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Yamaha 2009 VMX17YC Service Manual

Summary of 2009 VMX17YC

  • Page 1

    2009 service manual vmx17y(c) lit-11616-22-64 2s3-28197-10

  • Page 2

    Eas20050 vmx17y(c) service manual ©2008 by yamaha motor corporation, u.S.A. First edition, august 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-22-64.

  • Page 3

    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 4

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

  • Page 5

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...

  • Page 7: Table of Contents

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

  • Page 9: General Information

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

  • Page 10: Identification

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

  • Page 11: Features

    Features 1-2 eas20170 features eas30340 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sys...

  • Page 12: Features

    Features 1-3 eas2s31083 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ecu energizes the...

  • Page 13: Features

    Features 1-4 eas2s31084 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 14: Features

    Features 1-5 useful terms • wheel speed: the rotation speed of the front and rear wheels. • chassis speed: the speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • b...

  • Page 15: Features

    Features 1-6 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed v...

  • Page 16: Features

    Features 1-7 abs operation and vehicle control if the abs starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the abs has been designed to generate a reaction-force pulsating action in the brake l...

  • Page 17: Features

    Features 1-8 electronic abs features the yamaha abs (anti-lock brake system) has been developed with the most advanced electronic technology. The abs control is processed with good response under various vehicle travel conditions. The abs also includes a highly developed self-diagnosis function. The...

  • Page 18: Features

    Features 1-9 abs block diagram eas2s31085 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 housing...

  • Page 19: Features

    Features 1-10 the front and rear sensor rotors each have 92 magnetic poles (46 pairs) and are installed close to the wheel sensors. As the sensor rotor rotates, the hall element in the hall ic installed in the wheel sensor generates pulses. The pulse frequency, which is proportional to the magnetic ...

  • Page 20: Features

    Features 1-11 hydraulic unit assembly the hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an abs motor, and abs ecu. The hydraulic unit adjusts the front and rear wheel brake fluid pre...

  • Page 21: Features

    Features 1-12 • buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. 1 2 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston.

  • Page 22: Features

    Features 1-13 • 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 necessar...

  • Page 23: Features

    Features 1-14 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 24: Features

    Features 1-15 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 25: Features

    Features 1-16 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 26: Features

    Features 1-17 2. Pressurizing phase the outlet solenoid valve is closed by the “pressurization” signal transmitted from the abs ecu. At this time, the abs ecu controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, all...

  • Page 27: Features

    Features 1-18 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 28: Features

    Features 1-19 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 8-79.) tip the abs warning lig...

  • Page 29: Features

    Features 1-20 eas2s31088 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 30: Features

    Features 1-21 abs function warning ewa2s31036 • when hydraulic control is performed by the abs, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the abs is activated, the grip between the...

  • Page 31: Features

    Features 1-22 eas2s31089 ycc-t (yamaha chip controlled throttle)/ycc-i (yamaha chip controlled intake) mechanism characteristics yamaha developed the ycc-t and ycc-i system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles,...

  • Page 32: Features

    Features 1-23 aims and advantages of using ycc-i system • improved power band. By using a dual intake funnel system, ycc-i optimizes the effectiveness of the fuel injection system to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake vol- ume control give...

  • Page 33: Features

    Features 1-24 ycc-t/ycc-i system outline 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. Ecu (engine control unit) 5. Etv main cpu (32 bit) 6. Etv sub cpu (16 bit) 7. Fi cpu (32 bit) 8. Throttle servo motor driv...

  • Page 34: Features

    Features 1-25 ycc-t/ycc-i control outline 1. Accelerator position sensor 2. Throttle position sensor 3. Crankshaft position sensor 4. Speed sensor 5. Coolant temperature sensor 6. Neutral switch 7. Atmospheric pressure sensor 8. Accelerator position (two signals) 9. Throttle position (two signals) 1...

  • Page 35: Features

    Features 1-26 eas2s31097 instrument functions warning ewa2s31030 be sure to stop the vehicle before making any setting changes to the multi-function display. Changing settings while riding can distract the operator and increase the risk of an accident. A “select” button and a “reset” button are loca...

  • Page 36: Features

    Features 1-27 tip • the transmission must be in neutral to change settings in this mode. • shifting the transmission into gear saves all settings made, then cancels the select mode and displays the normal mode in all screens. • depending on the screen, pushing “reset” saves settings or cancels the s...

  • Page 37: Features

    Features 1-28 2. Push “reset”. 3. Push “select” to highlight “operation se- lection”. 4. Push “reset”. Push “select” and highlight “on” to activate the indicator light; the indicator light comes on and stays on when activated. Push “select” and highlight “flash” to acti- vate the indicator light; th...

  • Page 38: Features

    Features 1-29 1. Push “select” to highlight “all”. 2. Push “reset”; “on” is displayed. 3. Push “reset” and the r/min digits start flash- ing. 4. Push “select” to highlight the engine speed at which the shift timing indicator light is acti- vated. 5. Push “reset” to set the selected engine speed. “of...

  • Page 39: Features

    Features 1-30 1. Push “select” to highlight “display”. 2. Push “reset”; the following screen is dis- played. 3. Push “reset” and the hour digits start flash- ing. 4. Push “select” to increment the hours. 5. Push “reset”, and the minute digits start flashing. 6. Push “select” to increment the minutes...

  • Page 40: Features

    Features 1-31 2. Push “reset”. 3. Push “select” to highlight “stopwatch”. 4. Push “reset”. The multi-function display changes to the normal mode and the stopwatch is displayed in place of the clock. 5. Push “select” to start the stopwatch. 6. Push “select” or the start switch “ ” to stop the stopwat...

  • Page 41: Features

    Features 1-32 • if, when the engine is running while the system status menu is displayed, the fuel level warning light or coolant temperature warning light comes on, the normal mode is automatically displayed. 1. Push “select” to highlight “system status”, then push “reset”. 2. Push “select” to high...

  • Page 42: Features

    Features 1-33 4. Push “select” to scroll to “ ”. 5. Push “reset” to return to the previous menu. Self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light comes on a...

  • Page 43: Important Information

    Important information 1-34 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 1-37. 3. When disasse...

  • Page 44: Important Information

    Important information 1-35 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer 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 a...

  • Page 45: Checking The Connections

    Checking the connections 1-36 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 46: Special Tools

    Special tools 1-37 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 47: Special Tools

    Special tools 1-38 oil filter wrench 90890-01426 yu-38411 3-11 oil pressure gauge set 90890-03120 3-12 oil pressure adapter b 90890-03124 3-12 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-27, 4-81 damper rod holder (24 mm) 90890-01328 ym-01328 4-23, 4-27, 4-48, 4-50 hexagon w...

  • Page 48: Special Tools

    Special tools 1-39 ring gear fix bolt (m14) 90890-01548 ym-01548 4-97 universal joint holder 90890-04160 ym-04062 4-98, 4-102, 5-109, 5-111 bearing retainer wrench 90890-04159 pinion bearing retainer & remover ym-04159 4-99, 4-102 rotor holding tool 90890-01235 universal magneto & rotor holder yu-01...

  • Page 49: Special Tools

    Special tools 1-40 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-32 valve guide reamer (ø5) 90890-04099 valve guide reamer (5.0 mm) ym-04099 5-32 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-40, 5-41, 5-42 flywheel puller 90890-01362 heavy duty pull...

  • Page 50: Special Tools

    Special tools 1-41 piston pin puller set 90890-01304 piston pin puller yu-01304 5-82 damper spring compressor 90890-04090 5-109, 5-111 middle drive shaft nut wrench (55 mm) 90890-04054 offset wrench 55 mm ym-04054 5-110 middle gear backlash tool 90890-04080 5-113 radiator cap tester 90890-01325 radi...

  • Page 51: Special Tools

    Special tools 1-42 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-4 mechanical seal installer 90890-04132 water pump seal installer ym-33221-a 6-13 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-13 pressure gauge 90890-03153 yu-031...

  • Page 52: Special Tools

    Special tools 1-43.

  • Page 53: Specifications

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

  • Page 54: General Specifications

    General specifications 2-1 eas20280 general specifications model model 2s31 (usa) 2s32 (california) dimensions overall length 2395 mm (94.3 in) overall width 820 mm (32.3 in) overall height 1190 mm (46.9 in) seat height 775 mm (30.5 in) wheelbase 1700 mm (66.9 in) ground clearance 140 mm (5.51 in) m...

