

    Steering head 4-57 26 lower bearing outer race 1 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks ls t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 10 nm ...

  • Page 185: Steering Head

    Steering head 4-58 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 “1” • rubber washer • lower ring nut “2” • lower bracket warning ewa13730 securely ...

  • Page 186: Steering Head

    Steering head 4-59 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to “checking and adjusting the steering head” on page 3-26. 3. Install: • upper bracket • steering stem nut • right handlebar assembly • left handlebar assembly note: temporarily tigh...

  • Page 187: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-60 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks exhaust pipe assembly brackets refer to “engine removal” on page 5-1. Rear wheel refer to “rear wheel” on page 4-11. Fuel tank refer to “fuel tank”...

  • Page 188: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-61 13 oil seal 6 14 bearing 2 15 bearing 2 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order job/parts to remove q’ty remarks 1 1 1 1 2 9 13 15 14 13 12 15 10 9 9 3 5 13 8 4 6 7 14 13 11 3 5 2 1 1 ls ls ls ls ls new new ...

  • Page 189: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-62 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 190: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 • spring damage/wear → replace the rear shock ab- sorber assembly. • bushing damage/wear → replace. • spacer damage/scratches → replace. • bolts bends/damage/wear → replace. Eas23260 checking the connecting arm and relay arm 1. Check: • connecting arms • relay arm d...

  • Page 191: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-64 4. Tighten: • spacer bolt • rear shock absorber assembly lower nut • rear shock absorber assembly upper nut • rear shock absorber assembly bracket nut 5. Install: • connecting arms note: when installing the connecting arms, lift up the swingarm. 6. Tighten: • connec...

  • Page 192: Swingarm

    Swingarm 4-65 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-11. Rear shock absorber refer to “rear shock absorber as- sembly” on page 4-60. Drive chain guide (drive sprocket side) refer to “chain drive” on page 4-70. 1 drive...

  • Page 193: Swingarm

    Swingarm 4-66 13 swingarm 1 14 dust cover 2 15 bearing 1 16 bearing 1 17 spacer 1 18 spacer 1 19 oil seal 2 20 bearing 2 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks 4 16 9 14 14 20 13 15 19 17 6 5 3 10 12 8 3 2 18 11 1 1 2 ls ls 20 ...

  • Page 194: Swingarm

    Swingarm 4-67 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 195: Swingarm

    Swingarm 4-68 warning ewa13770 do not attempt to straighten a bent pivot shaft. 3. Wash: • pivot shaft • dust covers • spacers • washers • bearings 4. Check: • dust covers • spacers • oil seals damage/wear → replace. • bearings damage/pitting → replace. Eas23380 installing the swingarm 1. Lubricate:...

  • Page 196: Swingarm

    Swingarm 4-69 note: • lubricate the swingarm pivot ring nut threads and mating surfaces with lithium-soap-based grease. • tighten the swingarm pivot shaft ring nut with the ring nut wrench “2”. 5. Install: • swingarm pivot shaft nut note: lubricate the swingarm pivot shaft nut threads and mating sur...

  • Page 197: Chain Drive

    Chain drive 4-70 eas23400 chain drive removing the drive sprocket and drive chain order job/parts to remove q’ty remarks left lower side cowling refer to “general chassis” on page 4-1. Left bottom cowling refer to “general chassis” on page 4-1. Shift rod refer to “engine removal” on page 5-1. 1 driv...

  • Page 198: Chain Drive

    Chain drive 4-71 eas23410 removing the drive chain 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. Remove: • drive chain (with the ...

  • Page 199: Chain Drive

    Chain drive 4-72 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • o-rings “1” damage → replace the drive chain. • drive chain rollers “2” damage/wear → replace the drive chain. • drive chain side plates “3” damage/wear → replace the drive chain. Cracks → replace the drive chain and make...

  • Page 200: Chain Drive

    Chain drive 4-73 1 2 3 a a new.

  • Page 201: Engine

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

  • Page 202

    Clutch ........................................................................................................ 5-37 removing the clutch ..................................................................... 5-41 checking the friction plates .................................................... 5-41 c...

  • Page 203

    Transmission ........................................................................................... 5-71 removing the transmission ........................................................ 5-76 checking the shift forks ............................................................ 5-76 checking th...

  • Page 204: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the exhaust pipe assembly order job/parts to remove q’ty remarks lower side cowlings refer to “general chassis” on page 4-1. Bottom cowlings refer to “general chassis” on page 4-1. Radiator bracket refer to “radiator” on page 6-1. 1 exup valve pull...

  • Page 205: Engine Removal

    Engine removal 5-2 12 exhaust pipe assembly bracket (right side) 1 13 exup servo motor bracket 1 14 exup servo motor cover 1 15 exup servo motor coupler 1 disconnect. 16 exup servo motor 1 for installation, reverse the removal proce- dure. Removing the exhaust pipe assembly order job/parts to remove...

  • Page 206: Engine Removal

    Engine removal 5-3 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Canister (for california only) refer to “throttle bodies” on page 7-8. Throttle body refer to “throttle bodi...

  • Page 207: Engine Removal

    Engine removal 5-4 6 negative battery terminal 1 disconnect. 7 engine ground terminal 1 disconnect. 8 oil level switch coupler 1 disconnect. 9 crankshaft position sensor coupler 1 disconnect. 10 neutral switch coupler 1 disconnect. 11 speed sensor 1 12 stator coil assembly coupler 1 disconnect. 13 c...

  • Page 208: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the engine. 1 engine mounting bolt (front right side) 2 2 engine mounting collar (outside) 2 3 engine mounting collar (inside) 2 4 engine mounting bolt (front left side) 2 5 engine mounti...

  • Page 209: Engine Removal

    Engine removal 5-6 eas23720 installing the engine 1. Install: • engine “1” • engine mounting bolt (rear lower side) “2” • engine mounting bolt (rear upper side) “3” • engine mounting collars (inside) “4” • engine mounting collars (outside) “5” • engine mounting nut (rear lower side) “6” (temporarily...

  • Page 210: Camshafts

    Camshafts 5-7 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks radiator refer to “radiator” on page 6-1. Throttle body refer to “throttle bodies” on page 7-8. Air cut-off valve/reed valve assembly refer to “air induction system” on page 7-15. 1 ignition coil...

