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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

    2006 service manual yzf-r6(v) 2c0-28197-e0

  • Page 2

    Eas20040 yzf-r6(v) 2006 service manual ©2005 by yamaha motor co., ltd. First edition, november 2005 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

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

  • Page 4: How to Use This Manual

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

  • Page 5: Symbols

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

  • Page 7: Table of Contents

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

  • Page 9: General Information

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

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped 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 11: Features

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

  • Page 12: Features

    Features 1-3 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 13: 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 14: 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 15: 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 16: 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 17: 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 18: 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 19: Features

    Features 1-10 • display brightness: this function allows you to adjust the bright- ness of the displays and tachometer to suit the outside lighting conditions. • shift timing indicator light activity: this function allows you to choose whether or not the indicator light should be activated and wheth...

  • Page 20: Features

    Features 1-11 to adjust the shift timing indicator light bright- ness: 1. Push the “reset” button to select the de- sired indicator light brightness level. 2. Push the “select” button to confirm the se- lected indicator light brightness level. The dis- play will return to the odometer or tripmeter m...

  • Page 21: Important Information

    Important information 1-12 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 1-15. 3. When disasse...

  • Page 22: Important Information

    Important information 1-13 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 23: Checking The Connections

    Checking the connections 1-14 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 24: Special Tools

    Special tools 1-15 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 25: Special Tools

    Special tools 1-16 oil filter wrench 90890-01426 yu-38411 3-12 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, 4-57 fork spring compressor 90890-01441 ym-01441 4-47, 4-52 rod holder 90890-01434 damper rod h...

  • Page 26: Special Tools

    Special tools 1-17 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-50, 4-52 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-50, 4-52 ring nut wrench 90890-01268 spanner wrench yu-01268 4-57 ring nut wrench 90890-01507 4-66, 4-68 da...

  • Page 27: Special Tools

    Special tools 1-18 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 28: Special Tools

    Special tools 1-19 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 29: Special Tools

    Special tools 1-20 pressure gauge 90890-03153 pressure gauge yu-03153 7-10 fuel pressure adapter 90890-03176 ym-03176 7-10 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-11 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-102 tool name/tool no. ...

  • Page 30: Special Tools

    Special tools 1-21.

  • Page 31: Specifications

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

  • Page 32: General Specifications

    General specifications 2-1 eas20280 general specifications model model 2c01 (eur)(zaf) 2c02 (bel)(fra) 2c04 (aus) 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 ...

  • Page 33: 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 34: 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 35: 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 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: Chassis Specifications

    Chassis specifications 2-11 front disc brake disc outside diameter × thickness 310.0 × 4.5 mm (12.20 × 0.18 in) brake disc thickness limit 4.0 mm (0.16 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thic...

  • Page 43: Chassis Specifications

    Chassis specifications 2-12 spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 60.0 mm (2.36 in) 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–...

  • Page 44: 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 45: Electrical Specifications

    Electrical specifications 2-14 indicator light neutral indicator light led turn signal indicator light led oil level warning light led high beam indicator light led fuel level warning light led coolant temperature warning light led engine trouble warning light led immobilizer system indicator light ...

  • Page 46: Electrical Specifications

    Electrical specifications 2-15 starting circuit cut-off relay model/manufacturer g8r-30y-v4/omron headlight relay model/manufacturer acm33211m04/matsushita fuel pump relay model/manufacturer g8r-30y-v4/omron fan motor relay model/manufacturer acm33211m05/matsushita fuses main fuse 50.0 a headlight f...

  • Page 47: 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 48: 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 49: 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 50: 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 51: 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 52: 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 53: 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 54: 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 55: Tightening Torques

    Tightening torques 2-24 note: lower ring nut 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 14 nm (1.4 m·kg, 10 ft·lb) with a torque wrench. Note: lower bracket pinch...

  • Page 56: 2-25

    Lubrication points and lubricant types 2-25 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surface piston pins connecting rod bolts and nuts crankshaft journals generator rotor bolt and washer camshaft...