  • Page 55: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 1679.0 cm³ cylinder arrangement v-type 4-cylinder bore × stroke 90.0 × 66.0 mm (3.54 × 2.60 in) compression ratio 11.30 :1 minimum–maximum 1250–1650 kpa (12.5–16.5 kgf/cm², 177.8– 23...

  • Page 56: Engine Specifications

    Engine specifications 2-3 coolant reservoir capacity (up to the maximum level mark) 0.27 l (0.29 us qt, 0.24 imp.Qt) radiator cap opening pressure 107.9–137.3 kpa (1.08–1.37 kgf/cm², 15.6–19.9 psi) radiator core width 400.0 mm (15.75 in) height 200.2 mm (7.88 in) depth 24.0 mm (0.94 in) sub radiator...

  • Page 57: Engine Specifications

    Engine specifications 2-4 exhaust b 24.131–24.231 mm (0.9500–0.9540 in) limit 24.031 mm (0.9461 in) camshaft runout limit 0.030 mm (0.0012 in) timing chain tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.10–0.17 mm (0.0039–0.0067 in) exhaust 0.22–0.29 mm (0...

  • Page 58: Engine Specifications

    Engine specifications 2-5 valve margin thickness d (exhaust) 1.00 mm (0.0394 in) valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in) limit 4.945 mm (0.1947 in) valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in) limit 4.930 mm (0.1941 in) valve guide inside diameter (intake) 5...

  • Page 59: Engine Specifications

    Engine specifications 2-6 cylinder bore 90.000–90.010 mm (3.5433–3.5437 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.050 mm (0.0020 in) piston piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) limit 0.10 mm (0.0039 in) diameter d 89.960–89.975 mm (3.5417–3.5423 in) height h...

  • Page 60: Engine Specifications

    Engine specifications 2-7 oil ring dimensions (b × t) 2.00 × 2.80 mm (0.08 × 0.11 in) end gap (installed) 0.20–0.50 mm (0.0079–0.0197 in) connecting rod oil clearance 0.032–0.056 mm (0.0013–0.0022 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green crankshaft width a 83.92–83.97 mm (3.304–3.306 in...

  • Page 61: Engine Specifications

    Engine specifications 2-8 primary reduction ratio 86/57 (1.509) secondary reduction system shaft drive secondary reduction ratio 22/23 × 29/09 (3.082) operation left foot operation gear ratio 1st 38/16 (2.375) 2nd 38/21 (1.810) 3rd 35/25 (1.400) 4th 29/26 (1.115) 5th 29/31 (0.935) main axle runout l...

  • Page 62: Engine Specifications

    Engine specifications 2-9 intake vacuum -26.7 kpa (-200 mmhg, -7.9 inhg) water temperature 95.0–105.0 °c (203.00–221.00 °f) oil temperature 80.0–90.0 °c (176.00–194.00 °f) throttle cable free play 3.0–5.0 mm (0.12–0.20 in) air induction system solenoid resistance 20–23 Ω at 20 °c (68 °f) shaft drive...

  • Page 63: Chassis Specifications

    Chassis specifications 2-10 eas20300 chassis specifications chassis frame type diamond caster angle 31.00° trail 148.0 mm (5.83 in) front wheel wheel type cast wheel rim size 18m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 64: Chassis Specifications

    Chassis specifications 2-11 brake disc thickness limit 5.0 mm (0.20 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.8 mm (0.03 in) brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.8 mm (0.03 in) master cylinder inside diamete...

  • Page 65: Chassis Specifications

    Chassis specifications 2-12 standard 4 maximum 1 rebound damping adjusting positions minimum 17 click(s) out* standard 12 click(s) out* maximum 1 click(s) out* compression damping adjusting positions minimum 20 click(s) out* standard 12 click(s) out* maximum 1 click(s) out* rear suspension type swin...

  • Page 66: Electrical Specifications

    Electrical specifications 2-13 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci (digital) advancer type throttle position sensor and electrical ignition timing (b.T.D.C.) 3.0°/900 r/min engine control unit model/manufacturer tbdf56/denso ignition coi...

  • Page 67: Electrical Specifications

    Electrical specifications 2-14 engine trouble warning light led abs warning light led electric starting system system type constant mesh starter motor power output 0.90 kw armature coil resistance 0.0081–0.0099 Ω brush overall length 11.3 mm (0.44 in) limit 7.60 mm (0.30 in) brush spring force 7.36–...

  • Page 68: Electrical Specifications

    Electrical specifications 2-15 backup fuse 7.5 a electronic throttle valve fuse 7.5 a spare fuse 20.0 a spare fuse 15.0 a × 2 spare fuse 7.5 a spare fuse 30.0 a.

  • Page 69: Tightening Torques

    Tightening torques 2-16 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 70: Tightening Torques

    Tightening torques 2-17 eas20340 engine tightening torques item thread size q’ty tightening torque remarks throttle body joint bolt m6 8 10 nm (1.0 m·kgf, 7.2 ft·lbf) spark plug m10 4 13 nm (1.3 m·kgf, 9.4 ft·lbf) cylinder head bolt m10 16 see tip. Camshaft cap bolt m6 32 10 nm (1.0 m·kgf, 7.2 ft·lb...

  • Page 71: Tightening Torques

    Tightening torques 2-18 thermostat bracket bolt m6 2 10 nm (1.0 m·kgf, 7.2 ft·lbf) oil cooler union bolt m20 1 63 nm (6.3 m·kgf, 45 ft·lbf) engine oil drain bolt m14 1 43 nm (4.3 m·kgf, 31 ft·lbf) oil strainer bolt m6 1 10 nm (1.0 m·kgf, 7.2 ft·lbf) oil pipe 2 and oil strainer bolt m6 1 10 nm (1.0 m...

  • Page 72: Tightening Torques

    Tightening torques 2-19 front exhaust pipe and exhaust chamber bolt m8 2 20 nm (2.0 m·kgf, 14 ft·lbf) rear exhaust pipe protector bolt m6 4 8 nm (0.8 m·kgf, 5.8 ft·lbf) exhaust chamber bracket bolt (front side) m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) exhaust chamber bracket bolt (left and right sides) m6 ...

  • Page 73: Tightening Torques

    Tightening torques 2-20 crankcase cover bolt m6 15 10 nm (1.0 m·kgf, 7.2 ft·lbf) clutch cover bolt m6 5 12 nm (1.2 m·kgf, 8.7 ft·lbf) l=70 mm (2.76 in) clutch cover bolt m6 3 12 nm (1.2 m·kgf, 8.7 ft·lbf) l=25 mm (0.98 in) plate bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) plate bolt m6 1 10 nm (1.0 m·kgf...

  • Page 74: Tightening Torques

    Tightening torques 2-21 tip cylinder head bolt tighten the cylinder head bolts to 30 nm (3.0 m·kgf, 22 ft·lbf), and then tighten them further to reach the specified angle 85–95°. Tip crankcase bolt tighten the crankcase bolts (m10) to 30 nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening sequence. T...

  • Page 75: Tightening Torques

    Tightening torques 2-22 crankcase tightening sequence 30 29 1 2 3 4 5 6 7 8 10 9 11 13 12 14 15 16 17 18 19 21 20 22 23 24 25 26 27 28 a 42 39 41 37 34 33 32 31 35 40 36 38 b a. Lower crankcase b. Upper crankcase.

  • Page 76: Tightening Torques

    Tightening torques 2-23 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine bracket bolt (front side) m12 3 60 nm (6.0 m·kgf, 43 ft·lbf) engine mounting bolt (front side) m12 1 60 nm (6.0 m·kgf, 43 ft·lbf) engine mounting nut (front side) m12 2 60 nm (6.0 m·kgf...

  • Page 77: Tightening Torques

    Tightening torques 2-24 rear shock absorber assembly lower bolt m14 1 45 nm (4.5 m·kgf, 32 ft·lbf) swingarm damper bolt m8 1 16 nm (1.6 m·kgf, 11 ft·lbf) torque stop pin m22 1 115 nm (11.5 m·kgf, 85 ft·lbf) rebound damping adjusting hose guide bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) rebound damping a...