  • Page 211: Camshafts

    Camshafts 5-8 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “pickup rotor” on page 5-30. 1 camshaft sprocket bolt 4 loosen. 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 intake camshaft cap 3 5 exhaust camshaft cap 3 6 camshaft sprocket 2 ...

  • Page 212: Camshafts

    Camshafts 5-9 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to “pickup rotor” on page 5-30. 2. Align: • tdc mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at...

  • Page 213: Camshafts

    Camshafts 5-10 3. Measure: • camshaft runout out of specification → replace. 4. Measure: • camshaft-journal-to-camshaft-cap clearance out of specification → measure the camshaft journal diameter. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshaft into the cylinder head (withou...

  • Page 214: Camshafts

    Camshafts 5-11 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Measure: • camshaft journal diameter “a” out of specification → replace the camshaft. Within specification → replace the cylinder head and the camshaft caps as a set. Eas23870 checking the timing chain, camshaft sprockets, and timin...

  • Page 215: Camshafts

    Camshafts 5-12 note: prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain ten- sioner housing. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the timing chain tensioner springs, tim- ing chain tensioner spring seat, and timing chain tensioner r...

  • Page 216: Camshafts

    Camshafts 5-13 2. Install: • timing chain “1” • exhaust camshaft “2” • intake camshaft “3” (with the camshaft sprockets temporarily tightened) note: • make sure the match marks “a” on the cam- shaft sprockets are aligned with the cylinder head edge “b”. • be sure to install the timing chain so that ...

  • Page 217: Camshafts

    Camshafts 5-14 6. Rotate the crankshaft a few times to release the timing chain tensioner rod. Note: if the engine is not disassembled, set the engine stop switch to “ ”, and then crank the engine a few times by pressing the start switch for approx- imately 0.5–1.0 second each time. 7. Check that th...

  • Page 218: Cylinder Head

    Cylinder head 5-15 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 5-7. 1 coolant temperature sensor 1 2 cylinder head 1 3 cylinder head gasket 1 4 dowel pin 2 for installati...

  • Page 219: Cylinder Head

    Cylinder head 5-16 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts • cylinder head nuts note: • loosen the nuts, cap nuts, and bolts in de- creasing numerical order (refer to the numbers in the illustration). • loosen each nut 1/2 of a turn at a time. After all of the nuts are f...

  • Page 220: Cylinder Head

    Cylinder head 5-17 • cylinder head bolts “11”, “12” note: tighten the cylinder head nuts, cap nuts, and bolts in the proper tightening sequence as shown and torque them in two stages. T r . . Cylinder head cap nut (1st) 30 nm (3.0 m·kg, 22 ft·lb) cylinder head cap nut (final) 60 nm (6.0 m·kg, 43 ft·...

  • Page 221: Valves and Valve Springs

    Valves and valve springs 5-18 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 5-15. 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 222: Valves and Valve Springs

    Valves and valve springs 5-19 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 223: Valves and Valve Springs

    Valves and valve springs 5-20 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 224: Valves and Valve Springs

    Valves and valve springs 5-21 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 → replac...

  • Page 225: Valves and Valve Springs

    Valves and valve springs 5-22 b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Note: where the valve seat and valve face contacted one another, the blueing will have been re-...

  • Page 226: Valves and Valve Springs

    Valves and valve springs 5-23 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 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 spri...

  • Page 227: Valves and Valve Springs

    Valves and valve springs 5-24 3. 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. 4....

  • Page 228: Valves and Valve Springs

    Valves and valve springs 5-25 • each valve lifter and valve pad must be rein- stalled in its original position..

  • Page 229: Generator and Starter Clutch

    Generator and starter clutch 5-26 eas24480 generator and starter clutch removing the generator and starter clutch order job/parts to remove q’ty remarks left bottom cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-11. 1 stator coil assemb...

  • Page 230: Generator and Starter Clutch

    Generator and starter clutch 5-27 11 starter clutch gear 1 for installation, reverse the removal proce- dure. Removing the generator and starter clutch order job/parts to remove q’ty remarks 3 2 6 5 4 8 7 11 10 9 4 1 new new new lt lt e (9) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 ...

  • Page 231: Generator and Starter Clutch

    Generator and starter clutch 5-28 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”) caution: eca13880 ...

  • Page 232: Generator and Starter Clutch

    Generator and starter clutch 5-29 eas24500 installing the generator 1. Install: • generator rotor • washer • generator rotor bolt note: • clean the tapered portion of the crankshaft and the generator rotor hub. • lubricate the generator rotor bolt threads and washer mating surfaces with engine oil. ...

  • Page 233: Pickup Rotor

    Pickup rotor 5-30 eas24520 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks right bottom cowling 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 5-26. 1 clutch cable 1 dis...

  • Page 234: Pickup Rotor

    Pickup rotor 5-31 eas24530 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer • pickup rotor note: while holding the generator rotor “2” with the ro- tor sheave holder “3”, loosen the pickup rotor bolt. Eas24540 installing the pickup rotor 1. Install: • pickup rotor “1” • washer •...

  • Page 235: Pickup Rotor

    Pickup rotor 5-32.

  • Page 236: Electric Starter

    Electric starter 5-33 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air filter case refer to “air filter case” on page 7-5. Canister (for california only) refer to “throttle bodies” on page 7-8. Fuel tan...

  • Page 237: Electric Starter

    Electric starter 5-34 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 lock washer 1 4 oil seal 1 5 bearing 1 6 washer set 1 7 starter motor yoke 1 8 armature assembly 1 9 gasket 2 10 washer set 2 11 brush holder (along with the brushe...

  • Page 238: Electric Starter

    Electric starter 5-35 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 239: Electric Starter

    Electric starter 5-36 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: • starter motor yoke “1” note: align the tab “a” on the brush holder with the slot “b” in the sta...

  • Page 240: Clutch

    Clutch 5-37 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right bottom cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-11. Coolant drain. Refer to “changing the coolant” on page 3-19. 1 water pump breat...

  • Page 241: Clutch

    Clutch 5-38 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 1 2 pull lever shaft 1 3 oil seal 1 4 bearing 1 5 bearing 1 for installation, reverse the removal proce- dure. Ls new new e 5 4 3 2 ls 1.