  • Page 57: 2-26

    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 58: 2-27

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

  • Page 59: 2-28

    Lubrication points and lubricant types 2-28.

  • Page 60: 2-29

    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 61: 2-30

    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 62: 2-31

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

  • Page 63: 2-32

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

  • Page 64: 2-33

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

  • Page 65: 2-34

    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 66: 2-35

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

  • Page 67: 2-36

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

  • Page 68: 2-37

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

  • Page 69: 2-38

    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 70: 2-39

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

  • Page 71: 2-40

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

  • Page 72: 2-41

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

  • Page 73: 2-42

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

  • Page 74: Cooling System Diagrams

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

  • Page 75: Cooling System Diagrams

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

  • Page 76: 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 77: 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 78: 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 9 9 10 11 11 12 12 14 15 16 17 18 19 13.

  • Page 79: 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. Immobilizer unit lead 6. Main switch lead 7. Left handlebar switch lead 8. Clutch switch lead 9. Horn lead 10. Front brake hose 11. Throttle cable (decelerator ca...

  • Page 80: 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 81: 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 82: Cable Routing

    Cable routing 2-51 c c b b-b c-c a a b b a c n o d h i j k l m 1 2 2 3 4 5 6 7 7 8 8 9 11 12 13 14 10 9 15 7 8 14 15 e f g.

  • Page 83: Cable Routing

    Cable routing 2-52 1. Main switch lead 2. Immobilizer unit lead 3. Left handlebar switch lead 4. Left radiator fan motor lead 5. Wire harness 6. Radiator inlet pipe 7. Fuel tank breather hose 8. Sidestand switch lead 9. Ac magneto lead 10. Front left turn signal light lead 11. Main switch lead 12. L...

  • Page 84: Cable Routing

    Cable routing 2-53 b-b b c c a a b a b c d e f g h i j k l m n o e p e q r y z x s w v u t t 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 28 29 30 31 32 33 33 45˚ 135˚ a-a c-c.

  • Page 85: Cable Routing

    Cable routing 2-54 1. Front right turn signal 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 8. Sub-w...

  • Page 86: Cable Routing

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

  • Page 87: 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 88: Cable Routing

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

  • Page 89: Cable Routing

    Cable routing 2-58 1. Fuel tank breather hose (fuel tank to hose joint) 2. Fuel hose (fuel tank to primary injector fuel rail) 3. Crankcase breather hose 4. Fuel tank overflow hose 5. Fuel tank breather hose 6. Fuel tank overflow hose (fuel tank to hose joint) 7. Fuel hose (primary injector fuel rai...

  • Page 90: Cable Routing

    Cable routing 2-59 f f c c e e d d a a g g b b a b c d e g h f i j k l m 1 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 13 17 1 2 2 3 3 6 7 8 7 8 10 11 14 15 16 18 n 1 15 18 14 11 16 a-a b-b c-c d-d e-e f-f g-g.

  • Page 91: Cable Routing

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

  • Page 92: Cable Routing

    Cable routing 2-61.

  • Page 93

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

  • Page 94

    Electrical system................................................................................. 3-35 checking and charging the battery ....................................... 3-35 checking the fuses ........................................................................ 3-35 replacing the headli...

  • Page 96: 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 97: Periodic Maintenance

    Periodic maintenance 3-2 eau18680 note: • air filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the air filter element needs to be replaced more frequently when riding in unusually wet or dus...

  • Page 98: Engine

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

  • Page 99: Engine

    Engine 3-4 • measure the valve clearance in the following sequence. D. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft clockwise as specified in the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remove: • camshafts...

  • Page 100: Engine

    Engine 3-5 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 101: Engine

    Engine 3-6 eas20570 synchronizing the throttle bodies note: prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted. 1. Stand the vehicle on a level surface. Note: place the vehicle on a suitable stand. 2. Remove: • rider seat refer to ...

  • Page 102: Engine

    Engine 3-7 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ alternate procedure note: use this alternate procedure if you are unable to adjust the throttle body synchronization using the basic procedure. A. Start the engine, warm it up for several min- utes, and then let it run at the specified en-...

