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Yamaha 2009 Diversion XJ6S Service Manual

Summary of 2009 Diversion XJ6S

  • Page 1

    Service manual xj6s(y) 2009 36c-28197-e0 xj6sa ❄❆❍✤✤❇ ✣.

  • Page 2

    ❄❆❍✤✤❇ ✤.

  • Page 3

    Eas20040 xj6s(y) xj6sa service manual ©2009 by yamaha motor co., ltd. First edition, january 2009 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. ❊❏❍✤❇ ✣.

  • Page 4

    Eas20071 important 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 y...

  • Page 5

    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 6

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. G m bf b t r . . Ls m s lt e new serviceable with engine mounted filling fluid lubricant special tool tightening torque wear limit, clearance engine s...

  • Page 7: General Information

    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 eas20110 table of contents ❏❄✤❇ ✣.

  • Page 8

    ❏❄✤❇ ✤.

  • Page 9: General Information

    1 2 3 4 5 6 7 8 9 general information identification .......................................................................................... 1-1 vehicle identification number ................................................... 1-1 model label..........................................................

  • Page 10: Identification

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

  • Page 11: Features

    Features 1-2 eas20170 features eas4b51038 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixtu...

  • Page 12: Features

    Features 1-3 eas4b51039 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 245 – 255 kpa (2.45 – 2.55 kgf/ cm 2 , 35.5 – 37.0 psi) higher than the intake manifol...

  • Page 13: Features

    Features 1-4 eas20s1001 instrument functions multi-function meter unit warning ewa20s1001 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function ...

  • Page 14: Features

    Features 1-5 odometer and tripmeter modes push the “select” button to switch the display between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” in the following order: trip a → trip b → odo → trip a when the fuel amount in the fuel tank decreases to 3.2 l (0.85 us gal, 0.70 im...

  • Page 15: Features

    Features 1-6 1. Use the code re-registering key to start the engine. Tip make sure there are no other immobilizer keys close to the main switch, and do not keep more than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter- ference, which may prevent the engine f...

  • Page 16: Features

    Features 1-7 eas4b56001 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The abs features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. 3. The h...

  • Page 17: Features

    Features 1-8 ● side force: the force on the tires which supports the vehicle when cornering. ● slip ratio: when the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows t...

  • Page 18: Features

    Features 1-9 the difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ...

  • Page 19: Features

    Features 1-10 the abs functions to prevent the tendency of the wheel to lock by controlling the brake fluid pressure. However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking, the abs may not be able to prevent the wheel from locking. Warning ewa13870 th...

  • Page 20: Features

    Features 1-11 abs block diagram eas4b56009 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor contains a hall ic. The wheel sensors are installed in the sensor housin...

  • Page 21: Features

    Features 1-12 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off, so that the rider can check if the abs warning light is disconnected and check...

  • Page 22: Features

    Features 1-13 hydraulic control valve the hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve. The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it. Since this voltage is c...

  • Page 23: Features

    Features 1-14 buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston ❄❉❂❋✤❇ ✤✧.

  • Page 24: Features

    Features 1-15 abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. The necessary ...

  • Page 25: Features

    Features 1-16 tip ● some types of malfunctions are not recorded in the memory of the abs ecu (e.G., a blown abs ecu fuse). ● the abs performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can b...

  • Page 26: Features

    Features 1-17 normal braking (abs not activated) when the abs is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the abs ecu. Therefore, when the brake lever is squeezed, the hydraulic pressure in the brak...

  • Page 27: Features

    Features 1-18 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line...

  • Page 28: Features

    Features 1-19 eas4b56011 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the meter assembly. 12 13 7 6 11 3 4 5 9 8 10 1. Brake master cylinder 2. Brake light switch 3. Abs motor 4. Hydraulic ...

  • Page 29: Features

    Features 1-20 instances when the abs warning light comes on 1. The abs warning light comes on when the main switch is turned to “on”. The abs warning light comes on for 2 seconds while the abs is performing a self-diagnosis, then goes off if there are no problems. 2. The abs warning light comes on w...

  • Page 30: Features

    Features 1-21 4. The abs warning light flashes while riding. If the abs warning light flashes while riding, there is no problem with the function of the abs. How- ever, the abs ecu input has unstable factors. (for details, refer to “abs troubleshooting outline” on page 8-105.) tip the abs warning li...

  • Page 31: Features

    Features 1-22 eas4b56012 abs warning light and operation abs warning light ● when the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off. ● the abs warning light comes on while the start switch is being pushed. ● if the abs warning light comes on while riding,...

  • Page 32: Features

    Features 1-23 and tires is close to the limit. The abs cannot prevent wheel lock* on slippery surfaces, such as ice, when it is caused by engine braking, even if the abs is activated. ● the abs is not designed to shorten the braking distance or improve the cornering perfor- mance. ● depending on the...

  • Page 33: Important Information

    Important information 1-24 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 1-29. 3. When disasse...

  • Page 34: Important Information

    Important information 1-25 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 35: Checking The Connections

    Checking the connections 1-26 eas20250 checking the connections notice eca20s1001 electronic parts are very sensitive. Handle with care and do not give impact. Notice eca20s1002 ● mankind has static electricity. It`s voltage is very high and electronic parts are very sensitive. ● it is possible that...

  • Page 36: Checking The Connections

    Checking the connections 1-27 tip if the pin “1” on the terminal is flattened, bend it up. Tip if the contact seems not good, pull the terminal by hand and check its condition. 4. Connect: ● lead ● coupler ● connector tip make sure all connections are tight. 5. Check: ● continuity (with the pocket t...

  • Page 37: Checking The Connections

    Checking the connections 1-28 eas21850 installing the quick fastener tip to install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head...

  • Page 38: Special Tools

    Special tools 1-29 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 39: Special Tools

    Special tools 1-30 pressure gauge 90890-03153 yu-03153 3-26, 7-7, 7-9 oil pressure adapter h 90890-03139 3-26 compression gauge 90890-03081 engine compression tester yu-33223 5-18 steering nut wrench 90890-01403 spanner wrench yu-33975 3-19, 4-70 damper rod holder 90890-01460 4-63, 4-65 t-handle 908...

  • Page 40: Special Tools

    Special tools 1-31 fork seal driver weight 90890-01367 replacement hammer ym-a9409-7 4-65, 4-66 fork seal driver attachment ( ø 41) 90890-01381 replacement 41 mm ym-a5142-2 4-65 ring nut wrench 90890-01268 spanner wrench yu-1268 4-70 valve spring compressor 90890-04019 ym-04019 5-21, 5-26 valve spri...

  • Page 41: Special Tools

    Special tools 1-32 valve guide installer ( ø 4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-22 valve guide reamer ( ø 4) 90890-04113 valve guide reamer (4.0 mm) ym-04113 5-22 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-30, 5-31, 5-32 flywheel puller 90890-01362 heavy duty ...

  • Page 42: Special Tools

    Special tools 1-33 camshaft wrench 90890-04143 ym-04143 5-34 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-38, 7-10, 8-143, 8-152, 8-153, 8-157, 8-158, 8-160, 8-161, 8-162, 8-163, 8-164, 8-165, 8-166, 8-167, 8-168 universal clutch holder 90890-04086 ym-91042 5-50,...

  • Page 43: Special Tools

    Special tools 1-34 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-3 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-12 middle driven shaft bearing driver 90890-0...

  • Page 44: Special Tools

    Special tools 1-35 fuel pressure adapter 90890-03176 ym-03176 7-9 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-160 tool name/tool no. Illustration reference pages ❄❉❂❋✤❇ ✦.

  • Page 45: Specifications

    1 2 3 4 5 6 7 8 9 specifications general specifications ...................................................................... 2-1 engine specifications .......................................................................... 2-2 chassis specifications ................................................

  • Page 46: General Specifications

    General specifications 2-1 eas20280 general specifications model model xj6s 36c1 xj6sa 36d1 xj6sy 36c2 dimensions overall length 2120 mm (83.5 in) overall width 770 mm (30.3 in) overall height 1210 mm (47.6 in) seat height 785 mm (30.9 in) wheelbase 1440 mm (56.7 in) ground clearance 140 mm (5.51 in...

  • Page 47: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 599.8 cm 3 cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) compression ratio 12.20 :1 standard compression pressure (at sea le...

  • Page 48: Engine Specifications

    Engine specifications 2-3 depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 86/44 × 31/31 (1.955) spark plug (s) manufacturer/model ngk/cr9e spark plug gap 0.7 – 0.8 mm (0.028 – 0.031 in) cylinder head volume 10.33 – 10.93 cm 3 (0.63 – 0.67 cu.In) war...

  • Page 49: Engine Specifications

    Engine specifications 2-4 valve dimensions valve head diameter a (intake) 24.90 – 25.10 mm (0.9803 – 0.9882 in) valve head diameter a (exhaust) 21.90 – 22.10 mm (0.8622 – 0.8701 in) valve face width b (intake) 1.210 – 2.490 mm (0.0476 – 0.0980 in) valve face width b (exhaust) 1.210 – 2.490 mm (0.047...

  • Page 50: Engine Specifications

    Engine specifications 2-5 free length (intake) 39.08 mm (1.54 in) free length (exhaust) 39.08 mm (1.54 in) installed length (intake) 33.40 mm (1.31 in) installed length (exhaust) 33.40 mm (1.31 in) spring rate k1 (intake) 25.05 n/mm (2.55 kgf/mm, 143.04 lb/in) spring rate k2 (intake) 40.82 n/mm (4.1...

  • Page 51: Engine Specifications

    Engine specifications 2-6 piston ring top ring ring type barrel dimensions (b × t) 0.90 × 2.45 mm (0.04 × 0.10 in) end gap (installed) 0.25 – 0.35 mm (0.0098 – 0.0138 in) ring side clearance 0.030 – 0.065 mm (0.0012 – 0.0026 in) 2nd ring ring type barrel dimensions (b × t) 0.80 × 2.50 mm (0.03 × 0.1...

  • Page 52: Engine Specifications

    Engine specifications 2-7 wear limit 2.80 mm (0.1102 in) plate quantity 6 pcs friction plate thickness 2.92 – 3.08 mm (0.115 – 0.121 in) wear limit 2.80 mm (0.1102 in) plate quantity 1 pcs friction plate thickness 2.94 – 3.06 mm (0.116 – 0.120 in) water limit 2.84 mm (0.1118 in) plate quantity 1 pcs...

  • Page 53: Engine Specifications

    Engine specifications 2-8 idling condition engine idling speed 1250 – 1350 r/min co% 4.5 – 5.5 % intake vacuum 32.0 kpa (238 mmhg, 9.37 inhg) water temperature 95.0 – 105.0 ° c (203.00 – 221.00 ° f) oil temperature 75.0 – 85.0 ° c (167.00 – 185.00 ° f) throttle cable free play 3.0 – 5.0 mm (0.12 – 0...

  • Page 54: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 26.00 ° trail 103.5 mm (4.08 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum wheel travel 130.0 mm (5.12 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 55: Chassis Specifications

    Chassis specifications 2-10 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) 6.0 mm (0.24 in) limit 0.8 mm (0.03 in) brake pad lining thickness (outer) 6.0 mm (0.24 in) limit 0.8 mm (0.03 in) master cylinder inside diamete...

  • Page 56: Chassis Specifications

    Chassis specifications 2-11 spring free length 177.5 mm (6.99 in) installed length 165.5 mm (6.52 in) spring rate k1 176.50 n/mm (18.00 kgf/mm, 1007.82 lb/in) spring stroke k1 0.0 – 42.0 mm (0.00 – 1.65 in) optional spring available no enclosed gas/air pressure (std) 1500 kpa (15.0 kgf/cm 2 , 213.3 ...

  • Page 57: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 6.5 ° /1300 r/min engine control unit model/manufacturer xj6s/xj6sy fua0030/mitsubishi xj6sa fua0031/mitsubishi...

  • Page 58: Electrical Specifications

    Electrical specifications 2-13 coolant temperature warning light led engine trouble warning light led abs warning light xj6sa led immobilizer system indicator light led electric starting system system type constant mesh starter motor power output 0.60 kw armature coil resistance 0.0012 – 0.0022 Ω br...

  • Page 59: Electrical Specifications

    Electrical specifications 2-14 spare fuse xj6s/xj6sy 30.0 a xj6sa 30.0 a × 2 spare fuse 20.0 a spare fuse 10.0 a 7.5 a ❄❉❂❋✥❇ ✤✧.

  • Page 60: Tightening Torques

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

  • Page 61: Tightening Torques

    Tightening torques 2-16 thermostat cover bolt m6 2 12 nm (1.2 m · kgf, 8.7 ft · lbf) water jacket joint bolt m6 2 10 nm (1.0 m · kgf, 7.2 ft · lbf) water pump cover bolt m6 1 10 nm (1.0 m · kgf, 7.2 ft · lbf) coolant drain bolt m6 1 10 nm (1.0 m·kgf, 7.2 ft·lbf) water pump bolt m6 2 10 nm (1.0 m · k...

  • Page 62: Tightening Torques

    Tightening torques 2-17 muffler cap m6 3 10 nm (1.0 m · kgf, 7.2 ft · lbf) clutch cover bolt m6 10 10 nm (1.0 m · kgf, 7.2 ft · lbf) generator cover bolt m6 7 10 nm (1.0 m · kgf, 7.2 ft · lbf) crankcase bolt (main journal) m8 10 see tip apply oil to threads and sur- face crankcase bolt (bolt number ...

  • Page 63: Tightening Torques

    Tightening torques 2-18 tip ● cylinder head bolt 1.Tighten the bolts to 19 nm (1.9 m·kgf, 14 ft·lbf) “1” – “10” following the tightening order. 2.Retighten the bolts 50 nm (5.0 m·kgf, 36 ft·lbf) “1” – “10” following the tightening order. 3.Loosen the bolt “1” and retighten it 12 nm (1.2 m·kgf, 8.8 f...

  • Page 64: Tightening Torques

    Tightening torques 2-19 tighten at 75 ° – 85 ° angle according to the tightening order (“8”, “9”). Cylinder head tightening sequence. Crankcase tightening sequence. Eas20350 chassis tightening torques 6 2 8 10 4 3 1 9 7 5 4 6 8 2 10 5 7 3 9 1 13 21 16 19 20 27 17 11 12 18 15 14 26 24 22 23 25 item t...

  • Page 65: Tightening Torques

    Tightening torques 2-20 right handlebar switch screw m5 3 4 nm (0.4 m · kgf, 2.9 ft · lbf) steering stem nut m22 1 110 nm (11 m · kgf, 80 ft · lbf) upper handlebar holder bolt m8 4 24 nm (2.4 m · kgf, 17 ft · lbf) lower bracket pinch bolt – 2 30 nm (3.0 m · kgf, 22 ft · lbf) lower ring nut m25 1 see...

  • Page 66: Tightening Torques

    Tightening torques 2-21 fuel tank and fuel tank cap m5 4 6 nm (0.6 m · kgf, 4.3 ft · lbf) fuel pump and fuel tank m5 6 4 nm (0.4 m · kgf, 2.9 ft · lbf) ignition coil screw m6 2 1.5 nm (0.15 m · kgf, 1.1 ft · lbf) seat lock and frame m6 2 7 nm (0.7 m · kgf, 5.0 ft · lbf) seat key cylinder and mud gua...

  • Page 67: Tightening Torques

    Tightening torques 2-22 brake pedal and footrest bracket m6 1 7 nm (0.7 m · kgf, 5.0 ft · lbf) footrest bolt m8 2 10 nm (1.0 m · kgf, 7.2 ft · lbf) footrest bracket and frame m8 6 30 nm (3.0 m · kgf, 22 ft · lbf) rear brake fluid reservoir and bracket m6 1 3 nm (0.3 m · kgf, 2.2 ft · lbf) rear maste...