  • Page 242: Clutch

    Clutch 5-39 removing the clutch order job/parts to remove q’ty remarks ventilation chamber oil drain pipe refer to “oil pump” on page 5-50. 1 clutch spring 6 2 pressure plate 1 3 pull rod 1 4 friction plate 1 1 brown painting 5 clutch plate 1 1 6 friction plate 2 7 black painting 7 clutch plate 2 1 ...

  • Page 243: Clutch

    Clutch 5-40 17 bearing 1 18 clutch housing 1 19 oil pump drive chain 1 20 thrust washer 2 1 21 thrust washer 3 1 22 oil pump drive chain guide 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks 1 2 3 4 5 6 (6) (6) 7 8 9 11 10 12 13 14 15 1...

  • Page 244: Clutch

    Clutch 5-41 eas25070 removing the clutch 1. Remove: • friction plates • clutch plates note: be sure to mark the friction plates and clutch plates or note the position of each part so that they are installed in their original positions. 2. Loosen: • clutch boss nut “1” note: while holding the clutch ...

  • Page 245: Clutch

    Clutch 5-42 note: the clutch plate thickness specification listed above is for the plates with the standard thick- ness only. If a clutch plate with one of the other two plate thicknesses is installed, use 1.50–1.70 mm (0.059–0.067 in) or 2.20–2.40 mm (0.086– 0.094 in) for the specification accordin...

  • Page 246: Clutch

    Clutch 5-43 eas25150 checking the clutch housing 1. Check: • clutch housing dogs damage/pitting/wear → deburr the clutch housing dogs or replace the clutch housing. Note: pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: • bearing damage/wear → replace the bearing a...

  • Page 247: Clutch

    Clutch 5-44 2. Check: • bearing damage/wear → replace. Et2c01011 checking the oil pump drive sprocket and oil pump drive chain 1. Check: • oil pump drive sprocket cracks/damage/wear → replace the clutch housing, oil pump drive chain, and oil pump driven sprocket as a set. 2. Check: • oil pump drive ...

  • Page 248: Clutch

    Clutch 5-45 • stake the clutch boss nut at a cutout “a” in the main axle. 5. Lubricate: • friction plates • clutch plates (with the recommended lubricant) 6. Install: • friction plates • clutch plates note: • first, install a friction plate and then alternate between a clutch plate and a friction pl...

  • Page 249: Clutch

    Clutch 5-46 10.Install: • pull lever spring “1” • pull lever “2” • washer • circlip note: • make sure that the mark “a” on the pull lever is facing up. • when installing the pull lever, push it and check that its punch mark “b” aligns with the mark “c” on the clutch cover. Make sure that the pull ro...

  • Page 250: Shift Shaft

    Shift shaft 5-47 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks shift arm refer to “engine removal” on page 5-1. Clutch housing refer to “clutch” on page 5-37. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 circlip 1 6 washer 1 7 stopper l...

  • Page 251: Shift Shaft

    Shift shaft 5-48 13 bearing 2 for installation, reverse the removal proce- dure. Removing the shift shaft and stopper lever order job/parts to remove q’ty remarks 3 10 9 7 6 5 4 13 13 12 2 1 8 11 ls new new new lt e e t r . . 22 nm (2.2 m • kg, 16 ft • ib).

  • Page 252: Shift Shaft

    Shift shaft 5-49 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. • stopper lever ...

  • Page 253: Oil Pump

    Oil pump 5-50 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 3-11. Coolant drain. Refer to “changing the coolant” on page 3-19. Exhaust pipe assembly refer to “engine removal” on page 5-1. Water ...

  • Page 254: Oil Pump

    Oil pump 5-51 9 oil pipe 1 10 ventilation chamber oil drain pipe 1 11 oil pump assembly 1 12 dowel pin 2 13 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 8 10 13 6 5 12 7 9 7 9 11 10 4 4 2 1 3 11 4 ...

  • Page 255: Oil Pump

    Oil pump 5-52 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 housing 1 8 oil pump driven sprocket 1 for assembly, reverse the disassembly pro- cedure..

  • Page 256: Oil Pump

    Oil pump 5-53 eas24930 removing the oil pan 1. Remove: • oil level switch lead holder • bottom cowling brackets • oil pan • oil pan gasket 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. Eas24960 checkin...

  • Page 257: Oil Pump

    Oil pump 5-54 eas24980 checking the oil pipes the following procedure applies to all of the oil delivery pipes. 1. Check: • ventilation chamber oil drain pipe • oil pipe damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strain...

  • Page 258: Crankcase

    Crankcase 5-55 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 5-15. Starter clutch refer to “generator and starter clutch” on page 5-26. Shift shaft refer to “shift shaft”...

  • Page 259: Crankcase

    Crankcase 5-56 9 oil baffle plate 2 1 10 lower crankcase 1 11 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks 11 4 3 2 11 6 10 1 8 9 7 5 t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r . ...

  • Page 260: Crankcase

    Crankcase 5-57 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. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerical order (refer to the numbers in the il...

  • Page 261: Crankcase

    Crankcase 5-58 caution: eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand. 6. Install: • crankcase bolts note: • lubricate the bolts “1”–“10” thread part and washers with engine oil. • lubricate the bolts “...

  • Page 262: Connecting Rods and Pistons

    Connecting rods and pistons 5-59 eas24370 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 5-55. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston 4 ...

  • Page 263: Connecting Rods and Pistons

    Connecting rods and pistons 5-60 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 264: Connecting Rods and Pistons

    Connecting rods and pistons 5-61 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 265: Connecting Rods and Pistons

    Connecting rods and pistons 5-62 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 the oil ring rail’s gap is exces- sive, replace ...

  • Page 266: Connecting Rods and Pistons

    Connecting rods and pistons 5-63 et2c01013 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 267: Connecting Rods and Pistons

    Connecting rods and pistons 5-64 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Select: • big end bearings (p 1 –p 4 ) note: • the numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. • p 1 –p 4 refer to the...