  • Page 103: Engine

    Engine 3-8 5. Press the “select” and “reset” buttons to select a cylinder “1”. Note: the selected cylinder number appears on the odometer/trip meter/fuel reserve trip meter/stop- watch lcd. • to decrease the selected cylinder number, press the “reset” button. • to increase the selected cylinder numb...

  • Page 104: Engine

    Engine 3-9 • air filter case refer to “air filter case” on page 7-4. • air induction system solenoid refer to “air induction system” on page 7-13. 2. Remove: • ignition coils • spark plugs caution: eca13320 before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with ...

  • Page 105: Engine

    Engine 3-10 6. Measure: • compression pressure out of specification → refer to steps (c) and (d). ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning ewa12940...

  • Page 106: Engine

    Engine 3-11 caution: ec2c01005 • since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives, or use engine oils with a grade of cd “a” or higher, and do not use oils labeled “energy conserv- ing ii” “b”. • d...

  • Page 107: Engine

    Engine 3-12 c. Remove the oil filter cartridge “5” with an oil filter wrench “6”. 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 th...

  • Page 108: Engine

    Engine 3-13 eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark → add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several min- utes, and then turn it off. Caution: eca13410 when the engine is cold, the engine oi...

  • Page 109: Engine

    Engine 3-14 2. Adjust: • clutch lever free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 hand...

  • Page 110: 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 111: 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 112: Engine

    Engine 3-17 note: check that the projection “a” on the exup valve pulley contacts the stopper “b” (fully open posi- tion). If the projection does not contact the stop- per, adjust the exup cable free play. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • exup cable free play (at the exu...

  • Page 113: Engine

    Engine 3-18 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → remove the coolant reservoir cap, add the recom- mended coolant to the proper level. Note: to access the coolant reservoir cap, remove the r...

  • Page 114: Engine

    Engine 3-19 eas21130 changing the coolant 1. Remove: • right side panel • right upper side cowling • right lower side cowling • right bottom cowling refer to “general chassis” on page 4-1. 2. Remove: • radiator cap “1” warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the r...

  • Page 115: Engine

    Engine 3-20 • if coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • if coolant is swallowed, induce vomiting and get immediate medical attention. Caution: eca13480 • adding water instead of coolant lowers the antifreeze content of the coolant. If water ...

  • Page 116: 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 117: 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 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127: 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 128: 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 129: 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 130: Electrical System

    Electrical system 3-35 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-87. Eas21770 checking the fuses refer to “electrical components” on page 8-87. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 131: 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 132: Electrical System

    Electrical system 3-37.

  • Page 133: Chassis

    4 chassis general chassis....................................................................................... 4-1 front wheel............................................................................................... 4-5 removing the front wheel...................................................

  • Page 134

    Rear brake ............................................................................................... 4-29 introduction ..................................................................................... 4-34 checking the rear brake disc.................................................... 4-3...

  • Page 135

    Chain drive................................................................................................ 4-69 removing the drive chain............................................................. 4-70 checking the drive chain ............................................................. 4-70 chec...

  • Page 136: 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 caution: ec2c01025 install the passenger seat replacement cover if the vehicle is registered for only a solo rider. 3 passenger seat replacement cover 1...

  • Page 137: 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 138: General Chassis

    General chassis 4-3 12 right cowling hole cover 1 installed for solo riding only. 13 left cowling hole cover 1 installed for solo riding only. 14 rear lower cowling 1 for installation, reverse the removal proce- dure. Removing the tail/brake light assembly order job/parts to remove q’ty remarks t r ...

  • Page 139: General Chassis

    General chassis 4-4 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 light coupler 2 disconnect. 5 bottom cowling 2 6 bottom cowling inner panel 2 7 air intake duct 2 8 rearvi...

  • Page 140: Front Wheel

    Front wheel 4-5 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 front brake hose holder 1 2 right front brake hose holder 1 3 left front brake caliper 1 4 righ...