  • Page 68: Tightening Torques

    Tightening torques 2-23 tip ● lower ring nut 1.First, tighten the ring nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the ring nut completely. 2.Retighten the lower ring nut to 18 nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. ● engine mount bolts and engine mou...

  • Page 69: 2-24

    Lubrication points and lubricant types 2-24 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings and bushes crankshaft pins piston surfaces piston pins connecting rod bolts crankshaft journals camshaft profile journals valve stems...

  • Page 70: 2-25

    Lubrication points and lubricant types 2-25 eas20380 chassis cylinder head cover semicircular three bond no.1215b ® crankcase mating surface three bond no.1215 ® generator rotor cover (stator coil assembly lead grommet) three bond no.1215 ® pickup rotor cover (crankshaft position sensor lead grommet...

  • Page 71: 2-26

    Lubrication points and lubricant types 2-26 ❄❉❂❋✥❇ ✥✩.

  • Page 72: 2-27

    Lubrication system chart and diagrams 2-27 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 13 12 11 10 10 10 10 9 14 14 5 6 7 8 3 2 1 4 14 14 15 ❄❉❂❋✥❇ ✥✪.

  • Page 73: 2-28

    Lubrication system chart and diagrams 2-28 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Oil pipe 8. Drive axle 9. Main gallery 10. Oil nozzle 11. Timing chain tensioner 12. Intake camshaft 13. Exhaust camshaft 14. Big end 15. Crankshaft ❄❉❂❋✥❇ ✥✫.

  • Page 74: 2-29

    Lubrication system chart and diagrams 2-29 eas20410 lubrication diagrams 1 5 3 2 4 ❄❉❂❋✥❇ ✥✬.

  • Page 75: 2-30

    Lubrication system chart and diagrams 2-30 1. Oil level switch 2. Oil cooler 3. Relief valve 4. Ventilation chamber cover 5. Oil delivery pipe ❄❉❂❋✥❇ ✦✣.

  • Page 76: 2-31

    Lubrication system chart and diagrams 2-31 3 7 8 2 1 4 6 5 ❄❉❂❋✥❇ ✦✤.

  • Page 77: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer 5. Oil pipe 6. Oil delivery pipe 7. Timing chain tensioner 8. Oil check bolt ❄❉❂❋✥❇ ✦✥.

  • Page 78: 2-33

    Lubrication system chart and diagrams 2-33 3 6 5 1 2 4 ❄❉❂❋✥❇ ✦✦.

  • Page 79: 2-34

    Lubrication system chart and diagrams 2-34 1. Oil cooler 2. Oil strainer 3. Oil level switch 4. Oil pump 5. Oil pipe 6. Oil filter ❄❉❂❋✥❇ ✦✧.

  • Page 80: 2-35

    Lubrication system chart and diagrams 2-35 1 2 4 5 3 ❄❉❂❋✥❇ ✦.

  • Page 81: 2-36

    Lubrication system chart and diagrams 2-36 1. Main axle 2. Oil pump 3. Relief valve 4. Oil pipe 5. Oil delivery pipe ❄❉❂❋✥❇ ✦✩.

  • Page 82: 2-37

    Lubrication system chart and diagrams 2-37 3 2 5 4 1 ❄❉❂❋✥❇ ✦✪.

  • Page 83: 2-38

    Lubrication system chart and diagrams 2-38 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle ❄❉❂❋✥❇ ✦✫.

  • Page 84: 2-39

    Lubrication system chart and diagrams 2-39 2 3 1 ❄❉❂❋✥❇ ✦✬.

  • Page 85: 2-40

    Lubrication system chart and diagrams 2-40 1. Main axle 2. Drive axle 3. Oil pipe ❄❉❂❋✥❇ ✧✣.

  • Page 86: Cooling System Diagrams

    Cooling system diagrams 2-41 eas20420 cooling system diagrams 1 1 2 2 3 5 6 4 4 7 ❄❉❂❋✥❇ ✧✤.

  • Page 87: Cooling System Diagrams

    Cooling system diagrams 2-42 1. Radiator 2. Oil cooler 3. Water pump 4. Coolant reservoir 5. Fast idle plunger 6. Water pump breather hose 7. Water jacket joint ❄❉❂❋✥❇ ✧✥.

  • Page 88: Cable Routing

    Cable routing 2-43 eas20430 cable routing ❄❉❂❋✥❇ ✧✦.

  • Page 89: Cable Routing

    Cable routing 2-44 1. Clutch cable 2. Throttle cable (accelerator side) 3. Throttle cable (decelerator side) a. Clamp the left handlebar switch lead, main switch lead, immobilizer lead, and throttle cables. Clamp the leads at the white tape position. Direct the end of clamp down and outward.No need ...

  • Page 90: Cable Routing

    Cable routing 2-45 ❄❉❂❋✥❇ ✧.

  • Page 91: Cable Routing

    Cable routing 2-46 1. Fuel tank drain hose 2. Rear mudguard assembly 3. Ecu lead 4. Starter motor lead 5. Oil level switch lead 6. Sidestand switch lead 7. Sub-wire harness (throttle body) 8. Throttle body joint coupler 9. Wire harness a. Clamp the wire harness and ac magneto lead. Direct the end of...

  • Page 92: Cable Routing

    Cable routing 2-47 ❄❉❂❋✥❇ ✧✪.

  • Page 93: Cable Routing

    Cable routing 2-48 1. Right handlebar switch lead 2. Radiator fan motor lead 3. Ignition coil #2, #3 connector 4. Main switch lead 2 5. Main switch lead 1 6. Immobilizer lead 7. Left handlebar switch lead 8. Ignition coil #1, #4 connector 9. Throttle cables 10. High tension code 11. Cover 12. Spark ...

  • Page 94: Cable Routing

    Cable routing 2-49 ❄❉❂❋✥❇ ✧✬.

  • Page 95: Cable Routing

    Cable routing 2-50 1. Fuel tank breather hose 2. Rectifier/regulator 3. Battery negative lead 4. Starter relay 5. Battery positive lead 6. Starter motor lead 7. Fuel tank drain hose 8. Throttle body joint coupler a. To crankshaft position sensor b. To ac magneto c. To oil level switch d. To sidestan...

  • Page 96: Cable Routing

    Cable routing 2-51 ❄❉❂❋✥❇ ✤.

  • Page 97: Cable Routing

    Cable routing 2-52 1. Radiator fan motor relay 2. Relay unit 3. License plate light lead 4. Rear turn signal light leads (left/right) 5. Tail/brake light lead 6. Seat lock cable 7. Turn signal relay 8. Headlight relay 9. Lean angle sensor 10. Fuse box 11. Frame comp. 12. White tape 13. Wire harness ...

  • Page 98: Cable Routing

    Cable routing 2-53 ❄❉❂❋✥❇ ✦.

  • Page 99: Cable Routing

    Cable routing 2-54 1. Front brake hose 2. Front fork assembly a. Clamp it securely. The pawl must be directed toward the right side of the vehicle. B. Insert it securely until it reaches its end position. C. Secure for 3 or more notches. The pawl must be directed toward the front of the vehicle. D. ...

  • Page 100: Cable Routing

    Cable routing 2-55 ❄❉❂❋✥❇.

  • Page 101: Cable Routing

    Cable routing 2-56 1. Rear brake caliper 2. Dust cover 3. Rear brake hose 4. Rear brake reservoir 5. Rear brake light switch lead 6. Frame complete 7. Swingarm a. Clamp it securely. The pawl must be directed toward the rear of the vehicle. B. Install the terminal against the bracket with crimp barre...

  • Page 102: Cable Routing

    Cable routing 2-57 ❄❉❂❋✥❇ ✪.

  • Page 103: Cable Routing

    Cable routing 2-58 1. Clutch cable 2. Front brake pipe 3. Throttle cable (accelerator side) 4. Throttle cable (decelerator side) 5. Front wheel sensor lead a. Clamp the left handlebar switch lead, main switch lead, immobilizer lead, and throttle cables. Clamp the leads at the white tape position. Di...

  • Page 104: Cable Routing

    Cable routing 2-59 ❄❉❂❋✥❇ ✬.

  • Page 105: Cable Routing

    Cable routing 2-60 1. Fuel tank drain hose 2. Rear mudguard assembly 3. Ecu lead 4. Starter motor lead 5. Oil level switch lead 6. Sidestand switch lead 7. Sub-wire harness (throttle body) 8. Throttle body joint connector 9. Wire harness a. Clamp the wire harness and ac magneto lead. Direct the end ...

  • Page 106: Cable Routing

    Cable routing 2-61 ❄❉❂❋✥❇ ✩✤.

  • Page 107: Cable Routing

    Cable routing 2-62 1. Right handlebar switch lead 2. Radiator fan motor lead 3. Ignition coil #2, #3 connector 4. Main switch lead 2 5. Main switch lead 1 6. Immobilizer lead 7. Left handlebar switch lead 8. Front wheel sensor lead 9. Connector 10. Abs test coupler 11. Ignition coil #1, #4 connector...

  • Page 108: Cable Routing

    Cable routing 2-63 ❄❉❂❋✥❇ ✩✦.

  • Page 109: Cable Routing

    Cable routing 2-64 1. Fuel tank breather hose 2. Rectifier/regulator 3. Battery negative lead 4. Starter relay 5. Starter motor lead 6. Battery positive lead 7. Fuel tank drain hose 8. Throttle body joint coupler a. To crankshaft position sensor b. To ac magneto c. To oil level switch d. To sidestan...

  • Page 110: Cable Routing

    Cable routing 2-65 ❄❉❂❋✥❇ ✩.

  • Page 111: Cable Routing

    Cable routing 2-66 1. Radiator fan motor relay 2. Relay unit 3. License plate light lead 4. Rear turn signal light leads (left/right) 5. Tail/brake light lead 6. Seat lock cable 7. Turn signal relay 8. Headlight relay 9. Lean angle sensor 10. Fuse box 11. Frame comp. 12. White tape 13. Wire harness ...

  • Page 112: Cable Routing

    Cable routing 2-67 ❄❉❂❋✥❇ ✩✪.

  • Page 113: Cable Routing

    Cable routing 2-68 1. Front wheel sensor lead 2. Front brake pipe (front brake master cylin- der – hydraulic unit) 3. Brake pipe holder 4. Hydraulic unit 5. Front brake pipe (front brake caliper – hydraulic unit) 6. Frame 7. Radiator assembly 8. Front brake hose 9. Front brake caliper 10. Front fork...

  • Page 114: Cable Routing

    Cable routing 2-69 ❄❉❂❋✥❇ ✩✬.

  • Page 115: Cable Routing

    Cable routing 2-70 1. Front brake hose 2. Front fork assembly 3. Front brake caliper 4. Front wheel sensor lead 5. Clamp a. Clamp securely. The pawl must be directed toward the right side of the vehicle. B. Insert it securely until it reaches its end position. C. Secure for 3 or more notches. The pa...

  • Page 116: Cable Routing

    Cable routing 2-71 ❄❉❂❋✥❇ ✪✤.

  • Page 117: Cable Routing

    Cable routing 2-72 1. Rear wheel sensor housing 2. Rear wheel sensor 3. Rear brake caliper 4. Clamp 5. Rear brake hose (rear brake caliper – hydraulic unit) 6. Rear wheel sensor lead 7. Rear brake hose (rear brake master cylin- der – hydraulic unit) 8. Rear brake light switch lead 9. Wire harness 10...

  • Page 118: Cable Routing

    Cable routing 2-73 ❄❉❂❋✥❇ ✪✦.

  • Page 119: Cable Routing

    Cable routing 2-74 1. Rear wheel sensor 2. Clamp 3. Rear brake pipe (hydraulic unit – rear brake cali- per) 4. Rear brake pipe (rear brake master cylin- der – hydraulic unit) 5. Hydraulic unit 6. Wire harness 7. Front brake pipe (front brake master cylin- der – hydraulic unit) 8. Front brake pipe (h...

  • Page 120: Cable Routing

    Cable routing 2-75 ❄❉❂❋✥❇ ✪.

  • Page 121: Cable Routing

    Cable routing 2-76 1. Rear wheel sensor 2. Clamp 3. Wire harness 4. Front brake pipe (hydraulic unit – front brake cali- per) 5. Front brake pipe (front brake master cylin- der – hydraulic unit) 6. Frame 7. Hydraulic unit 8. Rear brake hose (rear brake master cylin- der – hydraulic unit) 9. Rear whe...

  • Page 122: Cable Routing

    Cable routing 2-77 ❄❉❂❋✥❇ ✪✪.

  • Page 123: Cable Routing

    Cable routing 2-78 1. Clutch cable 2. Left handlebar switch lead 3. Horn lead 4. Throttle cables 5. Right handlebar switch lead 6. Cable guide a. Clamp the main switch lead and immobilizer lead on to the left side of the cable guide where it is not curved. Clamp the leads at the white tape position....

  • Page 124: Cable Routing

    Cable routing 2-79 ❄❉❂❋✥❇ ✪✬.

  • Page 125: Cable Routing

    Cable routing 2-80 1. Radiator fan motor lead 2. Crankshaft position sensor lead 3. Wire harness 4. Connector cover a. To meter b. To headlight c. Clamp the wire harness, right handlebar switch lead, and radiator fan motor lead. Clamp the right handlebar switch lead so that there is no slack when th...

  • Page 126: Cable Routing

    Cable routing 2-81 ❄❉❂❋✥❇ ✫✤.

  • Page 127: Cable Routing

    Cable routing 2-82 1. Battery negative lead 2. Rear brake light switch lead 3. Fuel tank breather hose 4. O 2 sensor lead 5. Neutral switch lead 6. Rear turn signal light lead (right/left) 7. License plate light lead 8. Tail/brake light lead a. Install the wire harness inside frame from behind of th...

  • Page 128: Cable Routing

    Cable routing 2-83 ❄❉❂❋✥❇ ✫✦.

  • Page 129: Cable Routing

    Cable routing 2-84 1. Fuel tank cap 2. Fuel tank 3. Fuel pump 4. Fuel hose 5. Fuel tank breather hose (right side) 6. Fuel tank drain hose (left side) 7. Throttle body 8. Fuel hose connector 9. Fuel pump bracket 10. Rubber cover a. Release to atmospheric pressure b. Make sure that the connector is c...

  • Page 130: Cable Routing

    Cable routing 2-85 ❄❉❂❋✥❇ ✫.

  • Page 131: Cable Routing

    Cable routing 2-86 1. Synchronizing hose #1 2. Synchronizing hose #2 3. Synchronizing hose #3 4. Synchronizing hose #4 5. Fast idle plunger coolant hose 6. Throttle position sensor 7. Fuel injector #4 8. Intake air pressure sensor 9. Fuel injector #3 10. Fuel injector #2 11. Fuel injector #1 12. Fas...

  • Page 132: Cable Routing

    Cable routing 2-87 ❄❉❂❋✥❇ ✫✪.

  • Page 133: Cable Routing

    Cable routing 2-88 1. Fast idle plunger coolant hose 2. Fast idle plunger 3. Synchronizing hose #1 4. Synchronizing hose #2 5. Fast idle plunger hose (fast idle plunger-throttle body #1) 6. Intake air pressure sensor 7. Throttle position sensor 8. Fast idle plunger hose (fast idle plunger-throttle b...

  • Page 134: Cable Routing

    Cable routing 2-89 ❄❉❂❋✥❇ ✫✬.

  • Page 135: Cable Routing

    Cable routing 2-90 1. Air cut-off valve hose 1 2. Air cut-off valve hose 2 3. Air cut-off valve 4. Air cut-off valve hose 3 5. Air filter case 6. Bracket 7. Rubber cover 8. Reed valve a. Install the clamp with its end facing the right side of the vehicle. B. Install the clamp with its end facing the...