  • Page 78: Tightening Torques

    Tightening torques 2-25 battery box bolt m6 3 10 nm (1.0 m·kgf, 7.2 ft·lbf) brake hose holder and bracket of the upper radiator bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) brake hose flare nut m10 2 21 nm (2.1 m·kgf, 15 ft·lbf) brake hose flare nut (hydraulic unit assembly) m10 4 16 nm (1.6 m·kgf, 11 ft·...

  • Page 79: Tightening Torques

    Tightening torques 2-26 rear brake caliper retaining bolt m10 2 27 nm (2.7 m·kgf, 19 ft·lbf) rear brake caliper bleed screw m7 1 6 nm (0.6 m·kgf, 4.3 ft·lbf) brake pedal pinch bolt m6 1 8 nm (0.8 m·kgf, 5.8 ft·lbf) brake pedal bolt m6 1 8 nm (0.8 m·kgf, 5.8 ft·lbf) rear brake light switch bracket m5...

  • Page 80: Tightening Torques

    Tightening torques 2-27 headlight top cover and headlight side cover bolt m6 2 10 nm (1.0 m·kgf, 7.2 ft·lbf) meter assembly 1 bolt m8 2 10 nm (1.0 m·kgf, 7.2 ft·lbf) meter assembly 1 bracket bolt m6 4 7 nm (0.7 m·kgf, 5.1 ft·lbf) headlight lower bracket and headlight side cover bolt m6 2 10 nm (1.0 ...

  • Page 81: Tightening Torques

    Tightening torques 2-28 tip 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kgf, 37 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. Tip front wheel axle pinch bolt 1. Ins...

  • Page 82

    Lubrication points and lubricant types 2-29 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings camshaft lobes and camshaft journals valve lifters valve stems (intake and exhaust) valve stem ends (intake and exhaust) crankshaft b...

  • Page 83

    Lubrication points and lubricant types 2-30 shift forks and shift fork guide bars shift drum assembly shift shaft washer stopper lever seat ring gear thrust washer shaft drive gear oil (9079e-sh001-00) ring gear splines ring gear bearing shaft drive gear oil (9079e-sh001-00) cylinder head cover mati...

  • Page 84

    Lubrication points and lubricant types 2-31 eas20380 chassis lubrication point lubricant engine bracket bolt thread (front center, front right and front left) engine mounting bolt thread (front and rear) steering bearings and upper bearing cover lip lower bearing dust seal lip steering nut thread (u...

  • Page 85

    Lubrication points and lubricant types 2-32.

  • Page 86

    Lubrication system chart and diagrams 2-33 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 26 13 14 28 29 27 30 12 36 35 36 38 37 26 36 35 38 36 37 34 33 32 31 31 8 15 12 14 13 8 11 9 10 5 7 6 17 18 19 20 24 25 16 4 3 2 21 20 22 23 1 a b c.

  • Page 87

    Lubrication system chart and diagrams 2-34 1. Oil pan 2. Oil strainer 3. Oil pump 4. Relief valve 5. Oil cooler 6. Bypass valve 7. Oil filter cartridge 8. Crankcase oil gallery 9. Balancer 10. Balancer journal 11. Oil nozzle #4 12. Front cylinder head 13. Cylinder head 14. Timing chain tensioner 15....

  • Page 88

    Lubrication system chart and diagrams 2-35 eas20410 lubrication diagrams c 1 10 2 3 4 5 6 7 c a-a c-c d-d b-b b b d d a a 8 9 10 11 12 12.

  • Page 89

    Lubrication system chart and diagrams 2-36 1. Timing chain tensioner (rear cylinders) 2. Exhaust camshaft (rear cylinders) 3. Intake camshaft (rear cylinders) 4. Oil pipe 1 5. Timing chain tensioner (front cylinders) 6. Intake camshaft (front cylinders) 7. Exhaust camshaft (front cylinders) 8. Oil c...

  • Page 90

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

  • Page 91

    Lubrication system chart and diagrams 2-38 1. Balancer shaft 2. Main axle 3. Drive axle 4. Intake camshaft 5. Exhaust camshaft.

  • Page 92

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

  • Page 93

    Lubrication system chart and diagrams 2-40 1. Crankshaft 2. Main gallery bolt 3. Oil pipe 2 4. Oil strainer.

  • Page 94

    Lubrication system chart and diagrams 2-41 a-a 1 a a 7 6 8 5 4 3 2.

  • Page 95

    Lubrication system chart and diagrams 2-42 1. Oil filter cartridge 2. Oil nozzle 3. Oil pump 4. Oil strainer 5. Oil pan 6. Relief valve assembly 7. Oil cooler 8. Oil pipe 1.

  • Page 96: Cooling System Diagrams

    Cooling system diagrams 2-43 eas20420 cooling system diagrams 1 1 2 3 4 6 7 9 8 10 11 7 8 9 9 12 13 5 13 12 10 2 5 2 11 8 d e h 10 12 9 14 13 a b c f g g g-g i-i h k a f b c d e j b c a e d f h i i g i k j.

  • Page 97: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Thermostat inlet pipe (rear cylinder side) 2. Thermostat inlet hose (rear cylinder side) 3. Thermostat housing 4. Radiator cap 5. Thermostat inlet hose 2 (front cylinder side) 6. Coolant reservoir hose 7. Thermostat inlet pipe 2 (front cylinder side) 8. Thermostat inl...

  • Page 98: Cooling System Diagrams

    Cooling system diagrams 2-45 6 1 2 3 4 5 2 3 4 5 7 6 8 9 a b c f e d.

  • Page 99: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Thermostat outlet hose 2. Upper radiator inlet pipe 3. Upper radiator inlet hose 4. Left lower radiator inlet hose 5. Right lower radiator inlet hose 6. Coolant reservoir hose 7. Lower radiator outlet hose 8. Water pump inlet pipe 9. Coolant reservoir breather hose a....

  • Page 100: Cable Routing

    Cable routing 2-47 eas20430 cable routing c f e i-i b-b a-a d-d c-c f-f e-e h-h k-k j g a f c a a d d c b a h j g k k h i i a b c d e h i j k l m q r s t u v 14 1 2 6 5 12 13 6 3 4 9 8 16 15 17 10 20 25 21 22 23 24 b c o p n f g 2 5 18 18 10 9 8 7 6 5 11 19 27 26 w e.

  • Page 101: Cable Routing

    Cable routing 2-48 1. Front brake light switch lead 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Clutch switch lead 4. Left handlebar switch lead 5. Clutch hose 6. Wire harness 7. Coupler cover 8. Front right turn signal/position light lead 9. Front left turn signal/position ligh...

  • Page 102: Cable Routing

    Cable routing 2-49 a b-b a b b a b c d e f f h i 1 2 3 4 4 5 6 7 8 g 6.

  • Page 103: Cable Routing

    Cable routing 2-50 1. Throttle cables 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Clutch hose 4. Meter assembly 1 5. Left handlebar switch lead 6. Meter assembly 1 lead 7. Headlight coupler 8. Auxiliary light coupler a. Route the throttle cables as shown in the illustration. Whe...

  • Page 104: Cable Routing

    Cable routing 2-51 11 12 14 14 13 15 16 17 18 19 20 21 22 23 24 25 a p 1 g 1 h i 1 2 a 3 4 b 5 6 c 7 8 d 9 e f 10 a q j k l m n o.

  • Page 105: Cable Routing

    Cable routing 2-52 1. Meter assembly 2 coupler 2. Ignition coil sub-wire harness 2 coupler 3. Front wheel sensor coupler 4. Cylinder identification sensor coupler 5. Clutch hose 6. Wire harness 7. Accelerator position sensor coupler 8. Starter motor lead 9. Throttle position sensor coupler 10. Radia...

  • Page 106: Cable Routing

    Cable routing 2-53 a b 7 1 2 3 4 5 6 12 11 13 f e d 10 c g 14 9 8.

  • Page 107: Cable Routing

    Cable routing 2-54 1. Radiator fan motor relay 2. Headlight relay 3. Relay unit 4. Fuse box 1 5. Turn signal/hazard relay 6. Rear wheel sensor coupler 7. Wire harness 8. Gas cylinder hose (rear shock absorber assembly) 9. O 2 sensor lead 10. Brake hose (rear brake master cylinder to hydraulic unit) ...