  • Page 141: 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 142: 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 143: 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 144: 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 145: 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 146: 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 147: 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 148: 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 149: 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 150: 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 151: 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 152: 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 brake hose holder 1 2 front brake caliper 1 3 brake pad clip 2 4 brake pad pin 1 5 brake pad spring 1 6 front brake pad 2 ...

  • Page 153: 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 154: 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 155: 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 brake hose holder 1 2 front brake hose union bolt 1 3 coppe...

  • Page 156: 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 157: 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 158: 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 159: 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 160: 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 161: 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 162: 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 163: 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 164: 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 165: 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 166: 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 167: 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 168: 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 169: 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 170: 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 171: 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 172: 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 173: 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 174: 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 175: 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 7-4. Air induction system ...

  • Page 176: Handlebars

    Handlebars 4-41 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 19 left coupler holder 1 20 main switch coupler 2 d...

  • Page 177: 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 178: 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 179: 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 4-5. 1 front fender 1 2 upper bracket...

  • Page 180: 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 181: 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 182: 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 183: 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 184: Front Fork

    Front fork 4-49 caution: eca14200 • the front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • when disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter th...

  • Page 185: Front Fork

    Front fork 4-50 • before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 5. Install: • outer tube (to the inner tube) 6. Install: • washer • oil seal “1” (with the fork seal driver “2”) 7. Install: • oil seal clip “1” note:...

  • Page 186: 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 187: Front Fork

    Front fork 4-52 note: use the side of the rod holder that is marked “b”. I. Remove the rod puller and rod puller attach- ment. J. Install the nut “4” all the way onto the damper rod assembly. K. Install the damper adjusting rod. L. Install the washer and cap bolt, and then fin- ger tighten the cap b...

  • Page 188: Front Fork

    Front fork 4-53 note: tighten each bolt to 23 nm (2.3 m·kg, 17 ft·lb) in the order pinch bolt “1” → pinch bolt “2” → pinch bolt “1”. 3. Tighten: • cap bolt “1” • handlebar bolt “2” • handlebar pinch bolt “3” • upper bracket pinch bolt “4” 4. Check: • cable routing note: make sure the brake hose, thr...

  • Page 189: Steering Head

    Steering head 4-54 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 190: Steering Head

    Steering head 4-55 11 lower bracket cover 1 12 front brake hose joint bracket 1 13 steering stem nut 1 14 upper bracket 1 15 lock washer 1 16 upper ring nut 1 17 rubber washer 1 18 lower ring nut 1 19 lower bracket 1 20 upper bearing cover 1 21 upper bearing inner race 1 22 upper bearing 1 23 lower ...

  • Page 191: Steering Head

    Steering head 4-56 27 lower bearing outer race 1 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks 7 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 192: Steering Head

    Steering head 4-57 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 193: Steering Head

    Steering head 4-58 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 194: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-59 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 195: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-60 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 196: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-61 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 197: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-62 • 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 198: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 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 199: Swingarm

    Swingarm 4-64 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 4-59. Drive chain guide (drive sprocket side) refer to “chain drive” on page 4-69. 1 drive...

  • Page 200: Swingarm

    Swingarm 4-65 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 201: Swingarm

    Swingarm 4-66 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 202: Swingarm

    Swingarm 4-67 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: • bearings • spacers • dust covers • pivot shaft 2. Install: • be...

  • Page 203: Swingarm

    Swingarm 4-68 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 204: Chain Drive

    Chain drive 4-69 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 205: Chain Drive

    Chain drive 4-70 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 206: Chain Drive

    Chain drive 4-71 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 207: Chain Drive

    Chain drive 4-72 1 2 3 a a new.

  • Page 208: Chain Drive

    Chain drive 4-73.

  • Page 209: Engine

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

  • Page 210

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

  • Page 211

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

  • Page 212: 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 213: 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 214: 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 7-4. Throttle body refer to “throttle bodies” on page 7-7. Air cut-off valve refer to “air induction system” on p...

  • Page 215: Engine Removal

    Engine removal 5-4 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 clutch cable 1 disconnect. 14 cylinder iden...