  • Page 136: Cable Routing

    Cable routing 2-91 ❄❉❂❋✥❇ ✬✤.

  • Page 137

    1 2 3 4 5 6 7 8 9 periodic checks and adjustments periodic maintenance .......................................................................... 3-1 introduction ..................................................................................... 3-1 periodic maintenance chart for the emission con...

  • Page 138: 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 139: Periodic Maintenance

    Periodic maintenance 3-2 eau1770b general maintenance and lubrication chart no. Item check or maintenance job odometer reading annual check 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) 1 air filter element ● replace. √ 2 clutch ● check operation. ● ...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-3 tip ● 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 dusty areas. ●...

  • Page 141: Periodic Maintenance

    Periodic maintenance 3-4 eas21030 checking the fuel line the following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: ● seat refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. 2. Check: ● fuel tank breather hose “1” ● fuel tank drain ho...

  • Page 142: Periodic Maintenance

    Periodic maintenance 3-5 9. Connect: ● spark plug caps 10.Install: ● rubber cover refer to “air induction system” on page 7-11. ● air filter case refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. ● seat refer to “general chassis” on page 4-1. Eas20490 adjusting th...

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-6 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: ● camshafts tip ● refer to “camshafts” on page 5-8. ● when remov...

  • Page 144: Periodic Maintenance

    Periodic maintenance 3-7 tip 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 “158”, the pad thickness is 1.58 mm (0.062 in) d. Calculate the sum of the values obtained in steps (b) and (c) to ...

  • Page 145: Periodic Maintenance

    Periodic maintenance 3-8 ● spark plugs ● air filter element ● throttle body joints ● fuel hoses ● air induction system ● exhaust system ● breather hoses ● throttle body hoses ● fast idle plunger outlet hose ● fast idle plunger inlet hose 1. Start the engine and let it warm up for several minutes. 2....

  • Page 146: Periodic Maintenance

    Periodic maintenance 3-9 4. Install: ● fuel tank refer to “fuel tank” on page 7-1. 5. Start the engine and let it warm up for several minutes. 6. Check: ● engine idling speed out of specification → adjust. Refer to “adjusting the engine idling speed” on page 3-7. ● check the vacuum pressure. If out ...

  • Page 147: Periodic Maintenance

    Periodic maintenance 3-10 eas20s13005 checking the air induction system refer to “air induction system” on page 7-11. Eas21070 checking the crankcase breather hose 1. Remove: ● seat refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. 2. Check: ● crankcase breather h...

  • Page 148: Periodic Maintenance

    Periodic maintenance 3-11 ● seat refer to “general chassis” on page 4-1. Eas20870 adjusting the clutch cable free play 1. Check: ● clutch cable free play “a” out of specification → adjust. 2. Adjust: ● clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjusting bolt ...

  • Page 149: Periodic Maintenance

    Periodic maintenance 3-12 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 flu- ids may result in a ...

  • Page 150: Periodic Maintenance

    Periodic maintenance 3-13 eas21190 adjusting the rear disc brake 1. Check: ● brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) out of specification → adjust. 2. Adjust: ● brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1...

  • Page 151: Periodic Maintenance

    Periodic maintenance 3-14 eas21340 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 operation is faulty. Tip ● be careful no...

  • Page 152: Periodic Maintenance

    Periodic maintenance 3-15 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ bleeding the abs brake warning ewa36c1001 bleed the abs whenever: ● the system is disassembled. ● a brake hose is loosened, disconnected or replaced. ● th...

  • Page 153: Periodic Maintenance

    Periodic maintenance 3-16 m. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid level” on page 3-11. Warning ewa14020 after bleeding the abs, check the brake op- eration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 154: Periodic Maintenance

    Periodic maintenance 3-17 warning ewa13180 ● the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. ● the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories...

  • Page 155: Periodic Maintenance

    Periodic maintenance 3-18 warning ewa13210 new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Tip for tires with a direction of rotation mark “1”: ● inst...

  • Page 156: Periodic Maintenance

    Periodic maintenance 3-19 d. Tighten both locknuts to specification. E. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear...

  • Page 157: Periodic Maintenance

    Periodic maintenance 3-20 d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “steering head” on page 4-68. E. Install the rubber washer “2”. F....

  • Page 158: Periodic Maintenance

    Periodic maintenance 3-21 2. Adjust: ● handlebar position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the handlebar holder caps “1”, up- per handlebar holders “2” and handlebar “3”. B. Loosen the lower handlebar holder nuts “4”. C. Adjust the handlebar position by rotating both of the lower handlebar...

  • Page 159: Periodic Maintenance

    Periodic maintenance 3-22 eas21710 lubricating the pedal lubricate the pivoting point and metal-to-metal moving parts of the pedal. Eas21370 adjusting the shift pedal 1. Check: ● shift pedal position check the shift rod length “a”. Out of specification → adjust. 2. Adjust: ● shift pedal position ▼▼▼...

  • Page 160: Periodic Maintenance

    Periodic maintenance 3-23 no danger of it falling over. 2. Check: ● inner tube “1” damage/scratches → replace. ● oil seal “2” oil leakage → replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: ● front fork operation push down hard on the handlebar several times and check if the ...

  • Page 161: Periodic Maintenance

    Periodic maintenance 3-24 3. Check: ● engine oil level the engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → add the recommended engine oil to the proper level. Notice eca4s81007 ● engine oil also lubricates the clutch and the wr...

  • Page 162: Periodic Maintenance

    Periodic maintenance 3-25 4. Drain: ● engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” ...

  • Page 163: Periodic Maintenance

    Periodic maintenance 3-26 4. Install: ● oil pressure gauge “1” ● adapter “2” 5. Measure: ● engine oil pressure (at the following conditions) out of specification → adjust. 6. Install: ● main gallery bolt “1” eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip ● place the...

  • Page 164: Periodic Maintenance

    Periodic maintenance 3-27 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: ● coolant level tip before checking the coolant level, wait a few minutes until it settles. Eas21120 checking the cooling system 1. Check: ● radiator “1” ● radiator inlet hose “2” ● radia...

  • Page 165: Periodic Maintenance

    Periodic maintenance 3-28 warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: place a th...

  • Page 166: Periodic Maintenance

    Periodic maintenance 3-29 10.Install: ● radiator cap ● radiator cap lock bolt ● right side cowling refer to “general chassis” on page 4-1. 11.Fill: ● coolant reservoir (with the recommended coolant to the maxi- mum level mark “a”) 12.Install: ● coolant reservoir cap 13.Start the engine, warm it up f...

  • Page 167: Periodic Maintenance

    Periodic maintenance 3-30 eas20630 adjusting the throttle cable free play tip prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: ● throttle cable free play “a” out of specification → adjust. 2. Remove:...

  • Page 168: Periodic Maintenance

    Periodic maintenance 3-31 ● left side panel refer to “general chassis” on page 4-1. Warning ewa4s81001 after adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. Eas21760 che...

  • Page 169: Periodic Maintenance

    Periodic maintenance 3-32 3. Remove: ● headlight bulb holder “1” 4. Remove: ● headlight bulb “2” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: ● headlight bulb secure the new headlight bul...

  • Page 170: Periodic Maintenance

    Periodic maintenance 3-33 ❄❉❂❋✦❇ ✦✦.

  • Page 171: Chassis

    1 2 3 4 5 6 7 8 9 chassis general chassis..................................................................................... 4-1 front wheel............................................................................................. 4-5 removing the front wheel.......................................

  • Page 172

    Abs (anti-lock brake system)........................................................... 4-49 abs components chart ................................................................. 4-49 removing the hydraulic unit assembly ................................. 4-51 checking the hydraulic unit assembly .....

  • Page 173: General Chassis

    General chassis 4-1 eas21830 general chassis removing the cowlings order job/parts to remove q’ty remarks 1 seat 1 2 rear side cover 2 3 grab bar 1 4 rear cowling 2 5 bottom cowling 1 for installation, reverse the removal proce- dure. 1 2 3 4 4 5 16 nm (1.6 m • kgf, 11 ft • ibf) 7 nm (0.7 m • kgf, 5...

  • Page 174: General Chassis

    General chassis 4-2 removing the front cowling assembly order job/parts to remove q’ty remarks 1 front cowling left inner panel 1 2 front cowling right inner panel 1 3 front cowling center inner panel 1 4 left side cowling 1 5 right side cowling 1 6 left side panel 1 7 right side panel 1 8 front cow...

  • Page 175: General Chassis

    General chassis 4-3 removing the air filter case order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 clamp screw 4 loosen. 2 intake air temperature sensor coupler 1 disconnect. 3 throttle body hose 2 disconnect. 4 crankcas...

  • Page 176: General Chassis

    General chassis 4-4 removing the battery order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. 1 battery band 1 2 battery cover 1 3 negative battery lead 1 4 positive battery lead 1 5 battery 1 6 battery seat 1 for installation, reverse the removal proce- dure. 2.5 nm (...

  • Page 177: Front Wheel

    Front wheel 4-5 eas21880 front wheel removing the front wheel and brake discs (xj6s) order job/parts to remove q’ty remarks 1 brake hose holder 3 2 front brake caliper 2 3 front wheel axle pinch bolt 1 loosen. 4 front wheel axle 1 5 collar 2 6 front wheel 1 7 front brake disc 2 for installation, rev...

  • Page 178: Front Wheel

    Front wheel 4-6 *xj6sa removing the front wheel and brake discs (xj6sa) order job/parts to remove q’ty remarks 1 brake hose holder 3 2 front brake caliper 2 3 front wheel sensor 1 4 front wheel axle pinch bolt 1 loosen. 5 front wheel axle 1 6 collar 1 7 sensor housing 1 8 front wheel 1 9 front brake...

  • Page 179: Front Wheel

    Front wheel 4-7 *xj6sa disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 front wheel sensor rotor (xj6sa) 1 3 wheel bearing 2 4 spacer 1 for assembly, reverse the disassembly pro- cedure. 1 1 3 3 4 lt 8 nm (0.8 m • kgf, 5.8 ft • ibf) 2 ❄❉❂❋✧❇ ✪.

  • Page 180: Front Wheel

    Front wheel 4-8 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. Tip place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: ● left brake caliper ● rig...

  • Page 181: Front Wheel

    Front wheel 4-9 c. Remove the wheel bearings “3” with a gener- al bearing puller. Notice eca20s1009 do not damage the front wheel sensor rotor. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Notice eca14130 do not contact the wheel bearing inner race “4” or ball...

  • Page 182: Front Wheel

    Front wheel 4-10 to any metal part when removing the front wheel sensor from the sensor housing. ● do not operate the brake lever when re- moving the brake caliper. Checking the front wheel sensor and sen- sor rotor 1. Check: ● front wheel sensor “1” cracks/bends/distortion → replace. Iron powder/du...

  • Page 183: Front Wheel

    Front wheel 4-11 installing the front wheel sensor 1. Install: ● front wheel notice eca14470 make sure there are no foreign materials in the wheel hub. Foreign materials cause dam- age to the inner sensor rotor and wheel sen- sor. Tip align the slot in the sensor housing with the pro- jection of the...

  • Page 184: Front Wheel

    Front wheel 4-12 4. Connect: ● front wheel sensor coupler “1” 5. Check: ● front wheel sensor installation check if the wheel sensor housing is installed properly. Refer to “maintenance of the front wheel sensor and sensor rotor” on page 4-9. Eas21970 adjusting the front wheel static balance tip ● af...

  • Page 185: Front Wheel

    Front wheel 4-13 tip start with the lightest weight. B. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ is bala...

  • Page 186: Rear Wheel

    Rear wheel 4-14 eas22030 rear wheel removing the rear wheel (xj6s) order job/parts to remove q’ty remarks 1 locknut 2 loosen. 2 adjusting nut 2 loosen. 3 cap 2 4 rear wheel axle nut 1 5 rear wheel axle 1 6 washer 1 7 indicator plate 2 8 drive chain puller 2 9 rear wheel 1 10 rear brake caliper assem...

  • Page 187: Rear Wheel

    Rear wheel 4-15 removing the rear wheel (xj6sa) order job/parts to remove q’ty remarks 1 rear wheel sensor 1 2 lock nut 2 loosen. 3 adjusting nut 2 loosen. 4 cap 2 5 wheel axle nut 1 6 rear wheel axle 1 7 washer 1 8 indicator plate 2 9 drive chain puller 2 10 rear wheel 1 11 rear brake caliper assem...

  • Page 188: Rear Wheel

    Rear wheel 4-16 *xj6s 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 collar (xj6s) 1 5 oil seal 2 6 bearing 2 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 rear wheel 1 for installation...

  • Page 189: Rear Wheel

    Rear wheel 4-17 *xj6sa disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 oil seal 1 3 rear wheel sensor rotor (xj6sa) 1 4 bearing 2 5 spacer 1 for assembly, reverse the disassembly pro- cedure. 1 4 5 4 2 3 lt 8 nm (0.8 m • kgf, 5.8 ft • ibf) ❄❉❂❋✧❇ ✤✪.

  • Page 190: Rear Wheel

    Rear wheel 4-18 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. Tip place the vehicle on the centerstand so that the rear wheel is elevated. 2. Loosen: ● locknut “1” ● adjusting nut...

  • Page 191: Rear Wheel

    Rear wheel 4-19 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 sprocket. Tip tighten...

  • Page 192: Rear Wheel

    Rear wheel 4-20 checking the rear wheel sensor and sensor rotor 1. Check: ● rear wheel sensor cracks/bends/distortion → replace. Iron powder/dust → clean. 2. Check: ● rear wheel sensor rotor cracks/damage → replace. Installing the rear wheel sensor 1. Install: ● sensor rotor “1” notice eca4b56012 re...

  • Page 193: Rear Wheel

    Rear wheel 4-21 6. Install: ● rear wheel sensor lead holder “3” ● clamp “4” 7. Connect: ● rear wheel sensor coupler “5” notice eca14500 to route the rear wheel sensor lead, refer to “cable routing” on page 2-43. 8. Check: ● rear wheel sensor installation check if the wheel sensor housing is installe...

  • Page 194: Rear Wheel

    Rear wheel 4-22 4. Tighten: ● wheel axle nut drive chain slack 45.0 – 55.0 mm (1.77 – 2.17 in) wheel axle nut 90 nm (9.0 m·kgf, 64 ft·lbf) t r . . ❄❉❂❋✧❇ ✥✥.

  • Page 195: Front Brake

    Front brake 4-23 eas22210 front brake removing the front brake pads (xj6s) order job/parts to remove q’ty remarks 1 front brake caliper 1 2 brake pad 2 3 brake pad spring 2 for installation, reverse the removal proce- dure. 27 nm (2.7 m • kgf, 19 ft • ibf) 1 2 3 s ❄❉❂❋✧❇ ✥✦.

  • Page 196: Front Brake

    Front brake 4-24 removing the front brake pads (xj6sa) order job/parts to remove q’ty remarks 1 front brake caliper 1 2 brake pad 2 3 brake pad spring 2 for installation, reverse the removal proce- dure. 27 nm (2.7 m • kgf, 19 ft • ibf) 1 2 3 s ❄❉❂❋✧❇ ✥✧.

  • Page 197: Front Brake

    Front brake 4-25 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 3-14. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm holder 1 3 brake master cylinder reserv...

  • Page 198: Front Brake

    Front brake 4-26 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 master cylinder kit 1 2 master cylinder 1 for assembly, reverse the disassembly pro- cedure. 1 2 ❄❉❂❋✧❇ ✥✩.