  • Page 108: Cable Routing

    Cable routing 2-55 m d a-a b-b c-c e-e d a a b b c c e e a a a b c d e f h i j k l o n p q r s t u v w 1 2 3 3 4 6 5 5 6 8 9 7 8 9 13 14 15 16 16 17 18 19 19 20 21 22 23 24 g 12 11 10 10

  • Page 109: Cable Routing

    Cable routing 2-56 1. Meter assembly 2 2. Main switch couplers 3. Radiator fan motor sub-wire harness 4. Air induction system solenoid coupler 5. Air induction system hose (air cut-off valve to rear reed valve cover) 6. Brake hose (hydraulic unit to left front brake caliper) 7. Brake hose (hydraulic...

  • Page 110: Cable Routing

    Cable routing 2-57 a a a b d e f h 1 2 2 3 4 3 5 6 7 8 9 c 4 5 g.

  • Page 111: Cable Routing

    Cable routing 2-58 1. Abs test coupler 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel overflow hose 4. Fuel tank breather hose 5. Rollover valve 6. Fuel tank breather hose (rollover valve to canister) (for california only) 7. Canister (for california only) 8. Canister breather hose...

  • Page 112: Cable Routing

    Cable routing 2-59 r 19 20 20 s s 21 22 22 22 u v 23 w 24 g i-i g-g f-f d-d a-a b-b c-c e e h a a b b c c d d f f g i h i a b c d e f h i j k l m n o p q t 1 1 1 2 3 4 5 6 6 6 7 8 8 8 8 9 10 11 11 11 12 13 14 16 15 16 17 18 g.

  • Page 113: Cable Routing

    Cable routing 2-60 1. Meter assembly 1 lead 2. Upper radiator inlet pipe 3. Meter assembly couplers 4. Intake funnel servo motor coupler 5. Throttle servo motor lead 6. Canister purge hose (for california only) 7. Frame ground 8. Ignition coil sub-wire harness 1 9. Stator coil lead 10. Fuel pump lea...

  • Page 114: Cable Routing

    Cable routing 2-61 a-a a a a b c 1 2 3 4 5 6 7 8 9 10 11.

  • Page 115: Cable Routing

    Cable routing 2-62 1. Fuel pump coupler 2. Rear left turn signal light coupler 3. Tail/brake light coupler 4. Rear right turn signal light coupler 5. Tail/brake light lead 6. Rear right turn signal light lead 7. License plate light lead 8. Rear left turn signal light lead 9. License plate light coup...

  • Page 116: Cable Routing

    Cable routing 2-63 d b-b c-c e-e a d a b b c c e e a b b c d d e f 1 1 2 3 4 4 9 8 5 6 7 10 11 12 12 13 13 14 13 12 13 11 10

  • Page 117: Cable Routing

    Cable routing 2-64 1. Ecu (engine control unit) 2. Wire harness 3. Lean angle sensor 4. Positive battery lead (to positive battery terminal) 5. Main fuse lead 6. Starter relay lead 7. Battery 8. Main fuse 9. Starter relay 10. Brake hose (hydraulic unit to left front brake caliper) 11. Brake hose (fr...

  • Page 118: Cable Routing

    Cable routing 2-65 b a 1 2 3 4 5 5 7 6 8 9 c c 10 10 10 10 11 11 a a 14 11 12 13 13 12 15 d 12 d e e e.

  • Page 119: Cable Routing

    Cable routing 2-66 1. Accelerator position sensor 2. Throttle servo motor coupler 3. Sub-wire harness couplers 4. Intake air pressure sensor 5. Throttle position sensor 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Injector #2 coupler 9. Injector #1 coupler 10. Negat...

  • Page 120: Cable Routing

    Cable routing 2-67 b a c-c b a c c a b c d e f g h i j 1 2 1 2 5 1 2 3 5 3 4 5.

  • Page 121: Cable Routing

    Cable routing 2-68 1. Brake hose (hydraulic unit to left front brake caliper) 2. Brake hose (hydraulic unit to rear brake caliper) 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Hydraulic unit assembly 5. Brake hose (front brake master cylinder to hydraulic unit) a. 54 – 58 ° b. 89 ...

  • Page 122: Cable Routing

    Cable routing 2-69 a-a b-b b b a a a a b c d e f g g h i j k l m n o 1 2 2 3 3 3 3 3 3 4 4 5 5 6 6 7 7 7 7.

  • Page 123: Cable Routing

    Cable routing 2-70 1. Clutch hose 2. Brake hose (hydraulic unit to left front brake caliper) 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (left front brake caliper to right front brake caliper) 5. Front wheel sensor lead 6. Front right turn signal/position light lead 7...

  • Page 124: Cable Routing

    Cable routing 2-71.

  • Page 125

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

  • Page 126

    Chassis ....................................................................................................... 3-22 adjusting the front disc brake................................................ 3-22 checking the brake fluid level................................................. 3-22 checking the f...

  • Page 128: 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 129: Periodic Maintenance

    Periodic maintenance 3-2 4 * rear brake • check operation, fluid level, and for fluid leakage. • replace brake pads if neces- sary. √ √ √ √ √ √ 5 * brake hoses • check for cracks or damage. √ √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for damage. • replace if necessary. √ √ √ √ √...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-3 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Tip from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Eau38440 tip • air filter • this model’s...

  • Page 131: Engine

    Engine 3-4 eas20472 engine eas20530 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead cent...

  • Page 132: Engine

    Engine 3-5 b. Turn the crankshaft almost 1/2 of a turn (167 degrees) counterclockwise until the “r” mark “a” on the generator rotor is aligned with the stationary pointer “b” on the generator cover. C. Measure the valve clearance with a thickness gauge. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ...

  • Page 133: Engine

    Engine 3-6 tip • cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • make a note of the position of each valve lifter “1” and valve pad “2” so that they can be in- stalled in the correct place. B. Calculate the difference between the speci- fied valv...

  • Page 134: Engine

    Engine 3-7 g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Tip • refer to “camshafts” on page 5-9. • lubricate the camshaft lobes and camshaft journals. • turn the crankshaft clockwise several full turns to seat the parts. H. Measure the valve clearance again. I. If th...

  • Page 135: Engine

    Engine 3-8 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. B. Check the vacuum pressure. If out of specification → adjust the throttle body synchronization. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 136: Engine

    Engine 3-9 eas20630 adjusting the throttle cable free play tip prior to adjusting the throttle cable free play, the engine idling speed and throttle body synchroni- zation should be adjusted properly. 1. Check: • throttle cable free play “a” out of specification → adjust. 2. Adjust: • throttle cable...

  • Page 137: Engine

    Engine 3-10 8. Install: • spark plug tip before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug cap 10.Install: • battery box refer to “general chassis” on page 4-1. Eas28910 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • pla...

  • Page 138: Engine

    Engine 3-11 eas20780 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap “1” • engine oil drain bolt “2” (along with the gasket) 4. Drain: • engine oil (completel...

  • Page 139: Engine

    Engine 3-12 12.Check: • engine oil level refer to “checking the engine oil level” on page 3-10. 13.Check: • engine oil pressure refer to “measuring the engine oil pressure” on page 3-12. Eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark → add the re...

  • Page 140: Engine

    Engine 3-13 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas20890 checking the clutch fluid level 1. Stand the vehicle on a level surface. Tip place the vehicle on a suitable stand. 2. Check: • clutch fluid level below the minimum level mark “a” → add the recommended clutch fluid to the proper ...

  • Page 141: Engine

    Engine 3-14 2. Bleed: • hydraulic clutch system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Add the recommended clutch fluid to the proper level. B. Install the clutch master cylinder reservoir di- aphragm. C. Connect a clear plastic hose “1” tightly to the bleed screw “2”. D. Place the oth...

  • Page 142: Engine

    Engine 3-15 notice eca2s31058 never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle body synchronization, leading to poor engine ...

  • Page 143: Engine

    Engine 3-16 eas21070 checking the crankcase breather hose 1. Remove: • top cover • battery box refer to “general chassis” on page 4-1. 2. Pull back the battery box heat shield “1”. 3. Check: • crankcase breather hose “2” • crankcase breather pipe cracks/damage → replace. Loose connection → connect p...