  • Page 268: Connecting Rods and Pistons

    Connecting rods and pistons 5-65 3. Offset: • piston ring end gaps 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) 5. Lubricate: • bolt threads • nut seats (with the recommended lubricant) 6. Lubricate: • crankshaft pins • big end bearings • connecting rod inner sur...

  • Page 269: Connecting Rods and Pistons

    Connecting rods and pistons 5-66 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ warning ew2c01007 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 nuts with a torque wrench. B. Put a mark ...

  • Page 270: Crankshaft

    Crankshaft 5-67 eas25960 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-55. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-59. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft journa...

  • Page 271: Crankshaft

    Crankshaft 5-68 eas26040 removing the crankshaft journal bearings 1. Remove: • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) note: identify the position of each crankshaft journal bearing so that it can be reinstalled in i...

  • Page 272: Crankshaft

    Crankshaft 5-69 e. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves. Note: • align the projections “a” of the crankshaft jour- nal lower bearings with the notches “b” in the lower crankcase. • do not move the crankshaft until the clearance ...

  • Page 273: Crankshaft

    Crankshaft 5-70 eas26200 installing the crankshaft 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) note: • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcas...

  • Page 274: Transmission

    Transmission 5-71 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 5-55. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 shift drum retainer 2 6 spring 2 7 shif...

  • Page 275: Transmission

    Transmission 5-72 15 bearing 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 e e e e 12 11 7 13 5 6 7 6 10 5 4 9 8 1 2 3 15 14 lt lt e e lt e t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10...

  • Page 276: Transmission

    Transmission 5-73 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 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd/4th pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 col...

  • Page 277: Transmission

    Transmission 5-74 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 3rd wheel gear 1 8 collar 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 278: Transmission

    Transmission 5-75 18 2nd wheel gear 1 19 collar 1 20 bearing 1 21 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks e m 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 20 m m m 7 new new new m m.

  • Page 279: Transmission

    Transmission 5-76 et2c01014 removing the transmission 1. Remove: • main axle assembly “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the main axle assembly bearing housing bolts “2” b. Insert two bolts “3” of the proper size, as shown in the illustration, into the main axle assembly...

  • Page 280: Transmission

    Transmission 5-77 • shift drum bearing “2” damage/pitting → replace the shift drum as- sembly. Eas26300 checking the transmission 1. Measure: • main axle runout (with a centering device and dial gauge “1”) out of specification → replace the main axle. 2. Measure: • drive axle runout (with a centerin...

  • Page 281: Transmission

    Transmission 5-78 2. Install: • toothed lock washer retainer “1” • toothed lock washer “2” note: • with the toothed lock washer retainer “1” in the groove “a” in the axle, align the projection “c” on the retainer with an axle spline “b”, and then install the toothed lock washer “2”. • be sure to ali...

  • Page 282: Transmission

    Transmission 5-79 • shift fork guide bar • springs • shift drum retainers “3” • bearing • oil seal • circlip “4” • drive axle assembly “5” note: • install shift fork-r into the groove “a” in the 5th wheel gear and shift fork-l into the groove “b” in the 6th wheel gear on the drive axle. • install th...

  • Page 283: Cooling System

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

  • Page 284: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks lower side cowlings/bottom cowlings refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-19. 1 coolant reservoir breather hose 1 2 coolant reservoir hose 1 3 coolan...

  • Page 285: Radiator

    Radiator 6-2 13 radiator bracket 1 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to remove q’ty remarks t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft •...

  • Page 286: 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 287: 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 3-11. Coolant drain. Refer to “changing the coolant” on page 3-19. Exhaust pipe assembly refer to “engine removal” on page 5-1. 1 oil cooler ...

  • Page 288: Oil Cooler

    Oil cooler 6-5 10 o-ring 1 for installation, reverse the removal proce- dure. Removing the oil cooler order job/parts to remove q’ty remarks t r . . 63 nm (6.3 m • kg, 45 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) lt new new ls ls 4 3 5 6 2 7 9 10 8 1 e new.

  • Page 289: Oil Cooler

    Oil cooler 6-6 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose • water jacket joint hose cracks/damage/wear → replace. 3. Check: • water jacket joint pipe damage → replace. Obstruction → wash and blow out wit...

  • Page 290: Thermostat

    Thermostat 6-7 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks air filter case refer to “air filter case” on page 7-5. Canister (for california only) refer to “throttle bodies” on page 7-8. Coolant drain. Refer to “changing the coolant” on page 3-19. 1 coolant temp...

  • Page 291: 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 292: Water Pump

    Water pump 6-9 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 bottom cowling refer to “general chassis” on page 4-1. Air filter case re...

  • Page 293: Water Pump

    Water pump 6-10 eas26540 checking the water pump 1. Check: • water pump assembly cracks/damage → replace. 2. Check: • water pump inlet hose • water pump outlet hose • water pump breather hose cracks/damage/wear → replace. Eas26590 installing the water pump 1. Install: • water pump assembly “1” • o-r...

  • Page 294: Fuel System

    7 fuel system fuel tank .................................................................................................... 7-1 removing the fuel tank.................................................................. 7-3 removing the fuel pump ..........................................................

  • Page 295: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank and fuel pump order job/parts to remove q’ty remarks rider seat/fuel tank bracket refer to “general chassis” on page 4-1. 1 fuel tank side cover 2 2 fuel hose (fuel tank to primary injector fuel rail) 1 disconnect. 3 fuel sender coupler 1 disco...

  • Page 296: Fuel Tank

    Fuel tank 7-2 13 battery cover 1 for installation, reverse the removal proce- dure. Removing the fuel tank and fuel pump order job/parts to remove q’ty remarks 11 4 (6) 12 6 3 5 2 9 1 8 10 7 13 1 new t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 9 nm (0.9 m • ...

  • Page 297: Fuel Tank

    Fuel tank 7-3 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 (fuel tank to primary injector rail) warning ew2c01008 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel li...

  • Page 298: Fuel Tank

    Fuel tank 7-4 et2c01010 installing the fuel tank 1. Connect: • fuel tank breather hose (fuel tank to hose joint) “1” (except for california) • fuel tank overflow hose (fuel tank to hose joint) “2” • fuel tank breather hose “3” (except for cali- fornia) • fuel tank overflow hose “4” 2. Connect: • fue...