  • Page 216: 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 217: 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 218: 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 7-7. Air cut-off valve/reed valve assembly refer to “air induction system” on page 7-13. 1 ignition coil...

  • Page 219: 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 220: 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 221: 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 222: 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 223: 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 224: 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 225: 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 226: 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 227: 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 228: 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 229: 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 230: 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 231: 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 232: 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 233: 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 234: 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 235: 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 236: 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 237: 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 238: 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 239: 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 240: 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 241: 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 242: 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 243: Pickup Rotor

    Pickup rotor 5-32.

  • Page 244: 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 7-4. Fuel tank refer to “fuel tank” on page 7-1. Thermostat refer to “thermostat” on...

  • Page 245: 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 246: 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 247: 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 248: 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 249: 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 250: 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 251: 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 252: 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 253: 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 254: 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 255: 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 256: 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 257: 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 258: 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 259: 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 260: 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 261: 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 262: 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 263: 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 264: 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 265: 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 266: 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 267: 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 268: 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 269: 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 270: 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 271: 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 272: 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 273: 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 274: 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 275: 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 276: 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 277: 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 278: 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 279: 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 280: 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 281: 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 282: 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 283: 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 284: 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 285: 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 286: 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 287: 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 288: 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 289: 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 290: 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 291: Cooling System

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

  • Page 292: 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 293: 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 294: 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 295: 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 296: 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 297: 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 298: 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 7-4. Coolant drain. Refer to “changing the coolant” on page 3-19. 1 coolant temperature sensor coupler 1 disconnect. 2 thermostat outlet hose 1 3 therm...

  • Page 299: 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 300: 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 301: 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 302: Water Pump

    Water pump 6-11.

  • Page 303: Fuel System

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

  • Page 304: 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 305: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose (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 306: Fuel Tank

    Fuel tank 7-3 et2c01010 installing the fuel tank 1. Connect: • fuel tank breather hose (fuel tank to hose joint) “1” • fuel tank overflow hose (fuel tank to hose joint) “2” • fuel tank breather hose “3” • fuel tank overflow hose “4” 2. Connect: • fuel hose (fuel tank to primary injector rail) cautio...

  • Page 307: Air Filter Case

    Air filter case 7-4 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 308: Air Filter Case

    Air filter case 7-5 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 309: Air Filter Case

    Air filter case 7-6 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 310: Throttle Bodies

    Throttle bodies 7-7 eas26970 throttle bodies 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 7-4. Air induction system cover refer to “air induction system” on page 7-13. 1 throt...

  • Page 311: Throttle Bodies

    Throttle bodies 7-8 11 throttle body joint clamp 4 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 312: Throttle Bodies

    Throttle bodies 7-9 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 313: Throttle Bodies

    Throttle bodies 7-10 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 314: Throttle Bodies

    Throttle bodies 7-11 b. Check that the throttle valves are fully closed. C. Connect the throttle position sensor coupler to the throttle position sensor. D. Connect the digital circuit tester to the throttle position sensor. E. Measure the throttle position sensor voltage. F. Adjust the throttle pos...

  • Page 315: Throttle Bodies

    Throttle bodies 7-12 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 with the “r” mark onto the openings for cylinders #3 and #4. T r . . Throttle body joint bolt 10 nm (1.0 m·kg, 7.2 ft·lb) l r 1.

  • Page 316: Air Induction System

    Air induction system 7-13 eas27040 air induction system 2 1 2 4 3 4 3 6 4 5 a a.

  • Page 317: Air Induction System

    Air induction system 7-14 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 318: Air Induction System

    Air induction system 7-15 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 7-4. 1 air induction system cover 1 2 immobilizer unit coupler holder 1 3 air induction system solenoid coupl...

  • Page 319: Air Induction System

    Air induction system 7-16 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 320: Air Induction System

    Air induction system 7-17 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 321: Electrical System

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

  • Page 322

    Electrical components...................................................................... 8-87 checking the switches ................................................................. 8-91 checking the bulbs and bulb sockets ................................... 8-94 checking the fuses .................

  • Page 324: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram gy b gy b /l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y l/r b y l b...