  • Page 144: Engine

    Engine 3-17 5. Install: • fuel tank refer to “fuel tank” on page 7-1. • rear fender • passenger seat refer to “general chassis” on page 4-1. Eas21090 checking the canister (for california only) 1. Remove: • left side cover refer to “general chassis” on page 4-1. 2. Check: • canister “1” • canister p...

  • Page 145: Engine

    Engine 3-18 tip check that the projection “a” on the exup valve pulley contacts the stopper “b” (fully open posi- tion). If the projection does not contact the stop- per, adjust the exup cable. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • exup cable ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 146: Engine

    Engine 3-19 • upper radiator inlet pipe “3” • thermostat outlet hose “4” • lower radiator outlet hose “5” • left lower radiator inlet hose • right lower radiator inlet hose • thermostat inlet hose 2 (front cylinder side) “6” • thermostat inlet pipe 2 (front cylinder side) “7” • thermostat inlet hose...

  • Page 147: Engine

    Engine 3-20 be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hi...

  • Page 148: Engine

    Engine 3-21 13.Install: • coolant reservoir cap • coolant reservoir cap guide 14.Start the engine, warm it up for several min- utes, and then stop it. 15.Check: • coolant level refer to “checking the coolant lev- el” on page 3-18. Tip before checking the coolant level, wait a few minutes until the c...

  • Page 149: Chassis

    Chassis 3-22 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the brake lever forward, turn the adjusting knob “1” in or out until the...

  • Page 150: Chassis

    Chassis 3-23 tip in order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. 5. Install: • passenger seat refer to “general chassis” on page 4-1. 6. Return the backrest to its original position and make sure it is latched. Eas21250 che...

  • Page 151: Chassis

    Chassis 3-24 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas2s31012 bleeding the hydraulic brake system (abs) warning ewa14000 always bleed the brake system when the brake related parts are removed. Notice eca2s31004 • bleed the brake system in the following or- der. • 1st step: front brake ca...

  • Page 152: Chassis

    Chassis 3-25 notice eca2s31005 make sure that the main switch is turned to “off” before checking the operation of the hydraulic unit. K. After operating the abs, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper level with the recomme...

  • Page 153: Chassis

    Chassis 3-26 4. Tighten: • final gear oil check bolt eas21470 changing the final gear oil 1. Place a container under the final gear case. 2. Remove: • dust cover “1” 3. Remove: • final gear oil filler/breather assembly “1” • final gear oil drain bolt “2” completely drain the final drive case of its ...

  • Page 154: Chassis

    Chassis 3-27 b. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”. Tip set the torque wrench at a right angle to the steering nut wrench. C. Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench. Warning e...

  • Page 155: Chassis

    Chassis 3-28 eas2s31013 checking the rear suspension 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. Check: • rear shock absorber assembly gas leaks/oil leaks → replace the rear shock absorber assembly. Refer to...

  • Page 156: Chassis

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

  • Page 157: Chassis

    Chassis 3-30 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping notice eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting knob “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲...

  • Page 158: Chassis

    Chassis 3-31 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21650 checking the tires the following procedure applies to both of the tires. 1. Check: • tire pressure out of specification → regulate. Warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperat...

  • Page 159: Chassis

    Chassis 3-32 warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden deflation. • when using a tube tire, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. • to avoid ...

  • Page 160: Chassis

    Chassis 3-33 3. Check: • wheel bearings refer to “checking the front wheel” on page 4-14 and “checking the rear wheel” on page 4-24. Eas2s31015 checking the sidestand 1. Check: • sidestand operation check that the sidestand moves smoothly. Rough movement → repair or replace. Eas21690 checking and lu...

  • Page 161: Electrical System

    Electrical system 3-34 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-117. Eas21770 checking the fuses refer to “electrical components” on page 8-117. Eas21780 replacing the headlight bulb 1. Remove: • headlight lens unit “1” 2. Disco...

  • Page 162: Electrical System

    Electrical system 3-35 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas2s31019 checking the switches, lights and signals 1. Check that all switches operate and that all lights come on. Ref...

  • Page 163: Chassis

    4 chassis general chassis ....................................................................................... 4-1 installing the abs test coupler................................................. 4-4 installing the top cover ............................................................... 4-8 inst...

  • Page 164

    Rear brake ............................................................................................... 4-41 introduction ..................................................................................... 4-47 checking the rear brake disc.................................................... 4-4...

  • Page 165

    Swingarm ................................................................................................... 4-88 removing the swingarm................................................................ 4-89 checking the swingarm ................................................................ 4-89 ins...

  • Page 166: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats, side covers, and rear fender order job/parts to remove q’ty remarks 1 rider seat 1 2 passenger seat 1 3 left side cover 1 4 right side cover 1 5 rear fender 1 for installation, reverse the removal proce- dure. 3 1 2 5 4 7 nm (0.7 m • k...

  • Page 167: General Chassis

    General chassis 4-2 removing the side cover inner panels, tail/brake light assembly, and rear turn signal light assembly order job/parts to remove q’ty remarks rear fender refer to “removing the seats, side covers, and rear fender”. Rollover valve refer to “fuel tank” on page 7-1. Canister for calif...

  • Page 168: General Chassis

    General chassis 4-3 14 license plate light coupler 1 disconnect. 15 rear turn signal light coupler 2 disconnect. 16 rear turn signal light assembly 1 17 mudguard 1 1 for installation, reverse the removal proce- dure. Removing the side cover inner panels, tail/brake light assembly, and rear turn sign...

  • Page 169: General Chassis

    General chassis 4-4 eas2s31092 installing the abs test coupler 1. Install: • abs test coupler “1” tip • route the abs test coupler lead through the slot “a” in the left side cover inner panel. • make sure that the abs test coupler clasp fac- es inward, toward the left side cover inner pan- el. A 1.

  • Page 170: General Chassis

    General chassis 4-5 removing the passenger footrests and mudguard 2 order job/parts to remove q’ty remarks mudguard 1 refer to “removing the side cover inner panels, tail/brake light assembly, and rear turn signal light assembly”. Mufflers/exhaust chamber refer to “engine removal” on page 5-1. 1 sea...

  • Page 171: General Chassis

    General chassis 4-6 removing the top cover, intake duct assemblies, and meter assembly 2 order job/parts to remove q’ty remarks rider seat refer to “removing the seats, side covers, and rear fender”. 1 meter assembly 2 cover 1 2 top cover 1 3 left intake duct assembly 1 4 right intake duct assembly ...

  • Page 172: General Chassis

    General chassis 4-7 disassembling the intake duct assemblies order job/parts to remove q’ty remarks 1 left intake duct 1 2 left intake duct inner plate 1 3 left intake grill 1 4 left intake dust filter 2 5 right intake duct 1 6 right intake duct inner plate 1 7 right intake grill 1 8 right intake du...

  • Page 173: General Chassis

    General chassis 4-8 eas2s31033 installing the top cover 1. Install: • top cover brackets tip first, tighten the bolts on the front side of the top cover bracket, and then on the rear side. 2. Install: • top cover ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the top cover bolts “1” te...

  • Page 174: General Chassis

    General chassis 4-9 removing the battery order job/parts to remove q’ty remarks top cover refer to “removing the top cover intake duct assemblies, and meter assembly 2”. 1 negative battery lead 1 disconnect. 2 positive battery lead 1 disconnect. 3 ecu coupler 2 disconnect. 4 ecu (engine control unit...

  • Page 175: General Chassis

    General chassis 4-10 eas2s31032 installing the battery 1. Install: • battery seat “1” (to the battery “2”) tip install the battery seat as shown in the illustra- tion. 2. Install: • positive battery lead “1” • negative battery lead “2” notice eca2s31067 first, connect the positive battery lead “1”, ...

  • Page 176: General Chassis

    General chassis 4-11 removing the meter assembly 1 and headlight order job/parts to remove q’ty remarks lower air filter case refer to “air filter case” on page 7-6. 1 meter assembly 1 coupler 2 disconnect. 2 meter assembly 1 sub-wire harness coupler 1 disconnect. 3 select/reset button unit coupler ...