  • Page 199: Front Brake

    Front brake 4-27 removing the front brake calipers (xj6s) order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. 1 union bolt 2 2 copper washer 5 3 brake hose 2 4 brake caliper 1 5 brake pad 2 6 brake pad spring 2 7 brake caliper bracke...

  • Page 200: Front Brake

    Front brake 4-28 removing the front brake calipers (xj6sa) order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. 1 union bolt 2 2 copper washer 5 3 brake hose 2 4 brake caliper 1 5 brake pad 2 6 brake pad spring 2 7 brake caliper brack...

  • Page 201: Front Brake

    Front brake 4-29 disassembling the front brake calipers order job/parts to remove q’ty remarks 1 brake pad 2 2 brake caliper piston 2 3 brake caliper piston dust seal 2 4 brake caliper piston seal 2 5 brake pad spring 1 6 bleed screw 1 for assembly, reverse the disassembly pro- cedure. 6 nm (0.6 m •...

  • Page 202: Front Brake

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

  • Page 203: Front Brake

    Front brake 4-31 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ within specification, replace the brake disc. Eas...

  • Page 204: Front Brake

    Front brake 4-32 eas22300 removing the front brake calipers the following procedure applies to both of the brake calipers. Tip before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: ● union bolt “1” ● copper washers “2” ● brake hose “3” ● brake caliper tip ...

  • Page 205: Front Brake

    Front brake 4-33 warning ewa13600 whenever a brake caliper is disassembled, replace the piston seals. Eas22410 assembling the front brake calipers warning ewa13620 ● before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. ● never use solve...

  • Page 206: Front Brake

    Front brake 4-34 deteriorate, causing leakage and poor brake performance. ● refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. ● when refilling, be careful that water does not e...

  • Page 207: Front Brake

    Front brake 4-35 3. Check: ● brake master cylinder reservoir “1” cracks/damage → replace. ● brake master cylinder reservoir diaphragm “2” damage/wear → replace. 4. Check: ● brake hoses cracks/damage/wear → replace. Eas22520 assembling the front brake master cylinder warning ewa13520 ● before install...

  • Page 208: Front Brake

    Front brake 4-36 warning ewa13540 ● 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 flu- ids may result in a harmful c...

  • Page 209: Rear Brake

    Rear brake 4-37 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 2 5 bleed screw 1 6 brake pad spring 2 for installation, reverse the removal proce- dure. 22 nm (2.2 m • kgf, 15 ft • ibf) 5 nm ...

  • Page 210: Rear Brake

    Rear brake 4-38 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. Right rear side cover refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 rear brake fluid reservoir diap...

  • Page 211: Rear Brake

    Rear brake 4-39 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 3 connector 1 4 bushing 1 for installation, reverse the removal proce- dure. 14 nm (1.4 m • kgf, 10 ft • ibf) 1 2 3 4 18 nm (1.8 m • kgf, 1...

  • Page 212: Rear Brake

    Rear brake 4-40 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 3-14. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure. 22 nm (2.2 ...

  • Page 213: Rear Brake

    Rear brake 4-41 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 2 4 brake pad spring 2 5 brake caliper piston 1 6 brake caliper piston dust seal 1 7 brake caliper piston seal 1 8 bleed screw 1 for assembly, reverse the disassem...

  • Page 214: Rear Brake

    Rear brake 4-42 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 215: Rear Brake

    Rear brake 4-43 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: ● brake caliper ● brake pad pin ● screw plug 4. Check: ● brake fluid level below the minimum level mark “a” →...

  • Page 216: Rear Brake

    Rear brake 4-44 be careful not to get injured when the pis- ton is expelled from the brake caliper. ● never try to pry out the brake caliper pis- ton. C. Remove the brake caliper piston dust seal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ and brake caliper piston seal. Eas22640 checking the rear brake caliper...

  • Page 217: Rear Brake

    Rear brake 4-45 warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca- ble routing” on page 2-43. Notice eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper...

  • Page 218: Rear Brake

    Rear brake 4-46 8. Check: ● brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-14. Eas22700 removing the rear brake master cylinder 1. Remove: ● union bolt “1” ● copper washers “2” ● brake hose “3” tip to collect any remain...

  • Page 219: Rear Brake

    Rear brake 4-47 1. Install: ● master cylinder kit ● circlip eas22740 installing the rear brake master cylinder 1. Install: ● cotter pin “1” ● copper washers “2” ● brake hose “3” ● union bolt “4” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca-...

  • Page 220: Rear Brake

    Rear brake 4-48 below the minimum level mark “b” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-11. 5. Adjust: ● brake pedal position “c” refer to “adjusting the rear disc brake” on page 3-13. 6. Adjust: ● rear brake light operation timing ...

  • Page 221: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-49 eas22760 abs (anti-lock brake system) eas4b56003 abs components chart 1 2 4 3 5 6 7 12 10 14 15 9 11 13 8 a a 1. Hydraulic unit assembly 2. Abs warning light 3. Rear wheel sensor rotor 4. Rear wheel sensor 5. Front wheel sensor 6. Front wheel sensor rotor 7. Abs tes...

  • Page 222: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-50 removing the hydraulic unit assembly order job/parts to remove q ’ ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14 . 1 abs ecu coupler bracket 1 2 abs ecu coupler 1 disconnect. 3 brake pipe/joint assembly (hydraulic unit to ...

  • Page 223: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-51 eas4b56004 removing the hydraulic unit assembly notice eca4b56013 unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids...

  • Page 224: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-52 eas4b56007 installing the hydraulic unit assembly 1. Install: ● hydraulic unit assembly notice eca4b56016 do not remove the rubber plugs or bolts (m10 ×××× 1.0) installed in the flare nut holes be- fore installing the hydraulic unit assembly. Tip do not allow any fo...

  • Page 225: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-53 6. Fill: ● brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 ● use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. ...

  • Page 226: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-54 5. Connect the test coupler adapter “1” to the abs test coupler “2”. 6. Turn the main switch to “on” while operating the brake lever and then brake pedal simulta- neously. Tip do not push the start switch when turning the main switch to “on”, otherwise the operation...

  • Page 227: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 refer to “general chassis” on page 4-1. 4. Check: ● battery voltage lower than 12.8 v → charge or replace the battery. Tip ● if the battery voltage is lower than 12.8 v, charge the battery, and then perform hydraulic unit operation test 2. ● if the battery voltage i...

  • Page 228: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-56 11.After the pulsating action has stopped in the front brake pedal, it is generated in the rear brake pedal “1” 0.5 second later and contin- ues for approximately 2 seconds. Tip ● the reaction-force pulsating action consists of quick pulses. ● be sure to continue op...

  • Page 229: Handlebar

    Handlebar 4-57 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 grip end 2 2 handlebar grip 1 3 clutch switch connector 2 disconnect. 4 left handlebar switch 1 5 clutch cable 1 6 clutch switch 1 7 clutch lever 1 8 right handlebar switch 1 9 throttle grip 1 10 thrott...

  • Page 230: Handlebar

    Handlebar 4-58 eas22860 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” tip blow compressed air between the left handlebar and the handlebar grip, and gradual...

  • Page 231: Handlebar

    Handlebar 4-59 notice eca14250 ● first, tighten the bolts on the front side of the handlebar holder, and then on the rear side. ● turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. Tip ● the upper handlebar holders should ...

  • Page 232: Handlebar

    Handlebar 4-60 7. Install: ● clutch lever holder “1” ● clutch cable tip align the slit on the clutch lever holder with the punch mark “a” on the handlebar. 8. Install: ● left handlebar switch tip align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 9. Install: ● ...

  • Page 233: Front Fork

    Front fork 4-61 eas22950 front fork *xj6sa removing the front fork legs order job/parts to remove q’ty remarks front wheel refer to “front wheel” on page 4-5. Front brake calipers refer to “front brake” on page 4-23. 1 brake hose holder 2 2 front fender 1 3 cap bolt 1 loosen. 4 upper bracket pinch b...

  • Page 234: Front Fork

    Front fork 4-62 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt/o-ring 1/1 2 spacer 1 3 spring seat 1 4 front fork spring 1 5 dust seal 1 6 oil seal clip 1 7 damper rod assembly bolt/copper washer 1/1 8 damper rod assembly 1 9 oil seal 1 10 washer 1 11 inner tube ...

  • Page 235: Front Fork

    Front fork 4-63 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. Tip place the vehicle on a suitable stand so tha...

  • Page 236: Front Fork

    Front fork 4-64 vise with soft jaws. C. Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful- ly. Notice eca14190 ● excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. ● avoid bottoming the inner tube into th...

  • Page 237: Front Fork

    Front fork 4-65 eas23020 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13660 ● make sure the oil levels in both front fork legs are equal. ● uneven oil levels can result in poor han- dling and a loss of stability. Tip ● when assembling the ...

  • Page 238: Front Fork

    Front fork 4-66 tip ● before installing the oil seal, lubricate its lips with lithium soap base grease. ● lubricate the outer surface of the inner tube with fork oil. ● before installing the oil seal, cover the top of the front fork leg with a plastic bag “2” to protect the oil seal during installat...

  • Page 239: Front Fork

    Front fork 4-67 10.Install: ● spring “1” ● spring seat “2” ● spacer “3” ● cap bolt tip ● install the spring with the smaller pitch “a” fac- ing up. ● before installing the cap bolt, lubricate its o-ring with grease. ● temporarily tighten the cap bolt. Eas23050 installing the front fork legs the foll...

  • Page 240: Steering Head

    Steering head 4-68 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front wheel refer to “front wheel” on page 4-5. Front fender refer to “front fork” on page 4-61. Front fork refer to “front fork” on page 4-61. Handlebar refer to “handlebar” on page 4-57. Fue...

  • Page 241: Steering Head

    Steering head 4-69 removing the lower bracket order job/parts to remove q’ty remarks 14 dust seal 1 15 bearing outer race 2 for installation, reverse the removal proce- dure. 110 nm (11.0 m • kgf, 79 ft • ibf) 14 15 15 t r . . 1st 52 nm (5.2 m • kg, 37 ft • lb) 2nd 18 nm (1.8 m • kg, 13 ft • lb) ❄❉❂...

  • Page 242: Steering Head

    Steering head 4-70 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: ● steering stem nut ● washer ● lock washer ● upper ring nut “1” ● rubber washer ● lower ring nut “2”...

  • Page 243: Steering Head

    Steering head 4-71 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: ● upper bracket ● lower bracket (along with the steering stem) bends/cracks/damage → replace. Eas23140 installing the steering head 1. Lubricate: ● upper bearing ● lower bearing ● bearing races 2. Install: ● lower bracket ● lower ring nut...

  • Page 244: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-72 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rear side cover refer to “general chassis” on page 4-1. 1 self-locking nut/washer/bolt 1/1/1 2 self-locking nut/washer/bolt 1/1/1 3 plate 1 4 rear ...

  • Page 245: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-73 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 246: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-74 gas leaks/oil leaks → replace the rear shock absorber assembly. ● spring damage/wear → replace the rear shock ab- sorber assembly. ● bushings damage/wear → replace. ● oil seals damage/wear → replace. ● bolts bends/damage/wear → replace. Eas23300 installing the rear ...

  • Page 247: Swingarm

    Swingarm 4-75 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-37. Rear wheel refer to “rear wheel” on page 4-14. Rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-72. Drive sprocket refer t...

  • Page 248: Swingarm

    Swingarm 4-76 eas23340 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. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: ● rear shock absorber refer to “...

  • Page 249: Swingarm

    Swingarm 4-77 eas23380 installing the swingarm 1. Lubricate: ● bearings ● spacers ● oil seals ● dust covers ● pivot shaft 2. Install: ● bearing “1” ● spacer ● oil seal ● dust cover 3. Install: ● swingarm ● pivot shaft “1” ● pivot shaft nut “2” 4. Install: ● rear shock absorber assembly refer to “ins...

  • Page 250: Chain Drive

    Chain drive 4-78 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to “engine removal” on page 5-1. Shift rod refer to “engine removal” on page 5-1. Swingarm refer to “removing the swingarm” on page 4-76. 1 chain cover 1 2 drive chain 1 for ins...

  • Page 251: Chain Drive

    Chain drive 4-79 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. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: ● swingarm refer to “remov...

  • Page 252: Chain Drive

    Chain drive 4-80 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 sure the battery...

  • Page 253: Engine

    1 2 3 4 5 6 7 8 9 engine engine removal ...................................................................................... 5-1 installing the engine..................................................................... 5-6 installing the drive chain ..................................................

  • Page 254

    Checking the oil nozzles ............................................................. 5-44 checking the oil pump drive chain ........................................... 5-44 assembling the oil pump ............................................................... 5-44 installing the oil pump ...........

  • Page 255: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen push lever assembly refer to “clutch” on page 5-47. 1 locknut 2 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive sprocket nut 1 6 washer 1 7 drive sprocket 1 f...

  • Page 256: Engine Removal

    Engine removal 5-2 removing the exhaust pipe order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Bottom cowling refer to “general chassis” on page 4-1. Radiator lower mount bolt refer to “radiator” on page 6-1. 1 o 2 sensor ...

  • Page 257: Engine Removal

    Engine removal 5-3 disconnecting the leads and hoses order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Side cowling refer to “general chassis” on page 4-1. Rear side cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter...

  • Page 258: Engine Removal

    Engine removal 5-4 *xj6s disconnecting the leads and hoses order job/parts to remove q’ty remarks 8 speed sensor coupler (xj6s) 1 disconnect. For assembly, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 5 nm (0.5 m • kgf, 3.6 ft • ibf) 8* ❄❉❂❋❇ ✧.

  • Page 259: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks left footrest bracket assembly 1 right front engine mounting bolt 2 2 left front engine mounting bolt 2 3 self-locking nut 2 4 rear engine mounting bolt 2 5 engine 1 for installation, reverse the removal proce- dure. 1 2 3...

  • Page 260: Engine Removal

    Engine removal 5-6 eas23720 installing the engine 1. Install: ● rear engine mounting bolts “1” tip lubricate the rear engine mounting bolt threads with engine oil. 2. Install: ● right front engine mounting bolt “2” ● left front engine mounting bolts “3” tip do not fully tighten the bolts. 3. Tighten...

  • Page 261: Engine Removal

    Engine removal 5-7 7. Install: ● shift arm bolt “8” tip before installing, make sure to align the mark “a” of the shift shaft with the punch mark “b” of the shift arm. Eas20s15001 installing the drive chain 1. Lubricate: ● drive chain 2. Install: ● drive sprocket ● washer ● drive sprocket nut “1” ti...

  • Page 262: Camshafts

    Camshafts 5-8 eas23760 camshafts *yamaha bond no.1215 (three bond no.1215®) removing the cylinder head cover order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter...

  • Page 263: Camshafts

    Camshafts 5-9 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “pickup rotor” on page 5-33. 1 camshaft sprocket bolt 4 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 pin 2 5 timing chain guide (exhaust side)/timing chain guide (intake side) 1/...

  • Page 264: Camshafts

    Camshafts 5-10 eas23810 removing the camshafts 1. Remove: ● pickup rotor cover refer to “pickup rotor” on page 5-33. 2. Align: ● “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on ...

  • Page 265: Camshafts

    Camshafts 5-11 7. Remove: ● camshaft sprockets eas23850 checking the camshafts 1. Check: ● camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: ● camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: ● camshaft runout out o...

  • Page 266: Camshafts

    Camshafts 5-12 d. Remove the camshaft caps and then mea- sure the width of the plastigauge® “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. ...

  • Page 267: Camshafts

    Camshafts 5-13 ● timing chain tensioner outer spring “5” ● timing chain tensioner housing “6” tip squeeze the timing chain tensioner clip “4”, and then remove the timing chain tensioner springs and timing chain tensioner rod. 2. Check: ● timing chain tensioner housing ● timing chain tensioner rod ● ...