  • Page 325: Ignition System

    Ignition system 8-2 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 14.Relay unit 17.Neutral switch 18.Sidestand switch 23.Ecu (engine control unit) 24.Spark plug 25.Cylinder-#1 ignition coil 26.Cylinder-#2 ignition coil 27.Cylinder-#3 ignition coil 28.Cylinder-#4 ignition c...

  • Page 326: 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 327: 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. Side cowlings 5. Bottom cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ...

  • Page 328: 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 8-91. Replace the right handlebar switch. 9. Check the neutral switch. Refer to “checking the switches” on page 8-91. Replace the neutral switch. ...

  • Page 329: Ignition System

    Ignition system 8-6.

  • Page 330: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 b b b b bb3 bb4 bb2 bb1 w w g/y l/w2 r/w r/b g/y l/w r/w r/b b br 187 187 b l b l dg y w/y br/w r/y ch l/y b b/y br r r r r r/w l/w y l/r b y l b br y b b b r/...

  • Page 331: 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 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 66.Engine stop switch 67.Start switch 74.Clutch switch.

  • Page 332: 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 333: 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 334: 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. Side cowlings 5. Thermostat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. ...

  • Page 335: Electric Starting System

    Electric starting system 8-12 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the neutral switch. Refer to “checking the switches” on page 8-91. Replace the neutral switch. 9. Check the sidestand switch. Refer to “checking the switches” on page 8-91. Replace the sidestand switch...

  • Page 336: Charging System

    Charging system 8-13 eas27200 charging system eas27210 circuit diagram on off br/r r br/l br/r r br/l b2 b1 b2 b1 b b b b bb3 bb4 bb2 bb1 g/y l/w2 r/w r/b g/y l/w r/w r/b b br 187 187 r r r r r/w l/w b b2 r/g y/l lg r /w b b2 r/g y/l lg r/w b b2 lg y/l r/w r/g b br br r r r r r b w w w w w w r r r r...

  • Page 337: Charging System

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

  • Page 338: 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 339: Charging System

    Charging system 8-16.

  • Page 340: Lighting System

    Lighting system 8-17 eas27240 lighting system eas27250 circuit diagram gy b gy b /l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y l/r b y l ...

  • Page 341: Lighting System

    Lighting system 8-18 3. Main switch 6. Main fuse 7. Battery 11.Engine ground 23.Ecu (engine control unit) 59.High beam indicator light 62.Meter light 71.Pass switch 72.Dimmer switch 81.Headlight (low beam) 82.Headlight (high beam) 83.Auxiliary light 84.License plate light 86.Tail/brake light 87.Head...

  • Page 342: 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 343: Lighting System

    Lighting system 8-20 ng → ok ↓ ng → ok ↓ 8. Check the headlight relay (dimmer). Refer to “checking the re- lays” on page 8-99. Replace the headlight relay (dimmer). 9. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 8-17. Properly connect or repair the lighting sys- tem...

  • Page 344: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram gy b gy b /l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y l/r b y ...

  • Page 345: Signaling System

    Signaling system 8-22 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 14.Relay unit 17.Neutral switch 20.Fuel sender 23.Ecu (engine control unit) 41.Crankshaft position sensor 43.Coolant temperature sensor 46.Cylinder identification sensor 47.Speed sensor 51.Fuel level warni...

  • Page 346: 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 347: 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 ↓ ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Pr...

  • Page 348: Signaling System

    Signaling system 8-25 ng → ok ↓ the neutral indicator light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the oil level warning light fails to come. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come. Ng → ok ↓ 5. Check the entire signaling system’s wiring. Refer to “circuit diagram” on p...

  • Page 349: Signaling System

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

  • Page 350: 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 351: Signaling System

    Signaling system 8-28.

  • Page 352: Cooling System

    Cooling system 8-29 eas27300 cooling system eas27310 circuit diagram (dark green) gy b gy b /l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y...

  • Page 353: Cooling System

    Cooling system 8-30 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 23.Ecu (engine control unit) 43.Coolant temperature sensor 93.Radiator fan motor relay 94.Right radiator fan motor fuse 95.Left radiator fan motor fuse 96.Right radiator fan motor 97.Left radiator fan motor.