  • Page 299: Air Filter Case

    Air filter case 7-5 et2c01003 air filter case removing the air filter case and secondary injectors order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. 1 atmospheric pressure sensor coupler 1 disconnect. 2 atmospheric pressure sensor 1 3 crankcase breather hose 1 discon...

  • Page 300: Air Filter Case

    Air filter case 7-6 15 air filter element 1 16 air filter case joint (upper) 2 17 lower air filter case 1 18 air induction system hose (air filter case to air cut-off valve) 1 disconnect. 19 air filter case joint (lower) 2 for installation, reverse the removal proce- dure. Removing the air filter ca...

  • Page 301: Air Filter Case

    Air filter case 7-7 et2c01005 removing the fuel hose (primary injector fuel rail to secondary injector fuel rail) 1. Remove: • fuel hose (primary injector fuel rail to second- ary injector fuel rail) warning ew2c01008 cover fuel hose connections with a cloth when disconnecting them. Residual pres- s...

  • Page 302: Throttle Bodies

    Throttle bodies 7-8 eas26970 throttle bodies removing the rollover valve and canister (for california only) order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. 1 canister purge hose (throttle body-#4 to 3-way join...

  • Page 303: Throttle Bodies

    Throttle bodies 7-9 removing the throttle body assembly order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Canister (for california only) refer to “throttle bodies” on page 7-8. Air induction system cover refer t...

  • Page 304: Throttle Bodies

    Throttle bodies 7-10 12 heat protector 1 13 throttle body joint 4 for installation, reverse the removal proce- dure. Removing the throttle body assembly order job/parts to remove q’ty remarks t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 7 10 3 2 1 5 8 (8) 11 4 12 6 9 13.

  • Page 305: Throttle Bodies

    Throttle bodies 7-11 removing the primary injectors order job/parts to remove q’ty remarks 1 intake air pressure sensor coupler 1 disconnect. 2 cylinder-#1 primary injector coupler 1 disconnect. 3 cylinder-#2 primary injector coupler 1 disconnect. 4 cylinder-#3 primary injector coupler 1 disconnect....

  • Page 306: Throttle Bodies

    Throttle bodies 7-12 eas26980 checking the primary 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 307: Throttle Bodies

    Throttle bodies 7-13 et2c01007 adjusting the throttle position sensor (for throttle valves) 1. Check: • throttle position sensor (for throttle valves) refer to “checking the throttle po- sition sensor (for throttle valves)” on page 8-97. 2. Adjust: • throttle position sensor angle ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 308: Throttle Bodies

    Throttle bodies 7-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et2c01009 installing the throttle body joints 1. Install: • throttle body joints “1” note: be sure to install the throttle body joints with the “l” mark onto the throttle body openings for cyl- inders #1 and #2 and the joints wit...

  • Page 309: Air Induction System

    Air induction system 7-15 eas27040 air induction system 2 1 2 4 3 4 3 6 4 5 a a.

  • Page 310: Air Induction System

    Air induction system 7-16 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to cylinder head cover) 5. Reed valve assembly 6. Exhaust port.

  • Page 311: Air Induction System

    Air induction system 7-17 removing the air cut-off valve order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Canister (for california only) refer to “throttle bodies” on page 7-8. 1 air induction system cover 1 2 ...

  • Page 312: Air Induction System

    Air induction system 7-18 removing the reed valves order job/parts to remove q’ty remarks 1 reed valve cover 2 2 reed valve assembly 2 3 reed valve plate 4 for installation, reverse the removal proce- dure. 1 3 lt lt lt lt 1 2 2 3 lt lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • ...

  • Page 313: Air Induction System

    Air induction system 7-19 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 the emission of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 314: Electrical System

    8 electrical system ignition system ......................................................................................... 8-1 circuit diagram .................................................................................. 8-1 engine stopping due to sidestand operation....................... 8...

  • Page 315

    Electrical components ..................................................................... 8-77 checking the switches ................................................................. 8-81 checking the bulbs and bulb sockets ................................... 8-84 checking the fuses .................

  • Page 316: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l /y dg b l b /l w /y l b /l w /b r /y b /g y /b2 r /y...

  • Page 317: Ignition System

    Ignition system 8-2 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 17.Sidestand switch 22.Ecu (engine control unit) 23.Spark plug 24.Cylinder-#1 ignition coil 25.Cylinder-#2 ignition coil 26.Cylinder-#3 ignition coil 27.Cylinder-#4 ignition c...

  • Page 318: Ignition System

    Ignition system 8-3 et2c01023 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the neutral switch...

  • Page 319: Ignition System

    Ignition system 8-4 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Canister (for california only) 5. Side cowlings 6. Bottom cowlings ng → o...

  • Page 320: Ignition System

    Ignition system 8-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the engine stop switch. Refer to “checking the switches” on page 8-81. Replace the right handlebar switch. 9. Check the neutral switch. Refer to “checking the switches” on page 8-81. Replace the neutral switch. ...

  • Page 321: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram b b l/b b on off w w g/y l/w r/w r/b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g/y2 r/w ch ch b b dg b r/y b/g y/b2 r/y ch ch b b dg l l dg b b b b b b b b/g b/y b y b/g b b/y b l/r l/...

  • Page 322: Electric Starting System

    Electric starting system 8-8 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 8. Starter relay 10.Starter motor 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 64.Engine stop switch 65.Start switch 70.Clutch switch.

  • Page 323: Electric Starting System

    Electric starting system 8-9 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutr...

  • Page 324: Electric Starting System

    Electric starting system 8-10 a. When the transmission is in neutral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Relay unit (starting circuit cut-off relay) 7. Relay unit (diode) 8. Clutc...

  • Page 325: Electric Starting System

    Electric starting system 8-11 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Canister (for california only) 5. Side cowlings 6. Thermostat ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓...

  • Page 326: Electric Starting System

    Electric starting system 8-12 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 8-81. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-81. Replace the right hand...

  • Page 327: Charging System

    Charging system 8-13 eas27200 charging system eas27210 circuit diagram on off g/y l/w r/w r/b b br r r r r r/w l/w b br br r r r r r b w w w w w w r r r r r b b b b a r/w l/w2 r/b g/y l/w (black) r/w l/w3 r/w (blue) (blue) r/w r/g br/l br/l l/y l/b2 r/w g/y l/w2 r/w r/b b br w w w br/l br/l br r/y r...