  • Page 268: Camshafts

    Camshafts 5-14 “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: ● exhaust camshaft “1” ● intake camshaft “2” (with the camshaft sprockets temporarily tightened) tip make sure the match mark “a” on the camshaft sprockets is aligned with the cylinder head edge “b...

  • Page 269: Camshafts

    Camshafts 5-15 warning ewa5d01008 always use a new gasket. Notice eca5d01011 ● be sure to install the timing chain tensioner gasket so that its section with the “l” mark “a” is protruding from the lower left side of the timing chain tensioner. ● the arrow mark “b” on the timing chain tensioner shoul...

  • Page 270: Cylinder Head

    Cylinder head 5-16 eas24100 cylinder head *refer to “engine tightening torques” on page 2-15. Removing the cylinder head order job/parts to remove q’ty remarks thermostat refer to “thermostat” on page 6-6. Intake camshaft refer to “camshafts” on page 5-8. Exhaust camshaft refer to “camshafts” on pag...

  • Page 271: Cylinder Head

    Cylinder head 5-17 eas24120 removing the cylinder head 1. Remove: ● cylinder head bolts tip ● loosen the bolts in the proper sequence as shown. ● loosen each bolts 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: ● com...

  • Page 272: Cylinder Head

    Cylinder head 5-18 2. Install: ● cylinder head tip pass the timing chain through the timing chain cavity. 3. Tighten: ● cylinder head bolts “1” – “10” refer to “engine tightening torques” on page 2-15 *loosen the bolt and retighten to specifica- tion torque. ● cylinder head bolts “11” “12” tip ● lub...

  • Page 273: Cylinder Head

    Cylinder head 5-19 7. 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 ewa4s81003 to prev...

  • Page 274: Valves and Valve Springs

    Valves and valve springs 5-20 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 5-16. 1 intake valve lifter/exhaust valve lifter 8/8 2 intake valve pad/exhaust valve pad 8/8 3 intake valve cot...

  • Page 275: Valves and Valve Springs

    Valves and valve springs 5-21 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: ● valve lif...

  • Page 276: Valves and Valve Springs

    Valves and valve springs 5-22 guide. 2. Replace: ● valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 ° c (212 ° f) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”. B. In...

  • Page 277: Valves and Valve Springs

    Valves and valve springs 5-23 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: ● carbon deposits (from the valve face and valve seat) 4. Check: ● valve face pitting/wear → grind the valve face. ● valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. M...

  • Page 278: Valves and Valve Springs

    Valves and valve springs 5-24 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. Tip where the valve seat and valve face contacted one another, the blueing will have been re- m...

  • Page 279: Valves and Valve Springs

    Valves and valve springs 5-25 sion. J. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure:...

  • Page 280: Valves and Valve Springs

    Valves and valve springs 5-26 eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: ● valve lifter damage/scratches → replace the valve lift- ers and cylinder head. Eas24340 installing the valves the following procedure applies to all of the valve...

  • Page 281: Valves and Valve Springs

    Valves and valve springs 5-27 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Notice eca13800 hitting the valve tip with excessive force could damage the valve. 6. Lubricate: ● valve pad “1” ● valve lifter “2” (with the recommended lubricant) ti...

  • Page 282: Generator and Starter Clutch

    Generator and starter clutch 5-28 eas4s81014 generator and starter clutch removing the generator and starter clutch order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1 . Fuel tank refer to “fuel tank” on page 7-1 . Left side panel refer to “general chassis” on page 4-1...

  • Page 283: Generator and Starter Clutch

    Generator and starter clutch 5-29 removing the generator and starter clutch order job/parts to remove q ’ ty remarks 12 idler gear 1 for installation, reverse the removal proce- dure. Lt lt lt 10 nm (1.0 m • kgf, 7.2 ft • ibf) 12 lt e e e 32 nm (3.2 m • kgf, 23 ft • ibf) 75 nm (7.5 m • kgf, 54 ft • ...

  • Page 284: Generator and Starter Clutch

    Generator and starter clutch 5-30 eas24490 removing the generator 1. Remove: ● seat refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. 2. Drain: ● engine oil refer to “changing the engine oil” on page 3-24. 3. Remove: ● generator rotor cover tip loosen each bolt 1/...

  • Page 285: Generator and Starter Clutch

    Generator and starter clutch 5-31 2. Check: ● starter clutch idler gear “1” ● starter clutch drive gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: ● starter clutch gear’s contacting surfaces “a” damage/pitting/wear → replace the starter clutch gear. 4. Check: ● starter...

  • Page 286: Generator and Starter Clutch

    Generator and starter clutch 5-32 2. Tighten: ● generator rotor bolt “1” tip ● while holding the generator rotor “2” with the sheave holder “3”, tighten the generator rotor bolt. ● do not allow the sheave holder to touch the projection on the generator rotor. 3. Apply: ● sealant (onto the stator coi...

  • Page 287: Pickup Rotor

    Pickup rotor 5-33 eas4s81015 pickup rotor removing the pickup rotor order job/parts to remove q ’ ty remarks seat refer to “general chassis” on page 4-1 . Right side panel refer to “general chassis” on page 4-1 . Fuel tank refer to “fuel tank” on page 7-1 . Engine oil drain refer to “changing the en...

  • Page 288: Pickup Rotor

    Pickup rotor 5-34 eas4s81041 removing the pickup rotor 1. Remove: ● pickup rotor cover “1” ● pickup rotor cover gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: ● pickup rotor bolt “1” ● w...

  • Page 289: Pickup Rotor

    Pickup rotor 5-35 4. Install: ● pickup rotor cover gasket ● pickup rotor cover tip ● when installing the pickup rotor cover, align the timing chain guide pins “1” with the holes “2” in the pickup rotor cover. ● tighten the pickup rotor cover bolts in stages and in a crisscross pattern. Pickup rotor ...

  • Page 290: Electric Starter

    Electric starter 5-36 eas24780 electric starter *xj6s removing the starter motor order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Throttle body refer to “throttle bo...

  • Page 291: Electric Starter

    Electric starter 5-37 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 rear cover 1 8 washer set 1 9 brush holder 1 10 armature assembly 1 11 starter motor yoke 1 12...

  • Page 292: Electric Starter

    Electric starter 5-38 eas24790 checking the starter motor 1. Check: ● commutator dirt → clean with 600 grit sandpaper. 2. Measure: ● commutator diameter “a” out of specification → replace the starter motor. 3. Measure: ● mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 293: Electric Starter

    Electric starter 5-39 7. Check: ● gear teeth damage/wear → replace the gear. 8. Check: ● bearing ● oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: ● brush holder “1” 2. Install: ● armature “2” ● o-ring “3” tip align the tab “a” on the brush sea...

  • Page 294: Oil Pump

    Oil pump 5-40 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Clutch assembly refer to “clutch” on page 5-47. Engine oil drain. Refer to “changing the engine oil” on pa...

  • Page 295: Oil Pump

    Oil pump 5-41 removing the oil pan and oil pump order job/parts to remove q’ty remarks 10 oil strainer gasket 1 11 oil pump assembly 1 12 dowel pin 2 13 oil pump drive chain 1 14 chain guide 1 for installation, reverse the removal proce- dure. E 10 nm (1.0 m • kgf, 7.2 ft • ibf) 10 11 13 14 lt lt lt...

  • Page 296: Oil Pump

    Oil pump 5-42 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump 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 rotor housing 1 8 oil pump driven sprocket 1 for assembly, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7...

  • Page 297: Oil Pump

    Oil pump 5-43 eas24930 removing the oil pan 1. Remove: ● oil level switch lead holder ● oil level switch “1” ● oil pan “2” ● oil pan gasket tip 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 checking...

  • Page 298: Oil Pump

    Oil pump 5-44 eas24980 checking the oil delivery pipes 1. Check: ● oil delivery pipe “1” ● oil pipe “2” damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: ● oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas256...

  • Page 299: Oil Pump

    Oil pump 5-45 tip when installing the inner rotor, align the pin “4” in the oil pump shaft with the groove in the inner rotor “5”. 3. Check: ● oil pump operation refer to “checking the oil pump” on page 5-43. Eas25030 installing the oil pump 1. Install: ● oil pump drive chain ● oil pump ● oil pump b...

  • Page 300: Oil Pump

    Oil pump 5-46 1 2 ❄❉❂❋❇ ✧✩.

  • Page 301: Clutch

    Clutch 5-47 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side panel refer to “general chassis” on page 4-1. Engine oil drain refer to “changing the engine oil” on page 3-24. 1 dipstick 1 2 holder 1 3 clutch cover 1 4 clutch cover gasket 1 5 dowel pin 2 for i...

  • Page 302: Clutch

    Clutch 5-48 removing the push lever shaft order job/parts to remove q’ty remarks drive sprocket cover refer to “engine removal” on page 5-1. 1 push lever case 1 2 oil seal 1 3 dowel pin 2 4 drive chain guide 1 5 oil seal protector 1 6 oil seal 1 7 seat plate 1 8 push lever 1 9 spring 1 10 oil seal 1...

  • Page 303: Clutch

    Clutch 5-49 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 push rod 2 1 4 friction plate 1 1 5 clutch plate 6 6 friction plate 2 6 7 clutch boss nut 1 8 clutch boss 1 9 wire circlip 1 10 clutch plate 2/friction plate 3 1/1 11 spring/spring seat...

  • Page 304: Clutch

    Clutch 5-50 eas25070 removing the clutch 1. Remove: ● right side panel refer to “general chassis” on page 4-1. ● clutch cover “1” ● gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: ● compr...

  • Page 305: Clutch

    Clutch 5-51 7. Remove: ● clutch plate 2 “1” ● friction plate 3 “2” 8. Remove: ● spring “1” ● spring seat plate “2” 9. Remove: ● collar ● bearing ● clutch housing “1” ● ball ● push rod 1 tip ● turn the crankshaft and remove the clutch housing. ● carefully hung the oil pump drive chain “2” on the main...

  • Page 306: Clutch

    Clutch 5-52 eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: ● clutch spring damage → replace the clutch springs as a set. 2. Measure: ● clutch spring free length “a” out of specification → replace the clutch springs as a set. Eas25150 chec...

  • Page 307: Clutch

    Clutch 5-53 eas25190 checking the clutch push rods 1. Check: ● o-ring ● push rod 2 “1” ● ball “2” ● push rod 1 “3” cracks/damage/wear → replace the defec- tive part(s). ● push rod bearing damage/wear → replace. 2. Measure: ● clutch push rod 1 bending limit out of specification → replace the push rod...

  • Page 308: Clutch

    Clutch 5-54 6. Tighten: ● clutch boss nut tip while holding the clutch boss with the universal clutch holder “1”, tighten the clutch boss nut. 7. Lock the threads on the clutch boss nut “1” by staking them with a drift punch “2” at the point aligned with the groove “a” in the axle. 8. Lubricate: ● f...

  • Page 309: Clutch

    Clutch 5-55 tip ● align the punch mark “a” in the pressure plate with the punch mark “b” in the clutch boss. ● tighten the compression spring bolts in stages and in a crisscross pattern. 11.Install: ● push lever assembly (left side of the engine) 12.Check: ● push lever position push lever mark “a” a...

  • Page 310: Shift Shaft

    Shift shaft 5-56 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-47. Shift arm and shift rod refer to “engine removal” on page 5-1. 1 circlip 1 2 washer 1 3 shift shaft 1 4 stopper lever spring 1 5 was...

  • Page 311: Shift Shaft

    Shift shaft 5-57 eas5d01019 removing the shift shaft 1. Remove: ● clutch assembly refer to “clutch” on page 5-47. 2. Remove: ● shift arm ● shift rod refer to “engine removal” on page 5-1. 3. Remove: ● circlip “1” ● washer “2” (left side of the engine) 4. Remove ● shift shaft assembly “1” tip unhook ...

  • Page 312: Shift Shaft

    Shift shaft 5-58 ● stopper lever “2” ● washer “3” ● circlip “4” ● stopper lever spring “5” 2. Install: ● shift shaft assembly “1” tip ● mesh the stopper lever with the shift drum seg- ment assembly. ● lubricate the oil seal lips with lithium soap base grease. ● install the end of the shift shaft spr...

  • Page 313: Crankcase

    Crankcase 5-59 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 5-16. Starter motor refer to “electric starter” on page 5-36. Generator refer to “generator and starter clutc...

  • Page 314: Crankcase

    Crankcase 5-60 *refer to “engine tightening torques” on page 2-15 separating the crankcase order job/parts to remove q’ty remarks 6 plate 1 for installation, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 6 lt lt e e e e e e 12 nm (1.2 m • kgf, 8.6 ft • ibf) 12 nm (1.2 m • kgf, 8...

  • Page 315: Crankcase

    Crankcase 5-61 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: ● crankcase bolts tip ● loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. ● loosen the bolts in decreasing numerica...

  • Page 316: Crankcase

    Crankcase 5-62 3. Install: ● dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: ● lower crankcase “1” (onto the upper crankcase “2”) notice eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the sh...

  • Page 317: Crankcase

    Crankcase 5-63 8. Tighten: crankcase bolts “11” – “27” tip tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt (m8 ×××× 65 mm) “11, 12” 24 nm (2.4 m·kgf, 17 ft·lbf) crankcase bolt (m6 ×××× 65 mm) “13, 14” 12 nm (1.2 m·kgf, 8.6 ft·lbf) crankcase bolt (m6) “15 – 27” 10 n...

  • Page 318: Crankshaft

    Crankshaft 5-64 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-59. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 piston pin 4 6 piston 4 7 connecting...

  • Page 319: Crankshaft

    Crankshaft 5-65 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-59. Connecting rods and connecting rod caps refer to “crankshaft” on page 5-64. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft journal upper bearing 5 f...

  • Page 320: Crankshaft

    Crankshaft 5-66 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” ● big end bearings tip identify the position of each big end bearing so that it can be reinstalled in its original place....

  • Page 321: Crankshaft

    Crankshaft 5-67 eas24390 checking the cylinder and piston 1. Check: ● piston wall ● cylinder wall vertical scratches → replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: ● piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “c” with...

  • Page 322: Crankshaft

    Crankshaft 5-68 2. Install: ● piston ring (into the cylinder) tip level the piston ring into the cylinder with the piston crown. 3. Measure: ● piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap...

  • Page 323: Crankshaft

    Crankshaft 5-69 4. Calculate: ● piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas4s81037 checking the big end bearings 1. Measure: ● crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼▼▼...

  • Page 324: Crankshaft

    Crankshaft 5-70 d. Assemble the connecting rod halves. Tip ● do not move the connecting rod or crankshaft until the clearance measurement has been completed. ● lubricate the bolt threads and seats with mo- lybdenum disulfide grease. ● make sure that the “y” mark “c” on the connect- ing rod faces tow...

  • Page 325: Crankshaft

    Crankshaft 5-71 eas26190 installing the connecting rod and piston the following procedure applies to all of the con- necting rods and pistons. 1. Install: ● top ring “1” ● 2nd ring “2” ● upper oil ring rail “3” ● oil ring expander “4” ● lower oil ring rail “5” tip be sure to install the piston rings...

  • Page 326: Crankshaft

    Crankshaft 5-72 ● nut seats (with the recommended lubricant) 6. Lubricate: ● crankshaft pins ● big end bearings ● connecting rod big end inner surface (with the recommended lubricant) 7. Install: ● big end bearings ● connecting rod and piston assembly ● connecting rod cap (onto the connecting rod) t...

  • Page 327: Crankshaft

    Crankshaft 5-73 d. After the installation, check that the section shown “a” is flush with each other by touching the surface. Warning ewa13990 ● when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the pro...

  • Page 328: Crankshaft

    Crankshaft 5-74 e. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves. Tip ● 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 me...