  • Page 177: Front Wheel

    Front wheel 4-12 eas21880 front wheel removing the front wheel, brake discs, wheel sensor and sensor housing order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Lower air filter case refer to “air filter case” on page 7-6. 1 front wheel sensor coupler 1 disconne...

  • Page 178: Front Wheel

    Front wheel 4-13 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 1 2 oil seal 1 3 front wheel sensor rotor 1 4 wheel bearing 2 5 spacer 1 for assembly, reverse the disassembly pro- cedure. New new new 1 4 5 4 2 3 (5) lt ls ls 8 nm (0.8 m • kgf, 5.8 ft • ibf) t.R..

  • Page 179: Front Wheel

    Front wheel 4-14 eas21900 removing the front wheel notice eca2s31007 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs...

  • Page 180: Front Wheel

    Front wheel 4-15 • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-31 and “checking the wheels” on page 3-32. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns roughly or is lo...

  • Page 181: Front Wheel

    Front wheel 4-16 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the dial gauge at a right angle against the wheel sensor rotor surface. B. Measure the wheel sensor rotor deflection. Tip do not touch the surface of the rotor magnet with a sharp object. C. If the deflection is above specifi...

  • Page 182: Front Wheel

    Front wheel 4-17 notice eca2s31010 replace the wheel sensor rotor bolts with new ones. 3. Measure: • wheel sensor rotor deflection out of specification → correct the wheel sen- sor rotor deflection or replace the wheel sen- sor rotor. Refer to “maintenance of the front wheel sensor and sensor rotor”...

  • Page 183: Front Wheel

    Front wheel 4-18 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. B. If the front wheel does not remain stationary at all of the positions, rebalance it. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22000 installing the ...

  • Page 184: Front Wheel

    Front wheel 4-19 d. In the order pinch bolt “3” → pinch bolt “4” → pinch bolt “3”, tighten each bolt to 21 nm (2.1 m·kgf, 15 ft·lbf) without performing temporary tightening. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Measure: tip measure the distance “a” only if the wheel bear- ings, wheel...

  • Page 185: Rear Wheel

    Rear wheel 4-20 eas22030 rear wheel removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks right side cover refer to “general chassis” on page 4-1. 1 rear wheel sensor coupler 1 disconnect. 2 rear wheel sensor 1 3 rear brake caliper retaining bol...

  • Page 186: Rear Wheel

    Rear wheel 4-21 15 rear brake disc cover 1 16 rear brake disc 1 for installation, reverse the removal proce- dure. Removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks lt ls s s 13 16 14 15 2 12 (5) 11 1 10 5 6 8 3 9 4 7 9 23 nm (2.3 m • kgf, 1...

  • Page 187: Rear Wheel

    Rear wheel 4-22 disassembling the rear wheel order job/parts to remove q’ty remarks 1 dust cover 1 2 rear wheel drive hub stopper 1 3 dust seal 1 4 rear wheel drive hub 1 5 wheel bearing 1 6 rear wheel drive hub damper 6 7 o-ring 1 8 spacer 1 9 spacer 1 10 rear wheel ring plate 1 11 rear wheel ring ...

  • Page 188: Rear Wheel

    Rear wheel 4-23 eas22050 removing the rear wheel (disc) notice eca2s31015 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the...

  • Page 189: Rear Wheel

    Rear wheel 4-24 notice eca2s31017 the bearing retainer has left-handed threads. To loosen the retainer, turn it clock- wise. D. Remove the wheel sensor rotor. E. Remove the wheel bearings “1” with a gener- al bearing puller. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22090 checking the rea...

  • Page 190: Rear Wheel

    Rear wheel 4-25 1. Install: • bearing “1” 2. Install: • wheel bearings ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings in the reverse order of disassembly. Notice eca2s31011 do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only ...

  • Page 191: Rear Wheel

    Rear wheel 4-26 6. Measure: • wheel sensor rotor deflection out of specification → correct the wheel sen- sor rotor deflection or replace the wheel sen- sor rotor. Refer to “maintenance of the rear wheel sensor and sensor rotor” on page 4-24. Eas22150 adjusting the rear wheel static balance tip • af...

  • Page 192: Rear Wheel

    Rear wheel 4-27 5. Tighten: • rear wheel axle • rear wheel axle pinch bolts ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the rear wheel axle “1” with the damper rod holder (24 mm) “2”. B. In the order pinch bolt “3” → pinch bolt “4” → pinch bolt “3”, tighten each bolt to 16 nm (1.6 m...

  • Page 193: Rear Wheel

    Rear wheel 4-28 8. Install: • rear wheel sensor notice eca2s31021 to route the rear wheel sensor lead, refer to “cable routing” on page 2-47. Tip when installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials. 9. Check: • rear wheel ...

  • Page 194: Front Brake

    Front brake 4-29 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 front wheel sensor lead holder 1 left side only. 2 front brake caliper 1 3 brake pad clip 4 4 brake pad pin 2 5 brake pad ...

  • Page 195: Front Brake

    Front brake 4-30 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. 1 right rearview mirror 1 2 brake master cylinder reservoir cap 1 3 brake master cylinder reservoir diaphragm hold- e...

  • Page 196: Front Brake

    Front brake 4-31 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S 1 2 1 new new.

  • Page 197: Front Brake

    Front brake 4-32 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. 1 front wheel sensor lead holder 1 left side only. 2 br...

  • Page 198: Front Brake

    Front brake 4-33 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 4 2 brake pad pin 2 3 brake pad spring 2 4 front brake pad 4 5 brake caliper piston 6 6 brake caliper piston dust seal ...

  • Page 199: Front Brake

    Front brake 4-34 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 200: Front Brake

    Front brake 4-35 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 201: Front Brake

    Front brake 4-36 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-22. 5. Check: • brake lever operati...

  • Page 202: Front Brake

    Front brake 4-37 eas22390 checking the front brake calipers 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders “2” scratches/wear → replace the brake caliper assembly. • brake caliper body “3” cracks/damage → replace the brake cal...

  • Page 203: Front Brake

    Front brake 4-38 2. Remove: • front brake caliper 3. Install: • brake pads • brake pad springs • brake pad pins • brake pad clips • front brake caliper • front wheel sensor lead holder refer to “replacing the front brake pads” on page 4-35. 4. Fill: • brake master cylinder reservoir (with the specif...

  • Page 204: Front Brake

    Front brake 4-39 tip to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Eas22500 checking the front brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cyl...

  • Page 205: Front Brake

    Front brake 4-40 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) 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...

  • Page 206: Rear Brake

    Rear brake 4-41 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 rear brake caliper retaining bolt 2 2 rear brake caliper 1 3 brake pad shim 1 4 brake pad insulator 1 left side only. 5 rear brake pad 2 6 brake pad shim 1 7 brake pad support 2 for installation...

  • Page 207: Rear Brake

    Rear brake 4-42 removing the rear brake master cylinder order job/parts to remove q’ty remarks right side cover/rear fender refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. 1 brake fluid reservoir cap 1 2 brake fluid reserv...

  • Page 208: Rear Brake

    Rear brake 4-43 14 rear brake light switch 1 15 brake pedal pivot shaft 1 16 rear brake master cylinder 1 17 right rider footrest 1 for installation, reverse the removal proce- dure. Removing the rear brake master cylinder order job/parts to remove q’ty remarks 1 8 9 11 10 2 3 4 lt lt lt 5 7 12 14 1...

  • Page 209: Rear Brake

    Rear brake 4-44 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 rear brake master cylinder joint 1 2 brake master cylinder kit 1 3 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 2 3 1 s new 16 nm (1.6 m • kgf, 11 ft • ibf) t.R..

  • Page 210: Rear Brake

    Rear brake 4-45 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. 1 rear wheel sensor lead holder 1 2 brake hose union bolt 1 3 brake hose gasket 2 4 brake hose (hydraulic unit to rear brake ca...

  • Page 211: Rear Brake

    Rear brake 4-46 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 brake caliper piston 1 2 brake caliper piston dust seal 1 3 brake caliper piston seal 1 4 bleed screw 1 for assembly, reverse the disassembly pro- cedure. 1 3 4 new 2 new bf s 6 nm (0.6 m • kgf, 4.3 ft • ib...

  • Page 212: Rear Brake

    Rear brake 4-47 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 213: Rear Brake

    Rear brake 4-48 • brake pads tip always install new brake pads, brake pad shims, brake pad insulator, and brake pad supports as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open cont...