  • Page 328: Charging System

    Charging system 8-14 1. Ac magneto 2. Rectifier/regulator 6. Main fuse 7. Battery 11.Engine ground.

  • Page 329: Charging System

    Charging system 8-15 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Bottom cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on p...

  • Page 330: Lighting System

    Lighting system 8-17 eas27240 lighting system eas27250 circuit diagram (red) l /y l/ b2 (red) l/ y l/ b r br/l r br/l l l gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l ...

  • Page 331: Lighting System

    Lighting system 8-18 3. Main switch 6. Main fuse 7. Battery 11.Engine ground 22.Ecu (engine control unit) 57.High beam indicator light 60.Meter light 68.Dimmer switch 75.Front right turn signal/position light 76.Front left turn signal/position light 77.Headlight (low beam) 78.Headlight (high beam) 7...

  • Page 332: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fue...

  • Page 333: Lighting System

    Lighting system 8-20 ng → ok ↓ 8. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 8-17. Properly connect or repair the lighting sys- tem’s wiring. This circuit is ok..

  • Page 334: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l /y dg b l b /l w /y l b /l w /b r /y b /g y /b2 r...

  • Page 335: Signaling System

    Signaling system 8-22 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 19.Fuel sender 22.Ecu (engine control unit) 40.Crankshaft position sensor 42.Coolant temperature sensor 45.Cylinder identification sensor 46.Speed sensor 49.Fuel level warni...

  • Page 336: Signaling System

    Signaling system 8-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings 4. Bottom cowlings 5. Rear cowl...

  • Page 337: Signaling System

    Signaling system 8-24 ng → ok ↓ the brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Properly con...

  • Page 338: Signaling System

    Signaling system 8-25 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ 4. Check the entire signaling system’s wiring. Refer to “circuit diag...

  • Page 339: Signaling System

    Signaling system 8-26 ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ the shift timing indicator light fails to come on. Ng → ok ↓ 2. Check the entire signaling system’s wiring. Refer to “circuit diagram” on ...

  • Page 340: Signaling System

    Signaling system 8-27 ng → ok ↓ 2. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Properly connect or repair the signaling system’s wiring. This circuit is ok..

  • Page 341: Cooling System

    Cooling system 8-29 eas27300 cooling system eas27310 circuit diagram gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l /y dg b l b /l w /y l b /l w /b r /y b /g y /b2 r /y ...

  • Page 342: Cooling System

    Cooling system 8-30 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 22.Ecu (engine control unit) 42.Coolant temperature sensor 87.Radiator fan motor relay 88.Right radiator fan motor fuse 89.Left radiator fan motor fuse 90.Right radiator fan motor 91.Left radiator fan motor.

  • Page 343: Cooling System

    Cooling system 8-31 eas27320 troubleshooting note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and radiator fan mo- tor) refer to “checkin...

  • Page 344: Fuel Injection System

    Fuel injection system 8-33 eas27330 fuel injection system eas27340 circuit diagram gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l /y dg b l b /l w /y l b /l w /b r /y b ...

  • Page 345: Fuel Injection System

    Fuel injection system 8-34 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 12.Etv fuse 13.Relay unit 15.Fuel pump relay 16.Neutral switch 17.Sidestand switch 18.Fuel pump 20.Throttle position sensor (for throt...

  • Page 346: Fuel Injection System

    Fuel injection system 8-35 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 347: Fuel Injection System

    Fuel injection system 8-36 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 348: Fuel Injection System

    Fuel injection system 8-37 18 exup servo motor (stuck) exup servo motor is stuck. Able able 19 sidestand switch (open circuit in the wire to the ecu) open circuit is detected in the in- put line from the sidestand switch to the ecu. Unable unable 20 intake air pressure sensor or atmospher- ic pressu...

  • Page 349: Fuel Injection System

    Fuel injection system 8-38 communication error with the meter 39 primary injector (open circuit) primary injector: open circuit detected. Able (depending on the number of faulty cylin- ders) able (depending on the number of faulty cylin- ders) 40 secondary injector (open circuit) secondary injector:...

  • Page 350: Fuel Injection System

    Fuel injection system 8-39 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 the meter. B. Identify the faulty s...

  • Page 351: Fuel Injection System

    Fuel injection system 8-40 eas27420 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “select” and “reset” buttons, turn the main switch to “on”, and continue to press the buttons for 8 secon...

  • Page 352: Fuel Injection System

    Fuel injection system 8-41 fault code table fault code no. Symptom probable cause of malfunction diagnostic code no. 11 no normal signals are re- ceived from the cylinder identification sensor when the engine is started or while the vehicle is being driven. • open or short circuit in sub-wire-harnes...

  • Page 353: Fuel Injection System

    Fuel injection system 8-42 22 air temperature sensor: open or short circuit detect- ed. • open or short circuit in wire harness. • defective air temperature sensor. • malfunction in ecu. • improperly installed air temperature sensor. 05 23 atmospheric pressure sen- sor: open or short circuit detecte...

  • Page 354: Fuel Injection System

    Fuel injection system 8-43 43 power supply to the injec- tors and the fuel pump is not normal. • open or short circuit in wire harness. • malfunction in ecu. 09 44 an error is detected while reading or writing on ee- prom (co adjustment val- ue). • malfunction in ecu. (the co adjustment value is not...

  • Page 355: Fuel Injection System

    Fuel injection system 8-44 sensor operation table diag- nostic code no. Item meter display checking method 01 throttle position sensor (for throttle valves) signal 1 • fully closed position 12–21 check with throttle valves fully closed. • fully opened position 97–106 check with throttle valves fully...

  • Page 356: Fuel Injection System

    Fuel injection system 8-45 14 throttle position sensor (for throttle cable pulley) signal 1 • fully closed position 12–22 check with throttle grip fully closed. • fully opened position 97–107 check with throttle grip fully opened. 15 throttle position sensor (for throttle cable pulley) signal 2 • fu...