  • Page 329: Crankshaft

    Crankshaft 5-75 eas4s81040 installing the crankshaft 1. Install: ● crankshaft journal upper bearings “1” (into the upper crankcase) tip ● align the projections “a” on the crankshaft jour- nal upper bearings with the notches “b” in the upper crankcase. ● be sure to install each crankshaft journal upp...

  • Page 330: Transmission

    Transmission 5-76 eas26240 transmission removing the drive axle order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-59. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 shift fork guide bar retainer 1 5 shift fork guide bar 1 6 shift fork-l 1 7 shift fork-r 1 8 pl...

  • Page 331: Transmission

    Transmission 5-77 removing the main axle and shift drum order job/parts to remove q’ty remarks 1 shift fork guide bar retainer 1 2 shift fork guide bar 1 3 shift drum assembly 1 4 bearing housing 1 5 bearing 1 6 main axle assembly 1 7 bearing 1 8 shift fork-c 1 9 oil pipe 1 10 o-ring 3 12 nm (1.2 m ...

  • Page 332: Transmission

    Transmission 5-78 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 333: Transmission

    Transmission 5-79 disassembling the drive axle assembly order job/parts to remove q’ty remarks 16 circlip 1 17 washer 1 18 2nd wheel gear 1 19 collar 1 20 oil seal 1 21 collar 1 22 bearing 1 23 circlip 1 24 drive axle 1 for installation, reverse the removal proce- dure. 16 17 18 19 23 24 m m e m 22 ...

  • Page 334: Transmission

    Transmission 5-80 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 pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 335: Transmission

    Transmission 5-81 eas26250 removing the transmission 1. Remove: ● drive axle assembly ● main axle assembly “1” (with the torx® wrench) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “2” of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten th...

  • Page 336: Transmission

    Transmission 5-82 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 centering device and dial gauge “1”) out of specification → replace the drive axle. 3...

  • Page 337: Transmission

    Transmission 5-83 2. Install: ● toothed lock washer retainer “1” ● toothed lock washer “2” tip ● with the toothed lock washer retainer “1” in the groove “a” in the axle, align the projection on the retainer with an axle spline, and then install the toothed lock washer “2”. ● be sure to align the pro...

  • Page 338: Transmission

    Transmission 5-84 tip ● install shift fork-l into the groove in the 6th wheel gear and shift fork-r into the groove in the 5th wheel gear on the drive axle. ● make sure that the drive axle bearing circlip “a” is inserted into the grooves in the upper crank- case. ● make sure that the drive axle bear...

  • Page 339: Cooling System

    1 2 3 4 5 6 7 8 9 cooling system radiator .................................................................................................... 6-1 checking the radiator .................................................................. 6-3 installing the radiator .......................................

  • Page 340: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. 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 “general chassis” on page 4-1. Coolant dr...

  • Page 341: Radiator

    Radiator 6-2 *xj6sa removing the radiator order job/parts to remove q’ty remarks 12 rubber cover 1 13 radiator fan 1 14 radiator cover 1 15 coolant reservoir cover/coolant reservoir 1/1 16 coolant reservoir cap 1 for installation, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 4 ...

  • Page 342: Radiator

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

  • Page 343: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q ’ ty remarks coolant reservoir refer to “radiator” on page 6-1 . Radiator assembly refer to “radiator” on page 6-1 . Engine oil drain. Refer to “changing the engine oil” on page 3-24 . 1 oil cooler outlet hose 1 2...

  • Page 344: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: ● oil cooler cracks/damage → replace. 2. Check: ● oil cooler inlet hose ● oil cooler outlet hose cracks/damage/wear → replace. Eas26430 installing the oil cooler 1. Clean: ● mating surfaces of the oil cooler and the crankcase (with a cloth da...

  • Page 345: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Left side panel refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. C...

  • Page 346: Thermostat

    Thermostat 6-7 eas26450 checking the thermostat 1. Check: ● thermostat “1” does not open at 71 – 85 ° c (160 – 185 ° f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. B. Slowly heat the water “2”. C. Place a thermometer “1” in the wate...

  • Page 347: Thermostat

    Thermostat 6-8 below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3. ❄❉❂❋✩❇ ✫.

  • Page 348: 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. Coolant drain. Refer to “changing the coolant” on page 3-27. 1 radiator outlet ...

  • Page 349: Water Pump

    Water pump 6-10 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump cover 1 2 o-ring 1 3 circlip 1 4 impeller shaft 1 5 water pump seal 1 6 oil seal 1 7 bearing 1 8 water pump housing 1 9 o-ring 1 for assembly, reverse the disassembly pro- cedure. 10 nm (1.0 m • kgf, 7.2...

  • Page 350: Water Pump

    Water pump 6-11 eas26510 disassembling the water pump 1. Remove: ● water pump cover ● o-ring ● circlip ● impeller shaft 2. Remove: ● water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 3. Remove: ● oil seal “3” (with a thin, flat-head screwdriver) tip re...

  • Page 351: Water Pump

    Water pump 6-12 coolant onto its out surface. ● install the oil seal with a socket that matches its outside diameter. 2. Install: ● water pump seal “1” notice eca14080 never lubricate the water pump seal surface with oil or grease. Tip ● install the water pump seal with the special tools. ● before i...

  • Page 352: Water Pump

    Water pump 6-13 ● water pump assembly “1” tip ● align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft. ● lubricate the o-ring with a thin coat of lithi- um-soap-based grease. 2. Install: ● o-ring ● radiator outlet “1” ● o-rings ● water pump outlet hose “2” ● copper w...

  • Page 353: Fuel System

    1 2 3 4 5 6 7 8 9 fuel system fuel tank................................................................................................... 7-1 removing the fuel tank ................................................................ 7-2 removing the fuel pump .............................................

  • Page 354: Fuel Tank

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

  • Page 355: 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 sender coupler ● fuel pump coupler ● fuel tank breather hose ● fuel tank drain hose ● fuel hose notice eca4s81003 ● be sure to disconnect the fuel hose by hand....

  • Page 356: Fuel Tank

    Fuel tank 7-3 eas4s81001 installing the fuel tank 1. Install: ● fuel hose notice eca4s81001 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, oth- erwise the fuel hose will not be properly in- stalled. Tip ● install th...

  • Page 357: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Side panel refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on p...

  • Page 358: Throttle Bodies

    Throttle bodies 7-5 eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: ● throttle bodies refer to “throttle bodies” on page 7-4. 2. Check: ● throttle body joints “1” cracks/damage → replace. 3. Install: ● thr...

  • Page 359: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor coupler 1 disconnect. 3 fuel injector coupler 4 disconnect. 4 sub-wire harness 1 5 negative pressure hose 1 6 intake air pressure sensor 1 7...

  • Page 360: Throttle Bodies

    Throttle bodies 7-7 eas26980 checking the fuel injectors warning ewa2s31037 ● check the injectors in a well-ventilated area free of combustible materials. Make sure that there is no smoking or use of electric tools in the vicinity of the injectors. ● be careful when disconnecting the fuel hoses. Any...

  • Page 361: Throttle Bodies

    Throttle bodies 7-8 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the injector. Eas2s31095 checking and cleaning the throttle bodies warning ewa2s31033 if the throttle bodies are subjected to strong shocks or dropped during cleaning, replace them as a set. Tip clean the throttle bodies only if they cannot be syn...

  • Page 362: Throttle Bodies

    Throttle bodies 7-9 the portions of the throttle valve shafts be- tween the throttle bodies. E. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the engine side of the throttle body to the air filter case side. Notice eca2s31069 ● do not use a tool, such...

  • Page 363: Throttle Bodies

    Throttle bodies 7-10 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ faulty → replace the fuel pump. Eas27030 adjusting the throttle position sensor tip before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: ● throttle position sensor refer to “checking the th...

  • Page 364: Air Induction System

    Air induction system 7-11 eas27040 air induction system 1 2 3 4 5 2 3 6 ❄❉❂❋✪❇ ✤✤.

  • Page 365: Air Induction System

    Air induction system 7-12 1. Air filter case 2. Air cut-off valve hose (air filter case—air cut-off valve) 3. Air cut-off valve 4. Air cut-off valve hose (air cut-off valve—reed valve) 5. Air cut-off valve hose (air cut-off valve—reed valve) 6. Reed valve ❄❉❂❋✪❇ ✤✥.

  • Page 366: Air Induction System

    Air induction system 7-13 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. 1 air cut-off valve hose (air cut-off va...

  • Page 367: Air Induction System

    Air induction system 7-14 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 368: Air Induction System

    Air induction system 7-15 ❄❉❂❋✪❇ ✤.

  • Page 369: Electrical System

    1 2 3 4 5 6 7 8 9 electrical system ignition system ....................................................................................... 8-1 circuit diagram ................................................................................ 8-1 troubleshooting ..........................................

  • Page 370

    Abs (anti-lock brake system)........................................................... 8-99 circuit diagram ................................................................................ 8-99 abs components chart ................................................................. 8-101 abs coupler ...

  • Page 371

    ❄❉❂❋✫❇ ✣.

  • Page 372: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram ❄❉❂❋✫❇ ✤.

  • Page 373: Ignition System

    Ignition system 8-2 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 32. Crankshaft position sensor 33. Ecu (engine control unit) 38. Ignition coil #1,4 39. Ignition coil #2,3 40. Spark plug 55. C...

  • Page 374: Ignition System

    Ignition system 8-3 ❄❉❂❋✫❇ ✦.

  • Page 375: Ignition System

    Ignition system 8-4 5. Battery 6. Main fuse 12. Main switch 15. Relay unit 16. Starting circuit cut-off relay 18. Neutral switch 19. Sidestand switch 23. Engine stop switch 33. Crankshaft position sensor 34. Ecu (engine control unit) 39. Ignition coil #1,4 40. Ignition coil #2,3 41. Spark plug 61. C...

  • Page 376: Ignition System

    Ignition system 8-5 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Side cowling 1. Check the fuses. (main and ignition) refer to “checking the fuses” on page 8-153 . Ng →...

  • Page 377: Ignition System

    Ignition system 8-6 ok ↓ 11.Check the clutch switch. Refer to “checking the switches” on page 8-149 . Ng → replace the clutch switch. Ok ↓ 12.Check the starting circuit cut-off relay. Refer to “checking the relays” on page 8-157 . Ng → replace the relay unit. Ok ↓ 13.Check the entire ignition system...

  • Page 378: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram ❄❉❂❋✫❇ ✪.

  • Page 379: Electric Starting System

    Electric starting system 8-8 3. Battery 4. Main fuse 5. Starter relay 6. Starter motor 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 22. Start switch 55. Clutch switch 70. Ignition fuse ❄❉❂❋✫❇ ✫.

  • Page 380: Electric Starting System

    Electric starting system 8-9 ❄❉❂❋✫❇ ✬.

  • Page 381: Electric Starting System

    Electric starting system 8-10 5. Battery 6. Main fuse 7. Starter relay 8. Starter motor 12. Main switch 15. Relay unit 16. Starting circuit cut-off relay 18. Neutral switch 19. Sidestand switch 23. Engine stop switch 24. Start switch 61. Clutch switch 77. Ignition fuse ❄❉❂❋✫❇ ✤✣.

  • Page 382: Electric Starting System

    Electric starting system 8-11 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 neut...

  • Page 383: Electric Starting System

    Electric starting system 8-12 a. When the transmission is in neu- tral 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. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Sidestand sw...

  • Page 384: Electric Starting System

    Electric starting system 8-13 eas27190 troubleshooting the starter motor fails to turn. Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Fuel tank 1. Check the fuses. (main and ignition) refer to “checking the fuses” on page 8-153 . Ng → replace the fuse(s). Ok ...

  • Page 385: Electric Starting System

    Electric starting system 8-14 ok ↓ 11.Check the start switch. Refer to “checking the switches” on page 8-149 . Ng → replace the right handlebar switch. Ok ↓ 12.Check the entire starting system ’ s wiring. Refer to “circuit diagram” on page 8-7 . Ng → properly connect or repair the starting system ’ ...

  • Page 386: Charging System

    Charging system 8-15 eas27200 charging system eas27210 circuit diagram ❄❉❂❋✫❇ ✤!.

  • Page 387: Charging System

    Charging system 8-16 1. Ac magneto 2. Rectifier/regulator 3. Battery 4. Main fuse ❄❉❂❋✫❇ ✤✩.

  • Page 388: Charging System

    Charging system 8-17 ❄❉❂❋✫❇ ✤✪.

  • Page 389: Charging System

    Charging system 8-18 1. Ac magneto 2. Rectifier/regulator 5. Battery 6. Main fuse ❄❉❂❋✫❇ ✤✫.

  • Page 390: Charging System

    Charging system 8-19 eas27230 troubleshooting the battery is not being charged. Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Fuel tank 1. Check the fuse. (main) refer to “checking the fuses” on page 8-153 . Ng → replace the fuse. Ok ↓ 2. Check the battery. R...

  • Page 391: Charging System

    Charging system 8-20 ❄❉❂❋✫❇ ✥✣.

  • Page 392: Lighting System

    Lighting system 8-21 eas27240 lighting system eas27250 circuit diagram ❄❉❂❋✫❇ ✥✤.

  • Page 393: Lighting System

    Lighting system 8-22 3. Battery 4. Main fuse 10. Main switch 33. Ecu (engine control unit) 50. High beam indicator light 52. Meter light 56. Pass switch 57. Dimmer switch 66. License plate light 67. Tail/brake light 68. Headlight 69. Auxiliary light 70. Ignition fuse 72. Headlight fuse 73. Taillight...

  • Page 394: Lighting System

    Lighting system 8-23 ❄❉❂❋✫❇ ✥✦.

  • Page 395: Lighting System

    Lighting system 8-24 5. Battery 6. Main fuse 12. Main switch 34. Ecu (engine control unit) 55. High beam indicator light 58. Meter light 62. Pass switch 63. Dimmer switch 72. License plate light 73. Tail/brake light 74. Headlight 75. Auxiliary light 77. Ignition fuse 79. Headlight fuse 80. Taillight...

  • Page 396: Lighting System

    Lighting system 8-25 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 1. Check the each bulbs and bulb sockets condition. Refer to...

  • Page 397: Lighting System

    Lighting system 8-26 ❄❉❂❋✫❇ ✥✩.

  • Page 398: Signaling System

    Signaling system 8-27 eas27270 signaling system eas27280 circuit diagram ❄❉❂❋✫❇ ✥✪.

  • Page 399: Signaling System

    Signaling system 8-28 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 16. Neutral switch 18. Rear brake light switch 20. Front brake light switch 24. Fuel sender 28. Coolant temperature sensor 30. Speed sensor 33. Ecu (engine control unit) 44. Oil level warning light 45. Neutral indicator lig...

  • Page 400: Signaling System

    Signaling system 8-29 ❄❉❂❋✫❇ ✥✬.

  • Page 401: Signaling System

    Signaling system 8-30 5. Battery 6. Main fuse 12. Main switch 15. Relay unit 18. Neutral switch 20. Rear brake light switch 22. Front brake light switch 26. Fuel sender 30. Coolant temperature sensor 34. Ecu (engine control unit) 44. Rear wheel sensor 45. Abs ecu (electronic control unit) 49. Oil le...

  • Page 402: Signaling System

    Signaling system 8-31 eas27290 troubleshooting ● any of the following fail to light: turn signal light, brake light or an indicator light. ● the horn fails to sound. Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Fuel tank check the signaling system the horn f...

  • Page 403: Signaling System

    Signaling system 8-32 the tail/brake light fails to come on. The turn signal light, turn signal indicator light or both fail to blink. 1. Check the tail/brake light bulb and socket. Refer to “checking the bulbs and bulb sockets” on page 8-152 . Ng → replace the tail/brake light bulb, socket or both....