  • Page 214: Rear Brake

    Rear brake 4-49 eas22600 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston dust seal “2” • brake caliper piston seal “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pis...

  • Page 215: Rear Brake

    Rear brake 4-50 • never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. Eas22670...

  • Page 216: Rear Brake

    Rear brake 4-51 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • brake hose gaskets • brake hose (hydraulic unit to rear brake cali- per) “1” • brake hose union bolt “2” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing...

  • Page 217: Rear Brake

    Rear brake 4-52 8. Check: • brake pedal operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. Eas22700 removing the rear brake master cylinder tip before removing the rear brake master cylinder, drain the brake fluid from the ...

  • Page 218: Rear Brake

    Rear brake 4-53 2. Install: • brake hose gaskets • brake hose (rear brake master cylinder to hy- draulic unit) “1” • brake hose union bolt “2” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-47. Notice eca14160 when insta...

  • Page 219: Rear Brake

    Rear brake 4-54 7. Check: • brake pedal operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. 8. Adjust: • rear brake light operation timing refer to “adjusting the rear brake light switch” on page 3-23. A.

  • Page 220: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 eas22760 abs (anti-lock brake system) eas2s31022 abs components chart 1 2 a 3 4 5 6 7 8 9 10 11 12 2 3 4 9 10 a 1. Abs test coupler 2. Hydraulic unit assembly 3. Brake hose (hydraulic unit to left front brake caliper) 4. Brake hose (front brake master cylinder to hy...

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

    Abs (anti-lock brake system) 4-56 removing the hydraulic unit assembly order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-24. Rider seat/top cover/battery refer to “general chassis” on page 4-1. 1 abs ecu coupler 1 disconnect. 2 b...

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

    Abs (anti-lock brake system) 4-57 eas2s31023 removing the hydraulic unit assembly notice eca2s31024 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 223: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-58 eas2s31026 installing the hydraulic unit assembly 1. Install: • hydraulic unit assembly box • hydraulic unit assembly tip do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. Notice e...

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

    Abs (anti-lock brake system) 4-59 6. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and ...

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

    Abs (anti-lock brake system) 4-60 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 the brake pedal simulta- neously. Tip do not push the start switch when turning the main switch to “on”, otherwise the operation ...

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

    Abs (anti-lock brake system) 4-61 5. Connect the test coupler adapter “1” to the abs test coupler “2”. 6. Set the engine stop switch “1” to “ ”. 7. Turn the main switch to “on”. 8. Push the start switch “1” for at least 4 sec- onds. Notice eca14790 do not operate the brake lever or the brake pedal. ...

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

    Abs (anti-lock brake system) 4-62 • be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped. 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- mately 1.5 secon...

  • Page 228: Handlebar

    Handlebar 4-63 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 rearview mirror 2 2 plastic holder 2 3 front brake light switch connector 2 disconnect. 4 front brake master cylinder holder 1 5 front brake master cylinder assembly 1 6 right handlebar switch 1 7 throt...

  • Page 229: Handlebar

    Handlebar 4-64 17 upper handlebar holder 1 18 handlebar 1 19 select/reset button unit 1 20 left lower handlebar holder 1 21 right lower handlebar holder 1 for installation, reverse the removal proce- dure. Removing the handlebar order job/parts to remove q’ty remarks 1 5 3 17 14 11 1 2 2 (4) 18 4 6 ...

  • Page 230: Handlebar

    Handlebar 4-65 eas22860 removing the handlebar 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 graduall...

  • Page 231: Handlebar

    Handlebar 4-66 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Install: • left handlebar switch “1” tip align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 6. Install: • clutch master cylinder assembly • clutch master cylinder holder “1” tip • the clutch ma...

  • Page 232: Handlebar

    Handlebar 4-67 tip • align the mating surfaces of the brake master cylinder holder with the punch mark “a” on the handlebar. • first, tighten the upper bolt, then the lower bolt. 10.Adjust: • throttle cable free play refer to “adjusting the throttle ca- ble free play” on page 3-9. Throttle cable fre...

  • Page 233: Front Fork

    Front fork 4-68 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-12. 1 brake hose holder 1 2 fork leg protector 2 3 front fender outer bracket 2 4 front...

  • Page 234: Front Fork

    Front fork 4-69 14 lower bracket pinch bolt 2 loosen. 15 front fork leg 1 for installation, reverse the removal proce- dure. Removing the front fork legs order job/parts to remove q’ty remarks 13 12 15 1 5 4 6 2 3 7 8 6 9 10 3 2 4 11 14 lt lt 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf...

  • Page 235: Front Fork

    Front fork 4-70 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 locknut 1 4 damper adjusting rod 1 5 spacer 1 6 spring sleeve 1 7 spring seat 1 8 fork spring 1 9 dust seal 1 10 oil seal...

  • Page 236: Front Fork

    Front fork 4-71 17 oil seal 1 18 washer 1 19 outer tube bushing 1 20 inner tube bushing 1 21 outer tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the front fork legs order job/parts to remove q’ty remarks 1 2 new ls 4 5 6 7 8 new 9 new 10 new 17 18 new 19 15 14 13 new 20 21 ...

  • Page 237: Front Fork

    Front fork 4-72 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...

  • Page 238: Front Fork

    Front fork 4-73 tip while holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt. 5. Remove: • inner tube ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the front fork leg horizontally. B. Securely clamp the brake caliper bracket in a vise with soft jaw...

  • Page 239: Front Fork

    Front fork 4-74 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 front fork leg, be sure to replace the following parts: –inner tube bushing –outer tube bushing –oil sea...

  • Page 240: Front Fork

    Front fork 4-75 6. Install: • oil seal “1” (with the fork seal driver “2”) notice eca14220 make sure the numbered side of the oil seal faces up. Tip • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the inner tube with fork oil. • b...

  • Page 241: Front Fork

    Front fork 4-76 10.After filling the front fork leg, slowly stroke the damper rod assembly “1” up and down (at least ten times) to distribute the fork oil. Tip be sure to stroke the damper rod assembly slowly because the fork oil may spurt out. 11.Slowly stroke the inner tube “1” up and down. 12.Bef...

  • Page 242: Front Fork

    Front fork 4-77 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 16.Install: • cap bolt (to the outer tube) tip temporarily tighten the cap bolt. Eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg temporarily tighten ...

  • Page 243: Steering Head

    Steering head 4-78 eas23090 steering head removing the coupler holder and brake hose holder order job/parts to remove q’ty remarks front wheel refer to “front wheel” on page 4-12”. Handlebar refer to “handlebar” on page 4-63”. Front fork legs refer to “front fork” on page 4-68”. 1 coupler cover 1 2 ...

  • Page 244: Steering Head

    Steering head 4-79 13 brake hose guide 1 for installation, reverse the removal proce- dure. Removing the coupler holder and brake hose holder order job/parts to remove q’ty remarks 2 3 10 5 4 6 9 12 11 1 8 7 13 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 7 nm (0.7 m •...

  • Page 245: Steering Head

    Steering head 4-80 removing the lower bracket order job/parts to remove q’ty remarks 1 steering stem nut 1 2 upper bracket 1 3 lock washer 1 4 upper ring nut 1 5 rubber washer 1 6 lower ring nut 1 7 upper bearing cover 1 8 upper bearing 1 9 lower bracket 1 10 lower bearing 1 11 dust seal 1 12 upper ...

  • Page 246: Steering Head

    Steering head 4-81 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 247: Steering Head

    Steering head 4-82 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to “checking and adjusting the steering head” on page 3-26. 3. Install: • upper bracket • steering stem nut tip temporarily tighten the steering stem nut. 4. Install: • front fork leg...

  • Page 248: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-83 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Mufflers/exhaust pipe assembly refer to “engine removal” on page 5-1. 1 rebound damping adjusting knob ...

  • Page 249: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-84 12 relay arm and relay arm bracket locknut/wash- er/nut/bolt 1/1/1/1 13 relay arm 1 14 spacer 1 15 oil seal 2 16 bearing 1 17 collar 2 18 oil seal 2 19 bearing 2 20 relay arm bracket 1 for installation, reverse the removal proce- dure. Removing the rear shock absorb...