  • Page 354: 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 355: Cooling System

    Cooling system 8-32.

  • Page 356: 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 br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w ...

  • Page 357: Fuel Injection System

    Fuel injection system 8-34 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer, clock and immobilizer system) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 13.Etv fuse 14.Relay unit 16.Fuel pump relay 17.Neutral switch 18.Sidestand switch 19.Fuel pump 21.Throttle positi...

  • Page 358: 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 359: 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 360: 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 361: 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 362: 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 363: 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 364: 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 365: 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 366: 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 367: 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 368: 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 369: 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 370: 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 371: 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 372: 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 373: 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 374: 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 375: 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 376: 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 377: 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 378: 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 379: 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 380: 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 381: 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 382: 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 383: 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 384: 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 385: 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 386: 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 387: 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 388: 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 389: 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 390: 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 391: 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 392: 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 393: 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 394: 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 395: Fuel Injection System

    Fuel injection system 8-72.

  • Page 396: 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 br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y l/r b y ...

  • Page 397: 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 14.Relay unit 16.Fuel pump relay 19.Fuel pump 23.Ecu (engine control unit) 66.Engine stop switch.

  • Page 398: 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 399: Fuel Pump System

    Fuel pump system 8-76.

  • Page 400: Immobilizer System

    Immobilizer system 8-77 eas27640 immobilizer system eas27650 circuit diagram gy b gy b /l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 bb bb bb3 bb4 bb2 bb1 w w g /y l/ w2 r /w r /b g /y l/ w r /w r /b b br 187 187 b l b l 187 187 dg y w /y br /w r /y ch l /y b b /y br r r r r r/w l/w y l/r ...

  • Page 401: Immobilizer System

    Immobilizer system 8-78 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer, clock and immobilizer system) 6. Main fuse 7. Battery 11.Engine ground 12.Immobilizer unit 23.Ecu (engine control unit) 50.Immobilizer system indicator light 56.Multi-function meter.

  • Page 402: Immobilizer System

    Immobilizer system 8-79 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 403: Immobilizer System

    Immobilizer system 8-80 * accessory locks mean the seat lock, fuel tank cap or the helmet holder. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main sw...

  • Page 404: Immobilizer System

    Immobilizer system 8-81 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a standa...

  • Page 405: Immobilizer System

    Immobilizer system 8-82 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost sta...

  • Page 406: Immobilizer System

    Immobilizer system 8-83 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number ...

  • Page 407: Immobilizer System

    Immobilizer system 8-84 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 52 immobilizer unit codes between the key and immobilizer unit do no...

  • Page 408: Immobilizer System

    Immobilizer system 8-85 a. Light on b. Light off.

  • Page 409: Immobilizer System

    Immobilizer system 8-86.

  • Page 410: Electrical Components

    Electrical components 8-87 eas27970 electrical components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21.

  • Page 411: Electrical Components

    Electrical components 8-88 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Battery 6. Fuse box (backup, etv) 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10. Neutral switch 11. Exup servo motor 12. Rear brake light switch 13. O 2 sensor 14. Sidestand...

  • Page 412: Electrical Components

    Electrical components 8-89 1 5 4 3 2 6 7 8 9 10 12 13 11 14 15 16 17.

  • Page 413: Electrical Components

    Electrical components 8-90 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/hazard relay 9. Crankshaft position sensor 10. Intake air pressure sensor 11. Throttle servo m...

  • Page 414: Electrical Components

    Electrical components 8-91 eas27980 checking the switches br/r r br/l dg y w/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 9 10 11 12 13 2 3 4 5 6 1 7 8 sb r/y r/b l/w b on off r br/l br/r ch br/w dg r/y w/y y r/y br b l/y2 b/y ch dg br/w.