  • Page 404: Signaling System

    Signaling system 8-33 the neutral indicator light fails to come. The oil level warning light fails to come. The fuel meter fails to come. 1. Check the neutral indicator light bulb and socket. Ng → replace the neutral indicator light bulb, socket or both. Ok ↓ 2. Check the neutral switch. Refer to “c...

  • Page 405: Signaling System

    Signaling system 8-34 the speedometer fails to operate. Tip repair or replace if there is an open or short circuit. ● between rear wheel sensor and abs ecu coupler. (white-white) (black-black) ● between abs ecu coupler and ecu coupler. (white/yellow-white/yellow) ● between ecu coupler and meter asse...

  • Page 406: Cooling System

    Cooling system 8-35 eas27300 cooling system eas27310 circuit diagram ❄❉❂❋✫❇ ✦!.

  • Page 407: Cooling System

    Cooling system 8-36 3. Battery 4. Main fuse 9. Radiator fan fuse 10. Main switch 11. Radiator fan motor relay 12. Radiator fan motor 28. Coolant temperature sensor 33. Ecu (engine control unit) 70. Ignition fuse ❄❉❂❋✫❇ ✦✩.

  • Page 408: Cooling System

    Cooling system 8-37 ❄❉❂❋✫❇ ✦✪.

  • Page 409: Cooling System

    Cooling system 8-38 5. Battery 6. Main fuse 11. Radiator fan fuse 12. Main switch 13. Radiator fan motor relay 14. Radiator fan motor 30. Coolant temperature sensor 34. Ecu (engine control unit) 77. Ignition fuse ❄❉❂❋✫❇ ✦✫.

  • Page 410: Cooling System

    Cooling system 8-39 eas27320 troubleshooting tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Side cowling 3.Fuel tank 1. Check the fuses. (main, ignition and radiator fan) refer to “checking the fuses” on page 8-153 . Ng → replace the fuse(s). Ok ↓ 2. Check the battery. Refer to...

  • Page 411: Cooling System

    Cooling system 8-40 ❄❉❂❋✫❇ ✧✣.

  • Page 412: Fuel Injection System

    Fuel injection system 8-41 eas27330 fuel injection system eas27340 circuit diagram ❄❉❂❋✫❇ ✧✤.

  • Page 413: Fuel Injection System

    Fuel injection system 8-42 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 11. Radiator fan motor relay 13. Relay unit 14. Starting circuit cut-off relay 15. Fuel injection system relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 25. Throttle position sensor ...

  • Page 414: Fuel Injection System

    Fuel injection system 8-43 ❄❉❂❋✫❇ ✧✦.

  • Page 415: Fuel Injection System

    Fuel injection system 8-44 5. Battery 6. Main fuse 9. Fuel injection system fuse 12. Main switch 13. Radiator fan motor relay 15. Relay unit 16. Starting circuit cut-off relay 17. Fuel injection system relay 18. Neutral switch 19. Sidestand switch 23. Engine stop switch 27. Throttle position sensor ...

  • Page 416: Fuel Injection System

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

  • Page 417: Fuel Injection System

    Fuel injection system 8-46 the ecu takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ecu directly operates an actuator. Details on the fail-safe actions are given in the table below. ❄❉❂❋✫❇ ✧✩.

  • Page 418: Fuel Injection System

    Fuel injection system 8-47 eas20s1002 trouble shooting chart * operated when the engine trouble warning light is on. Fault code number displayed fault code number not displayed ok ng ok ok ok ng the engine trouble warning light comes on. Repairs completed malfunction of en- gine defective sensor or ...

  • Page 419: Fuel Injection System

    Fuel injection system 8-48 eas27411 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch t...

  • Page 420: Fuel Injection System

    Fuel injection system 8-49 eas27451 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 421: Fuel Injection System

    Fuel injection system 8-50 5 crankshaft position sen- sor malfunction replace if defective. Refer to “checking the crankshaft position sensor” on page 8-161. Crank the engine, and check the fault code indi- cation. No fault code indicated. ⇒ recovered. Fault code indicated. ⇒ check the next step. 6 ...

  • Page 422: Fuel Injection System

    Fuel injection system 8-51 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 13 symptom open or short circuit of intake air pressure sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitoring co...

  • Page 423: Fuel Injection System

    Fuel injection system 8-52 5 intake air pressure sen- sor malfunction check in the diagnostic mode (code no. D03). When engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa 1000 m above sea level: approx. 90 kpa 200...

  • Page 424: Fuel Injection System

    Fuel injection system 8-53 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 14 symptom the intake air pressure sensor has failed (due to clogging of hole or sensor disconnection). Fail-safe action engine startup: possible ridin...

  • Page 425: Fuel Injection System

    Fuel injection system 8-54 fault code no. 15 symptom open or short circuit of throttle position sensor lead fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. 01 meter display display the throttle opening (betwe...

  • Page 426: Fuel Injection System

    Fuel injection system 8-55 6 supply voltage of throttle position sensor lead check the supply volt- age. (black/blue – yellow) refer to “checking the throttle posi- tion sensor” on page 8-167. Repair/replace the wire harness, or replace the ecu (common to sepa- rate and integration mod- els). Line d...

  • Page 427: Fuel Injection System

    Fuel injection system 8-56 fault code no. 16 symptom open or short circuit of throttle position sensor lead fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. 01 meter display display the throttle opening (betwe...

  • Page 428: Fuel Injection System

    Fuel injection system 8-57 fault code no. 19 symptom open or short circuit of ecu input line (blue/yellow lead) fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 20 meter display sidestand retracted: on indication sidestand extended: off indication checkin...

  • Page 429: Fuel Injection System

    Fuel injection system 8-58 5 sidestand switch mal- function diagnostic mode (code no. D20) sidestand retracted: on indication sidestand extended: off indication indication is incorrect. ⇒ replace the sidestand switch. Refer to “checking the switches” on page 8-149 . Place the main switch to the on p...

  • Page 430: Fuel Injection System

    Fuel injection system 8-59 2 connection of main har- ness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- ing, wear, or locking). Poor connection ⇒ con- nect it securely, or repair/ replace the wire harness. Place the main switch to the on...

  • Page 431: Fuel Injection System

    Fuel injection system 8-60 *check the sensor only when the engine is cold. Fault code no. 22 symptom open or short circuit of intake air temperature sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 05 meter display -30 to 120 °°°° c during cold st...

  • Page 432: Fuel Injection System

    Fuel injection system 8-61 5 intake air temperature sensor malfunction check in the diagnostic mode (code no. D05). During cold starting: a temperature close to the ambient temperature is indicated. Indication is incorrect. ⇒ replace the intake air temperature sensor. Refer to “checking the intake a...

  • Page 433: Fuel Injection System

    Fuel injection system 8-62 fault code no. 24 symptom the o 2 sensor does not operate. Fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspection proc...

  • Page 434: Fuel Injection System

    Fuel injection system 8-63 fault code no. 30 symptom turnover of vehicle fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 08 meter display the lean angle sensor value is indicated. 0 to 5.0 v the vehicle is in a vertical position: 0.4 – 1.4 v the vehicle ...

  • Page 435: Fuel Injection System

    Fuel injection system 8-64 fault code no. 33 symptom ignition coil primary lead malfunction fail-safe action engine startup: possible (depending on the number of failed cylinders) riding: possible (depending on the number of failed cylinders) diagnostic monitoring code no. 30 meter display each igni...

  • Page 436: Fuel Injection System

    Fuel injection system 8-65 5 ignition coil malfunction (check the resistance of primary coil.) replace if defective. Refer to “checking the ignition coil” on page 8-160. Start and idle the engine for approximately 5 sec- onds. Then, check the fault code indication. No fault code indicated. ⇒ recover...

  • Page 437: Fuel Injection System

    Fuel injection system 8-66 fault code no. 34 symptom ignition coil primary lead malfunction fail-safe action engine startup: possible (depending on the number of failed cylinders) riding: possible (depending on the number of failed cylinders) diagnostic monitoring code no. 31 meter display each igni...

  • Page 438: Fuel Injection System

    Fuel injection system 8-67 5 ignition coil malfunction (check the resistance of primary coil.) replace if defective. Refer to “checking the ignition coil” on page 8-160. Start and idle the engine for approximately 5 sec- onds. Then, check the fault code indication. No fault code indicated. ⇒ recover...

  • Page 439: Fuel Injection System

    Fuel injection system 8-68 fault code no. 41 symptom open or short circuit of lean angle sensor lead fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 08 meter display the lean angle sensor value is indicated. 0 to 5.0 v the vehicle is in a vertical positi...

  • Page 440: Fuel Injection System

    Fuel injection system 8-69 fault code no. 42 symptom a. Normal signals are not received from the speed sensor. B. Open or short circuit of neutral switch lead fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 07 (speed sensor) 21 meter display vehicle speed pu...

  • Page 441: Fuel Injection System

    Fuel injection system 8-70 a. Speed sensor system malfunction order item/components and probable cause check or maintenance job sensor inspection procedure 1 connection of speed sensor (meter) coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- in...

  • Page 442: Fuel Injection System

    Fuel injection system 8-71 b. Neutral switch system malfunction order item/components and probable cause check or maintenance job sensor inspection procedure 1 connection of neutral switch coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- ing, w...

  • Page 443: Fuel Injection System

    Fuel injection system 8-72 fault code no. 43 symptom incorrect voltage supplied to the fuel injector and fuel pump fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 50 meter display the relay turns on or off 5 times per second. The engine warning light flashes...

  • Page 444: Fuel Injection System

    Fuel injection system 8-73 fault code no. 44 symptom an error is detected while reading or writing on eep-rom fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 60 meter display the in self diagnostic code 44 detected eep-rom errors are indicated. If there are ...

  • Page 445: Fuel Injection System

    Fuel injection system 8-74 fault code no. 46 symptom incorrect voltage is supplied to the ecu. Fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspec...

  • Page 446: Fuel Injection System

    Fuel injection system 8-75 fault code no. 50 symptom ecu memory malfunction fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check o...

  • Page 447: Fuel Injection System

    Fuel injection system 8-76 fault code no. Er-1 symptom no signal is received from the ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspec...

  • Page 448: Fuel Injection System

    Fuel injection system 8-77 fault code no. Er-2 symptom no signal is sent from ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspection pro...

  • Page 449: Fuel Injection System

    Fuel injection system 8-78 fault code no. Er-3 symptom correct data cannot be received from the ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sen...

  • Page 450: Fuel Injection System

    Fuel injection system 8-79 fault code no. Er-4 symptom no registration data can be received from the meter unit. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or mainten...

  • Page 451: Fuel Injection System

    Fuel injection system 8-80 eas4s81002 adjusting the exhaust gas volume tip be sure to set the co density level to standard, and then adjust the exhaust gas volume. 1. Turn the main switch to “off” and set the en- gine stop switch to “on”. 2. Simultaneously press and hold the “se- lect” and “reset” b...

  • Page 452: Fuel Injection System

    Fuel injection system 8-81 eas20s18001 other diagnostic monitoring codes this table shows diagnostic monitoring codes which are not linked to the fault code symptoms. Diagnostic code table diagnos tic code no. Item meter display checking method 09 fuel system voltage (battery voltage) approximately ...

  • Page 453: Fuel Injection System

    Fuel injection system 8-82 63 malfunction code reinstate ● no malfunction code 00 — ● malfunction code exists fault code 24 ● (if more than one code number is detected, the display changes every two seconds to show all the detected code num- bers are shown, the dis- play repeats.) to reinstate, set ...

  • Page 454: Fuel Pump System

    Fuel pump system 8-83 eas27550 fuel pump system eas27560 circuit diagram ❄❉❂❋✫❇ ✫✦.

  • Page 455: Fuel Pump System

    Fuel pump system 8-84 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 13. Relay unit 15. Fuel injection system relay 21. Engine stop switch 23. Fuel pump 33. Ecu (engine control unit) 70. Ignition fuse ❄❉❂❋✫❇ ✫✧.

  • Page 456: Fuel Pump System

    Fuel pump system 8-85 ❄❉❂❋✫❇ ✫!.

  • Page 457: Fuel Pump System

    Fuel pump system 8-86 5. Battery 6. Main fuse 9. Fuel injection system fuse 12. Main switch 15. Relay unit 17. Fuel injection system relay 23. Engine stop switch 25. Fuel pump 34. Ecu (engine control unit) 77. Ignition fuse ❄❉❂❋✫❇ ✫✩.

  • Page 458: Fuel Pump System

    Fuel pump system 8-87 eas27570 troubleshooting if the fuel pump fails to operate. Tip ● before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 1. Check the fuses. (main, ignition and fuel injection sys- tem) refer to “checking the fuses” on page 8-153 . Ng → replace the fuse(s). Ok...

  • Page 459: Fuel Pump System

    Fuel pump system 8-88 ❄❉❂❋✫❇ ✫✫.

  • Page 460: Immobilizer System

    Immobilizer system 8-89 eas27640 immobilizer system eas27650 circuit diagram ❄❉❂❋✫❇ ✫✬.

  • Page 461: Immobilizer System

    Immobilizer system 8-90 3. Battery 4. Main fuse 8. Backup fuse (odometer, clock and immobi- lizer system) 10. Main switch 33. Ecu (engine control unit) 43. Immobilizer system indicator light 47. Multi-function meter 70. Ignition fuse 76. Immobilizer unit ❄❉❂❋✫❇ ✬✣.

  • Page 462: Immobilizer System

    Immobilizer system 8-91 ❄❉❂❋✫❇ ✬✤.

  • Page 463: Immobilizer System

    Immobilizer system 8-92 5. Battery 6. Main fuse 10. Backup fuse (odometer, clock and immobi- lizer system) 12. Main switch 34. Ecu (engine control unit) 48. Immobilizer system indicator light 52. Multi-function meter 77. Ignition fuse 83. Immobilizer unit ❄❉❂❋✫❇ ✬✥.

  • Page 464: Immobilizer System

    Immobilizer system 8-93 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 465: Immobilizer System

    Immobilizer system 8-94 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu (engine control unit) is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the mai...

  • Page 466: Immobilizer System

    Immobilizer system 8-95 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 (engine control unit) are replaced. Tip do not start the engine with a...

  • Page 467: Immobilizer System

    Immobilizer system 8-96 standard key code voiding method eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Eas27721 self-diagnosis fault code indication when a system malfunction occurs, the fault code number is indi...

  • Page 468: Immobilizer System

    Immobilizer system 8-97 fault code part symptom cause action 51 immobilizer unit code cannot be transmitted between the key and the immobilizer unit. 1.Radio wave interfer- ence caused by objects around the keys and antennas. 2.Immobilizer unit mal- function. 3.Key malfunction. 1.Keep magnets, metal...

  • Page 469: Immobilizer System

    Immobilizer system 8-98 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 55 immobilizer unit key code registra- tion malfunction. Same standa...

  • Page 470: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-99 eas28790 abs (anti-lock brake system) eas27730 circuit diagram ❄❉❂❋✫❇ ✬✬.

  • Page 471: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-100 3. Abs motor fuse 4. Abs solenoid fuse 5. Battery 6. Main fuse 7. Starter relay 12. Main switch 15. Relay unit 16. Starting circuit cut-off relay 18. Neutral switch 19. Sidestand switch 20. Rear brake light switch 22. Front brake light switch 23. Engine stop switch...

  • Page 472: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-101 eas27740 abs components chart 1 2 4 3 5 6 7 8 ❄❉❂❋✫❇ ✤✣✤.

  • Page 473: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-102 1. Hydraulic unit assembly 2. Abs warning light 3. Rear wheel sensor rotor 4. Rear wheel sensor 5. Front wheel sensor 6. Front wheel sensor rotor 7. Abs test coupler 8. Fuse box ❄❉❂❋✫❇ ✤✣✥.