  • Page 357: Fuel Injection System

    Fuel injection system 8-46 actuator operation table 62 malfunction history code erasure • no history 00 — • history exists • displays the total number of malfunctions, including the current malfunction, that have occurred since the history was last erased. (for example, if there have been three malf...

  • Page 358: Fuel Injection System

    Fuel injection system 8-47 33 cylinder-#4 ignition coil actuates the cylinder-#4 igni- tion coil five times at one- second intervals. Illuminates the engine trou- ble warning light. Check the spark five times. • connect an ignition checker. 36 primary injector #1 actuates the primary injector #1 fiv...

  • Page 359: Fuel Injection System

    Fuel injection system 8-48 eas27460 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 360: Fuel Injection System

    Fuel injection system 8-49 fault code no. 11 symptom no normal signals are received from the cylinder identifi- cation sensor when the engine is started or while the ve- hicle is being driven. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement met...

  • Page 361: Fuel Injection System

    Fuel injection system 8-50 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 l...

  • Page 362: Fuel Injection System

    Fuel injection system 8-51 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 363: Fuel Injection System

    Fuel injection system 8-52 fault code no. 15 symptom throttle position sensor (for throttle valves): open or short circuit detected. Diagnostic code no. 01 13 throttle position sensor (for throttle valves) signal 1 throttle position sensor (for throttle valves) signal 2 order item/components and pro...

  • Page 364: Fuel Injection System

    Fuel injection system 8-53 fault code no. 17 symptom exup servo motor circuit: open or short circuit detected. Diagnostic code no. 53 exup servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness e...

  • Page 365: Fuel Injection System

    Fuel injection system 8-54 fault code no. 19 symptom open circuit is detected in the input lead from the side- stand switch to the ecu. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu...

  • Page 366: Fuel Injection System

    Fuel injection system 8-55 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 connections • coolant temperature sensor coupl...

  • Page 367: Fuel Injection System

    Fuel injection system 8-56 fault code no. 23 symptom atmospheric pressure sensor: open or short circuit de- tected. Diagnostic code no. 02 atmospheric pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • atmospheric pressure sensor co...

  • Page 368: Fuel Injection System

    Fuel injection system 8-57 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 state of o 2 sensor. Check for looseness or pinching. Execute the di- agno...

  • Page 369: Fuel Injection System

    Fuel injection system 8-58 fault code no. 33 symptom open circuit detected in the primary lead of the cylinder- #1 ignition coil. Diagnostic code no. 30 cylinder-#1 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#1 igniti...

  • Page 370: Fuel Injection System

    Fuel injection system 8-59 fault code no. 35 symptom open circuit detected in the primary lead of the cylinder- #3 ignition coil. Diagnostic code no. 32 cylinder-#3 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#3 igniti...

  • Page 371: Fuel Injection System

    Fuel injection system 8-60 fault code no. 36 symptom open circuit detected in the primary lead of the cylinder- #4 ignition coil. Diagnostic code no. 33 cylinder-#4 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#4 igniti...

  • Page 372: Fuel Injection System

    Fuel injection system 8-61 fault code no. 39 symptom open circuit detected in a primary injector. Diagnostic code no. 36 37 38 39 primary injector #1 primary injector #2 primary injector #3 primary injector #4 order item/components and probable cause check or maintenance job reinstatement method 1 c...

  • Page 373: Fuel Injection System

    Fuel injection system 8-62 fault code no. 40 symptom open circuit detected in a secondary injector. Diagnostic code no. 40 41 42 43 secondary injector #1 secondary injector #2 secondary injector #3 secondary injector #4 order item/components and probable cause check or maintenance job reinstatement ...

  • Page 374: Fuel Injection System

    Fuel injection system 8-63 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 • main wire harness ecu co...

  • Page 375: Fuel Injection System

    Fuel injection system 8-64 fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or maintenance job reinstatement m...

  • Page 376: Fuel Injection System

    Fuel injection system 8-65 fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or maintenance job reinstatement m...

  • Page 377: Fuel Injection System

    Fuel injection system 8-66 fault code no. 43 symptom power supply to the injectors and fuel pump is not nor- mal. Diagnostic code no. 09 fuel system voltage (battery voltage) order item/components and probable cause check or maintenance job reinstatement method 1 connections • relay unit coupler (fu...

  • Page 378: Fuel Injection System

    Fuel injection system 8-67 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 379: Fuel Injection System

    Fuel injection system 8-68 fault code no. 59 symptom throttle position sensor (for throttle cable pulley): open or short circuit detected. Throttle position sensor (for throttle cable pulley): coupler connection is loose. Diagnostic code no. 14 15 throttle position sensor (for throttle cable pulley)...

  • Page 380: Fuel Injection System

    Fuel injection system 8-69 fault code no. 60 symptom throttle servo motor: open or short circuit detected. Defective throttle servo motor. Malfunction in ecu (servo motor driving system). Diagnostic code no. 01 13 throttle position sensor (for throttle valves) signal 1 throttle position sensor (for ...

  • Page 381: Fuel Injection System

    Fuel injection system 8-70 fault code no. Er-2 symptom no signals are received from the ecu within the specified duration. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness ...

  • Page 382: Fuel Injection System

    Fuel injection system 8-71 fault code no. Er-4 symptom non-registered data has been received from the meter. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly...

  • Page 383: Fuel Pump System

    Fuel pump system 8-73 eas27550 fuel pump system eas27560 circuit diagram gy b gy b /l b b l/b b on off w w g /y l/ w r /w r /b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g /y2 r /w ch ch b b b /l y /g l p b /w o /r w b /l l /y dg b l b /l w /y l b /l w /b r /y b /g y /b2 r...

  • Page 384: Fuel Pump System

    Fuel pump system 8-74 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 13.Relay unit 15.Fuel pump relay 18.Fuel pump 22.Ecu (engine control unit) 64.Engine stop switch.

  • Page 385: Fuel Pump System

    Fuel pump system 8-75 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and fu...

  • Page 386: Electrical Components

    Electrical components 8-77 eas27970 electrical components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

  • Page 387: Electrical Components

    Electrical components 8-78 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Battery 5. Fuse box (backup, etv) 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Neutral switch 10. Exup servo motor 11. Rear brake light switch 12. O 2 sensor 13. Sidestand switch 14. Speed sen...