  • Page 415: Electrical Components

    Electrical components 8-92 1. Clutch switch 2. Main switch 3. Hazard switch 4. Pass switch 5. Dimmer switch 6. Horn switch 7. Turn signal switch 8. Sidestand switch 9. Front brake light switch 10. Engine stop switch 11. Start switch 12. Neutral switch 13. Rear brake light switch.

  • Page 416: Electrical Components

    Electrical components 8-93 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 417: Electrical Components

    Electrical components 8-94 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 418: Electrical Components

    Electrical components 8-95 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 419: Electrical Components

    Electrical components 8-96 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 420: Electrical Components

    Electrical components 8-97 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 421: Electrical Components

    Electrical components 8-98 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 422: Electrical Components

    Electrical components 8-99 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 423: Electrical Components

    Electrical components 8-100 headlight relay (dimmer) radiator fan motor relay et2c01021 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must...

  • Page 424: Electrical Components

    Electrical components 8-101 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Note: the pocket tester or th...

  • Page 425: Electrical Components

    Electrical components 8-102 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 co...

  • Page 426: Electrical Components

    Electrical components 8-103 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 ...

  • Page 427: Electrical Components

    Electrical components 8-104 b. Measure the stator coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28170 checking the rectifier/regulator 1. Check: • charging voltage out of specification → replace the rectifi- er/regulator. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. S...

  • Page 428: Electrical Components

    Electrical components 8-105 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a battery (12 v) to the horn. B. Turn the adjusting screw in direction “a” or “b” until the horn sound is obtained. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28190 checking the oil level switch 1. Dra...

  • Page 429: Electrical Components

    Electrical components 8-106 eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the speed sensor coupler (wire harness side) as shown. B. Turn the main s...

  • Page 430: Electrical Components

    Electrical components 8-107 b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. Note: make sure the coolant temperature sensor ter- minals do not get wet. C. Place a thermometer “3” in the coolant. D. Slowly heat the coolant, then let it cool down to the specified t...

  • Page 431: Electrical Components

    Electrical components 8-108 b. Measure the throttle position sensor (for throttle cable pulley) maximum resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • throttle position sensor (for throttle cable pul- ley) note: when installing the throttle position sensor (for throttle ...

  • Page 432: Electrical Components

    Electrical components 8-109 b. Connect the pocket tester ( Ω × 1) to the air in- duction system solenoid terminal as shown. C. Measure the air induction system solenoid re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28380 checking the atmospheric pressure sensor 1. Check: • atmos...

  • Page 433: Electrical Components

    Electrical components 8-110 b. Turn the main switch to “on”. C. Rotate the crankshaft. D. Measure the voltage of white/black and black/blue. Turn the crankshaft twice and check that the output voltage rises to approx- imately 4.8 v once. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28410 che...

  • Page 434: Electrical Components

    Electrical components 8-111.

  • Page 435: Troubleshooting

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

  • Page 436: 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 437: 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 438: 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 439: 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 440: Wiring Diagram

    Eas28740 wiring diagram yzf-r6(v) 2006 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer, clock and immobilizer system) 6. Main fuse 7. Battery 8. Starter relay 9. Fuel injection system fuse 10. Starter motor 11. Engine ground 12. Immobilizer unit 13. Etv ...

  • Page 442

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

  • Page 443

    Yzf-r6(v) 2006 wiring diagram yzf-r6(v) 2006 schÉma de cblage yzf-r6(v) 2006 schaltplan schema elettrico yzf-r6(v) 2006 diagrama elÉctrico de la yzf-r6(v) 2006 gy b gy b/l b b l/b b on off br/r r br/l br/r r br/l b2 b1 b2 b1 b b b b bb3 bb4 bb2 bb1 w w g/y l/w r/w r/b b br b l b l dg y w/y br/w r/y ...

  • Page 444

    Yzf-r6(v) 2006 wiring diagram yzf-r6(v) 2006 schÉma de cblage yzf-r6(v) 2006 schaltplan schema elettrico yzf-r6(v) 2006 diagrama elÉctrico de la yzf-r6(v) 2006 (black) (black) (black) (black) headlight sub-wire-harness headlight sub- wire-harness wire harness b wire harness sub-wire-harness1 c wire ...