  • Page 474: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-103 eas27750 abs coupler location chart 3 2 1 5 4 ❄❉❂❋✫❇ ✤✣✦.

  • Page 475: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-104 1. Meter assembly coupler 2. Abs test coupler 3. Rear wheel sensor coupler 4. Front wheel sensor coupler 5. Abs ecu coupler ❄❉❂❋✫❇ ✤✣✧.

  • Page 476: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-105 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: ● terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set. ● terminals “2” of the abs ecu coupler connection...

  • Page 477: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-106 service is finished, check the normal operation of the vehicle, and then delete the fault code(s). (refer to “[d-3] final check” on page 8-144.) by deleting the fault codes stored in the abs ecu memory, it is possible to pursue the cause correctly if another malfun...

  • Page 478: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-107 eas27810 basic process for troubleshooting [a] turn the main switch to , and the check the abs warning light. [b-1] does the abs warning light fail to come on? [b-2] does the abs warning light flash? [b-3] does the abs warning light remain on? [b-4] does the abs wa...

  • Page 479: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-108 warning ewa4b56008 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[d-3] final check” on page 8-144.) eas27830 [a] checking the abs warning l...

  • Page 480: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-109 2.The abs warning light flashes every 0.5 second for more than 6 seconds. The abs warning light flashes every 0.5 second if a fault code for a past malfunction is not stored in the memory of the abs ecu. The abs warning light flashes quicker if a fault code is disp...

  • Page 481: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-110 3. Main fuse ● check the fuse for continuity. Refer to “checking the fuses” on page 8-153. ● if the main fuse is blown, replace the fuse. 4. Circuit ● check the meter assembly circuit. Refer to “circuit diagram” on page 8-99. ● if the meter assembly circuit is open...

  • Page 482: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-111 defective. Replace the meter assembly. Eas4b56022 [c-5] diagnosis using the fault codes connect the test coupler adapter to the abs test coupler, and then turn the main switch to “on”. Information for the fault codes from the abs ecu is contained in the following t...

  • Page 483: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-112 abs_21 hydraulic unit solenoid circuit is open or short-circuited. ● hydraulic unit assembly abs_22 start switch signal is not received prop- erly (start switch circuit or start switch monitor circuit). ● wire harness ● connection of the starting circuit cut-off re...

  • Page 484: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-113 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the center stand). Tip fault codes n...

  • Page 485: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-114 tip with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). Fault code no. Abs_11 abs_25 symptom front wheel sensor signal is not received properly. Order ...

  • Page 486: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-115 fault code no. Abs_12 symptom rear wheel sensor signal is not received properly. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace the wh...

  • Page 487: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-116 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_13 abs_26 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of ...

  • Page 488: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-117 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_14 abs_27 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of w...

  • Page 489: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-118 2 wire harness continuity. ● check for continuity between the white terminal “1” and the white terminal “3” and between the black terminal “2” and the black terminal “4”. ● if there is no continuity, the wire harness is defective. Properly repair or replace the wir...

  • Page 490: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-119 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and front wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_15 could not be deleted, the front wheel sensor is defec...

  • Page 491: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-120 2 wire harness continuity. ● check for continuity between the white terminal “1” and the white terminal “3” and between the black terminal “2” and the black terminal “4”. ● if there is no continuity, the wire harness is defective. Properly repair or replace the wir...

  • Page 492: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-121 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and rear wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_16 could not be deleted, the rear wheel sensor is defecti...

  • Page 493: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-122 fault code no. Abs_18 abs_46 symptom missing pulses detected in the rear wheel sensor signal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel bearings, axle, sensor housing, and sens...

  • Page 494: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-123 fault code no. Abs_21 symptom hydraulic unit solenoid circuit is open or short-circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 open or short circuit in solenoid cir- cuit. Replace the hydraulic unit a...

  • Page 495: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-124 fault code no. Abs_22 symptom start switch signal is not received properly (start switch circuit or start switch monitor circuit). Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 engine startability. Check the e...

  • Page 496: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 fault code no. Abs_24 symptom brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order item/components and probable cause check or maintenance job reinstatement confirmation met...

  • Page 497: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 fault code no. Abs_31 symptom solenoid relay is defective. Power is not supplied to the solenoid relay. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “...

  • Page 498: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 fault code no. Abs_32 symptom hydraulic unit solenoid relay is short-circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in solenoid relay. Replace the hydraulic unit assembly. ● turn the ma...

  • Page 499: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128 fault code no. Abs_33 symptom abs motor is defective. Power is not supplied to the abs motor. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking a...

  • Page 500: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 fault code no. Abs_34 symptom hydraulic unit abs motor relay is short-circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in abs motor relay. Replace the hydraulic unit assembly. ● turn the ...

  • Page 501: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 fault code no. Abs_41 symptom front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hydraulic pressure (when the battery voltage is normal) order item/components and probable cause ...

  • Page 502: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 warning ewa4b56001 the front brakes will not function properly if the connections are reversed. ● brake pipe/joint assembly “1” and front brake hose “2” inlet: from the front brake master cyl- inder ● brake pipe/joint assembly “3” and front brake hose outlet: to th...

  • Page 503: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 tip ● if the brake pipe inlet and outlet connections are incorrect on the hydraulic unit, the front brake lever will be pulled to its full-stroke position without responding, and then it will be pushed back slowly with- out pulsating when the final check on page “[...

  • Page 504: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 fault code no. Abs_42 abs_47 symptom rear wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hydraulic pressure. Order item/components and probable cause check or maintenance job reins...

  • Page 505: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 warning ewa4b56002 the rear brake will not function properly if the connections are reversed. ● brake pipe/joint assembly “1” and rear brake hose “2” inlet: from the rear brake master cylin- der ● brake pipe/joint assembly “3” and rear brake hose “4” outlet: to the...

  • Page 506: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 fault code no. Abs_43 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace...

  • Page 507: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 fault code no. Abs_44 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace ...

  • Page 508: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 fault code no. Abs_53 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 8-154...

  • Page 509: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138 fault code no. Abs_54 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 3-31 ...

  • Page 510: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 fault code no. Abs_56 symptom hydraulic unit sensor power monitor circuit is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 defective internal monitor circuit (sen- sor power). Replace the hydraulic u...

  • Page 511: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 fault code no. Abs_63 symptom front wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. ● check that there is no short circuit between the white ter- mi...

  • Page 512: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 fault code no. Abs_64 symptom rear wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. ● check that there is no short circuit between the black ter- min...

  • Page 513: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 eas4b56023 [d-1] deleting the fault codes notice eca4b56026 since the fault codes remain in the memory of the abs ecu until they are deleted, al- ways delete the fault codes after the service has been completed. 1. Connect the test coupler adapter “1” to the abs te...

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

    Abs (anti-lock brake system) 8-143 b. Measure the abs ecu voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: ● abs-ecu-to-start-switch-lead continuity no continuity → replace or repair the wire harness. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the abs ecu coupler an...

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

    Abs (anti-lock brake system) 8-144 8. If the above-mentioned checks are within spec- ification, replace the hydraulic unit assembly. Eas4b56024 [d-3] final check checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir. Refer to “checking the brake fluid level” on pa...

  • Page 516: Electrical Components

    Electrical components 8-145 eas27970 electrical components 2 1 3 4 5 6 10 8 9 11 7 12 13 14 15 ❄❉❂❋✫❇ ✤✧!.

  • Page 517: Electrical Components

    Electrical components 8-146 1. Front brake light switch 2. Clutch switch 3. Air induction system solenoid 4. Battery 5. Starter relay 6. Fuse box 7. Neutral switch 8. Rear brake light switch 9. Sidestand switch 10. Speed sensor (xj6s) 11. Oil level switch 12. Radiator fan motor 13. Horn 14. Ignition...

  • Page 518: Electrical Components

    Electrical components 8-147 2 1 3 4 5 6 10 8 9 11 7 12 13 14 15 16 17 ❄❉❂❋✫❇ ✤✧✪.

  • Page 519: Electrical Components

    Electrical components 8-148 1. Fuel injector 2. Intake air temperature sensor 3. Fuel pump 4. Intake air pressure sensor 5. Lean angle sensor 6. Relay unit 7. Turn signal relay 8. Radiator fan motor relay 9. Headlight relay 10. Rear wheel sensor (xj6sa) 11. Ecu (engine control unit) 12. O 2 sensor 1...

  • Page 520: Electrical Components

    Electrical components 8-149 eas27980 checking the switches 9 10 11 14 13 16 12 5 1 2 3 4 6 7 8 15 ❄❉❂❋✫❇ ✤✧✬.

  • Page 521: Electrical Components

    Electrical components 8-150 1. Main switch 2. Horn switch 3. Turn signal switch 4. Hazard switch 5. Dimmer switch 6. Pass switch 7. Clutch switch 8. Sidestand switch 9. Start switch 10. Engine stop switch 11. Front brake light switch 12. Oil level switch 13. Neutral switch 14. Rear brake light switc...

  • Page 522: Electrical Components

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

  • Page 523: Electrical Components

    Electrical components 8-152 eas27990 checking the bulbs and bulb sockets tip 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 continu- ity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or...

  • Page 524: Electrical Components

    Electrical components 8-153 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: ● bulb socket (for continuity) (with the digital circuit tester) no continuity → replace. Tip check each bulb socket for conti...

  • Page 525: Electrical Components

    Electrical components 8-154 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: ● seat refer to “general chassis” on page 4-1. Eas28030 checking and charging the battery this model is equipped with a vrla (v...

  • Page 526: Electrical Components

    Electrical components 8-155 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: ● battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Notice eca20s1011 ● never remove the vrla battery sealing caps. ● do not use a high-rate battery charger since it forces a high...

  • Page 527: Electrical Components

    Electrical components 8-156 tip set the charging voltage to 16 – 17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be over-charged. C. Make sure that the current is higher than the standard charging current written on the bat- tery. Tip if the current is l...

  • Page 528: Electrical Components

    Electrical components 8-157 eas28040 checking the relays check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect the relay from the wire harness. 2. Connect the digital circuit tester and battery (12 v) to the relay...

  • Page 529: Electrical Components

    Electrical components 8-158 radiator fan motor relay eas4b51020 checking the turn signal/hazard relay 1. Check: ● turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼...

  • Page 530: Electrical Components

    Electrical components 8-159 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28050 checking the relay unit (diode) 1. Check: ● relay unit (diode) out of specification → replace. Tip the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disco...

  • Page 531: Electrical Components

    Electrical components 8-160 unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28930 checking the ignition spark gap 1. Check: ● ignition spark gap out of specification → perform the ignition ...

  • Page 532: Electrical Components

    Electrical components 8-161 c. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● secondary coil resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. Connect the digital circuit tester...

  • Page 533: Electrical Components

    Electrical components 8-162 b. Measure the crankshaft position sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28130 checking the lean angle sensor 1. Remove: ● lean angle sensor 2. Check: ● lean angle sensor output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a....

  • Page 534: Electrical Components

    Electrical components 8-163 eas28150 checking the stator coil 1. Disconnect: ● stator coil coupler (from the wire harness) 2. Check: ● stator coil resistance out of specification → replace the crank- shaft position sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester ( Ω × ...

  • Page 535: Electrical Components

    Electrical components 8-164 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn ter- minals. B. Connect the digital circuit tester ( Ω × 1) to the horn terminals. C. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● horn sound faulty sound → replace. E...

  • Page 536: Electrical Components

    Electrical components 8-165 c. Measure the air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28230 checking the fuel sender 1. Disconnect: ● fuel pump coupler ● fuel sender coupler ● fuel hose (from the fuel pump) refer to “fuel tank” on page 7-1. 2. Remove: ● fuel pump (...

  • Page 537: Electrical Components

    Electrical components 8-166 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. Set the main switch to “on”. C. ...

  • Page 538: Electrical Components

    Electrical components 8-167 tip 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, and then let it cool down to the specified temperature. E. Measure the coolant temperature sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 539: Electrical Components

    Electrical components 8-168 b. Turn the main switch to “on”. C. Measure the intake air pressure sensor out- put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28420 checking the intake air temperature sensor 1. Remove: ● intake air temperature sensor (from the air filter case.) warning ewa14110 ● hand...

  • Page 540: Electrical Components

    Electrical components 8-169 ❄❉❂❋✫❇ ✤✩✬.

  • Page 541: Troubleshooting

    1 2 3 4 5 6 7 8 9 troubleshooting troubleshooting................................................................................... 9-1 general information ..................................................................... 9-1 starting failures ......................................................

  • Page 542: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information tip 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, ad...

  • Page 543: Troubleshooting

    Troubleshooting 9-2 ● 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 ● faulty spark plug cap 3. Ignition coil(s) ● broken or shorted primary or secondary coils ● faulty spark plu...

  • Page 544: Troubleshooting

    Troubleshooting 9-3 ● hose(s) and pipe(s) ● damaged hose ● improperly connected hose ● damaged pipe ● improperly connected pipe fuel system 1. Throttle body(-ies) ● damaged or loose throttle body joint 2. Air filter ● clogged air filter element chassis 1. Brake(s) ● dragging brake electrical system ...

  • Page 545: Troubleshooting

    Troubleshooting 9-4 ● incorrect connection ● improperly grounded circuit ● poor contacts (main or light switch) ● burnt-out headlight bulb headlight bulb burnt out ● wrong headlight bulb ● faulty battery ● faulty rectifier/regulator ● improperly grounded circuit ● faulty main switch ● faulty light s...

  • Page 546: Troubleshooting

    Troubleshooting 9-5 ❄❉❂❋✬❇.

  • Page 547

    Eas28740 wiring diagram xj6s 2009 1.Ac magneto 2.Rectifier/regulator 3.Battery 4.Main fuse 5.Starter relay 6.Starter motor 7.Fuel injection system fuse 8.Backup fuse (odometer, clock and immobilizer system) 9.Radiator fan fuse 10.Main switch 11.Radiator fan motor relay 12.Radiator fan motor 13.Relay...

  • Page 548

    Xj6sa 2009 1.Ac magneto 2.Rectifier/regulator 3.Abs motor fuse 4.Abs solenoid fuse 5.Battery 6.Main fuse 7.Starter relay 8.Starter motor 9.Fuel injection system fuse 10.Backup fuse (odometer, clock and immobilizer sys- tem) 11.Radiator fan fuse 12.Main switch 13.Radiator fan motor relay 14.Radiator ...

  • Page 549

    ❄❆❍✧✤❇ ✣.

  • Page 550

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan ❄❆❍✧✤❇ ✤.

  • Page 551

    Xj6s 2009 wiring diagram xj6s 2009 schaltplan xj6s 2009 schÉma de cblage xj6s 2009 schema elettrico xj6s 2009 diagrama elÉctrico xj6s̲a̲w.D 09.1.20 17:19 ページ 1.

  • Page 552

    Xj6s 2009 wiring diagram xj6s 2009 schaltplan xj6s 2009 schÉma de cblage xj6s 2009 schema elettrico xj6s 2009 diagrama elÉctrico xj6s̲a̲w.D 09.1.20 17:19 ページ 2.

  • Page 553

    Xj6sa 2009 wiring diagram xj6sa 2009 schaltplan xj6sa 2009 schÉma de cblage xj6sa 2009 schema elettrico xj6sa 2009 diagrama elÉctrico xj6s̲a̲w.D 09.1.20 17:19 ページ 3.

  • Page 554

    Xj6sa 2009 wiring diagram xj6sa 2009 schaltplan xj6sa 2009 schÉma de cblage xj6sa 2009 schema elettrico xj6sa 2009 diagrama elÉctrico xj6s̲a̲w.D 09.1.20 17:19 ページ 4.