  • Page 388: Electrical Components

    Electrical components 8-79 1 5 4 3 2 6 7 8 9 10 12 13 11 14 15 16 17.

  • Page 389: Electrical Components

    Electrical components 8-80 1. Air temperature sensor 2. Atmospheric pressure sensor 3. Coolant temperature sensor 4. Fuel pump 5. Ecu (engine control unit) 6. Lean angle sensor 7. Relay unit 8. Turn signal relay 9. Crankshaft position sensor 10. Intake air pressure sensor 11. Throttle servo motor 12...

  • Page 390: Electrical Components

    Electrical components 8-81 eas27980 checking the switches dg y br/w r/y ch l/y b b/y br b b (blue) g/y l/w r/w r/b b br (blue) b b (brown) br g/y 7 8 9 10 11 2 3 4 1 5 6 sb r/y r/b l/w b on off r br/l l/y l/b y r/y br b l/y2 b/y ch dg br/w (red) l/y l/b r br/l.

  • Page 391: Electrical Components

    Electrical components 8-82 1. Clutch switch 2. Main switch 3. Dimmer switch 4. Horn switch 5. Turn signal switch 6. Sidestand switch 7. Front brake light switch 8. Engine stop switch 9. Start switch 10. Neutral switch 11. Rear brake light switch.

  • Page 392: Electrical Components

    Electrical components 8-83 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 probe...

  • Page 393: Electrical Components

    Electrical components 8-84 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 394: Electrical Components

    Electrical components 8-85 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 395: Electrical Components

    Electrical components 8-86 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • left upper side cowling • rider seat refer to “general chassis” on page 4-1. Eas28030 checking and charging t...

  • Page 396: Electrical Components

    Electrical components 8-87 b. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Charge: • battery (refer to the appropriate charging method il- lustration) warning ewa13300 do not quick charge a battery. Caution: e...

  • Page 397: Electrical Components

    Electrical components 8-88 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 398: Electrical Components

    Electrical components 8-89 10.Install: • fuel tank bracket • rider seat 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 har...

  • Page 399: Electrical Components

    Electrical components 8-90 headlight relay (dimmer) radiator fan motor relay et2c01021 checking the turn signal relay 1. Check: • turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal relay cou- pler is faulty and must be repaired. ▼▼▼ ▼ ▼ ...

  • Page 400: Electrical Components

    Electrical components 8-91 b. Turn the main switch to “on”. C. Measure the turn signal relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Note: the pocket tester or the analog...

  • Page 401: Electrical Components

    Electrical components 8-92 c. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28100 checking the ignition coils the following procedure applies to all of the igni- tion coils. 1. Check: • primary coi...

  • Page 402: Electrical Components

    Electrical components 8-93 d. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap un- til a misfire occurs. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28120 checking the crankshaft position sensor 1. Disconnect: • crankshaft position sensor coupler (from t...

  • Page 403: Electrical Components

    Electrical components 8-94 • this check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. B. Check the starter motor operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from...

  • Page 404: Electrical Components

    Electrical components 8-95 eas28180 checking the horn 1. Check: • horn resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the horn leads from the horn ter- minals. B. Connect the pocket tester ( Ω × 1) to the horn terminals. C. Measure the horn...

  • Page 405: Electrical Components

    Electrical components 8-96 • fuel sender coupler (from the wire harness) 2. Remove: • fuel tank 3. Remove: • fuel pump (from the fuel tank) 4. Check: • fuel sender resistance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the fuel sender terminal as shown....

  • Page 406: Electrical Components

    Electrical components 8-97 eas28260 checking the coolant temperature sensor 1. Remove: • coolant temperature sensor refer to “thermostat” on page 6-7. Warning ewa14130 • handle the coolant temperature sensor with special care. • never subject the coolant temperature sen- sor to strong shocks. If the...

  • Page 407: Electrical Components

    Electrical components 8-98 note: when installing the throttle position sensor (for throttle valves), adjust its angle properly. Refer to “adjusting the throttle position sensor (for throttle valves)” on page 7-13. Et2c01001 checking the throttle position sensor (for throttle cable pulley) 1. Remove:...

  • Page 408: Electrical Components

    Electrical components 8-99 d. Check the fuel pump operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a....

  • Page 409: Electrical Components

    Electrical components 8-100 eas28390 checking the cylinder identification sensor 1. Remove: • timing plate cover 2. Check: • cylinder identification sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the c...

  • Page 410: Electrical Components

    Electrical components 8-101 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the air temperature sensor terminal as shown. B. Immerse the air temperature sensor “1” in a container filled with water “2”. Note: make sure that the air temperature sensor termi...

  • Page 411: Troubleshooting

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

  • Page 412: 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 413: Troubleshooting

    Troubleshooting 9-2 electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator 3. Ignition coil(s) • broken or shorted primary or secondar...

  • Page 414: Troubleshooting

    Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump • thermos...

  • Page 415: Troubleshooting

    Troubleshooting 9-4 rear shock absorber assembly • faulty rear shock absorber spring • leaking oil or gas tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose whe...

  • Page 416

    Yzfr6v(c) 2006 wiring diagram gy b gy b/l b b l/b b on off w w g/y l/w r/w r/b b br b l b l r r r r r/w l/w y l/r b y l b br y b b b r/l b g/w brg r g/y2 r/w ch ch b b b/l y/g l p b/w o/r w b/l l/y dg b l b/l w/y l b/l w/b r/y b/g y/b2 r/y ch ch b l b dg l dg b b o b b b b b b/g b/y b y gy/r b/g b b...

  • Page 417

    Yzfr6v(c) 2006 wiring diagram (black) (black) (black) headlight sub-wire-harness headlight sub- wire-harness wire harness b wire harness sub-wire-harness1 c wire harness sub-wire-harness2 d wire harness neutral switch sub -wire-harness e wire harness sub-wire-harness3 f wire harness a w l l y b y l ...

  • Page 418

    Eas28740 wiring diagram yzfr6v(c) 2006 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 8. Starter relay 9. Fuel injection system fuse 10. Starter motor 11. Engine ground 12. Etv fuse 13. Relay unit 14. Starting circuit ...

  • Page 419

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