  • Page 250: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-85 eas23170 handling the rear shock absorber and gas cylinder warning ewa13750 this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Be- fore handling the rear shock absorber or gas cylinder, read and make sure you under- stand the following...

  • Page 251: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-86 3. Check: • spacers • collars damage/scratches → replace. Eas23310 installing the rear shock absorber assembly 1. Install: • relay arm bracket “1” tip make sure that the paint mark “a” on the relay arm bracket faces to the upper side. 2. Lubricate: • oil seals • bea...

  • Page 252: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-87 tip • hold the connecting arm and relay arm bolt so that it does not turn while tightening the con- necting arm and relay arm nut. • hold the connecting arm and swingarm bolt so that it does not turn while tightening the con- necting arm and swingarm nut. C. Tighten...

  • Page 253: Swingarm

    Swingarm 4-88 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-20. Rear shock absorber assembly refer to “rear shock absorber as- sembly” on page 4-83. Final drive assembly refer to “shaft drive” on page 4-91. 1 brake hose cove...

  • Page 254: Swingarm

    Swingarm 4-89 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm...

  • Page 255: Swingarm

    Swingarm 4-90 d. Tighten the pivot bolt locknut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Pivot bolt locknut 100 nm (10.0 m·kgf, 72 ft·lbf).

  • Page 256: Shaft Drive

    Shaft drive 4-91 eas23551 shaft drive removing the final drive assembly order job/parts to remove q’ty remarks final gear oil drain. Refer to “changing the final gear oil” on page 3-26. Rear wheel refer to “rear wheel” on page 4-20. 1 swingarm inner panel 1 2 final drive assembly 1 for installation,...

  • Page 257: Shaft Drive

    Shaft drive 4-92 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 drive shaft end cap 1 2 circlip 4 3 bearing 4 4 circlip 1 5 universal joint (final drive side) 1 6 drive shaft 1 7 ring gear bearing housing 1 8 ring gear 1 9 thrust washer 1 refer to “adjusting the fina...

  • Page 258: Shaft Drive

    Shaft drive 4-93 14 bearing retainer (ring gear) 1 15 oil seal 1 16 bearing 1 17 universal joint yoke nut (final drive side) 1 18 universal joint yoke (final drive side) 1 19 bearing retainer (final drive pinion gear) 1 left-hand threads 20 oil seal 1 21 final drive pinion gear 1 22 bearing 1 23 fin...

  • Page 259: Shaft Drive

    Shaft drive 4-94 * shaft drive gear oil (9079e-sh001-00) 27 final drive case 1 for assembly, reverse the disassembly pro- cedure. Disassembling the final drive assembly order job/parts to remove q’ty remarks 7 10 11 13 12 8 (3) (6) (6) 14 2 2 3 3 5 4 26 (4) 27 16 9 24 15 21 25 23 22 19 20 18 17 3 3 ...

  • Page 260: Shaft Drive

    Shaft drive 4-95 eas23560 troubleshooting tip causes a, b, and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individually. ...

  • Page 261: Shaft Drive

    Shaft drive 4-96 no → yes ↓ yes → no ↓ eas23570 checking the final gear oil for contamination and checking the shaft drive for leaks 1. Drain: • final gear oil (from the final gear case) refer to “changing the final gear oil” on page 3-26. 2. Check: • final gear oil large amount of metal particles →...

  • Page 262: Shaft Drive

    Shaft drive 4-97 4. Measure: • final gear backlash out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the ring gear fix bolt “1” into the final gear oil drain hole. B. Finger tighten the ring gear fix bolt until it stops the ring gear from moving. Tip do not ...

  • Page 263: Shaft Drive

    Shaft drive 4-98 3. Adjust: • final gear backlash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select the suitable ring gear shim(s) and thrust washer with the following chart. B. If it is necessary to increase the final gear backlash by more than 0.2 mm, reduce the ring gear shim thickness ...

  • Page 264: Shaft Drive

    Shaft drive 4-99 4. Remove: • bearing retainer (with the special tool “1”) notice eca14330 the bearing retainer has left-hand threads. To loosen the bearing retainer, turn it clock- wise. 5. Remove: • final drive pinion gear warning ewa13800 always use new bearings. Notice eca14340 the final drive p...

  • Page 265: Shaft Drive

    Shaft drive 4-100 • install the final drive case stud bolts so that the specified installed length “a” is obtained. Eas23640 aligning the final drive pinion gear and ring gear tip aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: • final dr...

  • Page 266: Shaft Drive

    Shaft drive 4-101 since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. In the example above, the calculated final drive pinion gear shim thickness is 0.28 mm. The chart instructs you to round off the 8 to 10. Thus, you should use a 0.30...

  • Page 267: Shaft Drive

    Shaft drive 4-102 notice eca14350 the bearing retainer has left-hand threads. To tighten the bearing retainer, turn it coun- terclockwise. 3. Install: • universal joint yoke (final drive side) • washer “1” tip install the washer with its “out” mark “a” facing outward. 4. Install: • universal joint y...

  • Page 268: Shaft Drive

    Shaft drive 4-103 e. Measure the width of the flattened plasti- gauge® “1”. F. If the ring-gear-to-thrust-washer clearance is within specification, install the ring gear bear- ing housing (along with the ring gear). G. If the ring-gear-to-thrust-washer clearance is out of specification, select the c...

  • Page 269: Shaft Drive

    Shaft drive 4-104 tip lift the universal joint “1” and make sure that it falls freely when released. 4. Install: • final drive assembly tip align the wide spline “b” on the drive shaft with the wide groove “a” in the universal joint (middle gear side). 5. Tighten: • final drive assembly nut 6. Insta...

  • Page 270: Shaft Drive

    Shaft drive 4-105.

  • Page 271: Engine

    5 engine engine removal ........................................................................................ 5-1 installing the engine....................................................................... 5-7 installing the exup cables ..............................................................

  • Page 272

    Clutch ........................................................................................................ 5-48 removing the clutch ..................................................................... 5-56 checking the friction plates..................................................... 5-56 c...

  • Page 273

    Crankshaft and balancer ................................................................ 5-92 removing the balancer shaft journal bearings .............. 5-93 removing the crankshaft journal bearings ...................... 5-93 checking the timing chains ................................................

  • Page 274: Engine Removal

    Engine removal 5-1 eas23711 engine removal removing the exhaust chamber and exhaust pipes order job/parts to remove q’ty remarks rear fender refer to “general chassis” on page 4-1. 1 right-muffler protector 1 2 right muffler 1 3 left-muffler protector 1 4 left muffler 1 5 gasket 2 6 exup valve pulle...

  • Page 275: Engine Removal

    Engine removal 5-2 15 gasket 2 16 exhaust chamber bracket (right side) 1 17 exhaust chamber bracket (left side) 1 18 exhaust chamber bracket (front side) 1 19 right front exhaust pipe 1 20 left front exhaust pipe 1 21 gasket 2 22 gasket 1 for installation, reverse the removal proce- dure. Removing t...

  • Page 276: Engine Removal

    Engine removal 5-3 disconnecting the leads and hose order job/parts to remove q’ty remarks right rider footrest assembly refer to “rear brake” on page 4-41. Drive shaft refer to “shaft drive” on page 4-91. Shift arm refer to “shift shaft” on page 5-65. Clutch pipe refer to “clutch” on page 5-48. Sta...

  • Page 277: Engine Removal

    Engine removal 5-4 4 crankshaft position sensor coupler 1 disconnect. 5 left rider footrest assembly 1 6 sidestand switch coupler 1 disconnect. 7 sidestand 1 8 oil level switch coupler 1 disconnect. 9 gear position switch coupler 1 disconnect. For installation, reverse the removal proce- dure. Disco...

  • Page 278: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks tip place a suitable stand under the engine. 1 engine bracket bolt (left side) 2 2 engine mounting bolt (left side) 2 3 engine bracket (left side) 1 4 engine bracket bolt (right side) 2 5 engine mounting bolt (right side) ...

  • Page 279: Engine Removal

    Engine removal 5-6 16 engine mounting collar (inside) 1 17 engine mounting bolt (rear left upper side) 1 18 engine mounting nut (rear lower side) 1 19 engine mounting bolt (rear lower side) 1 20 engine mounting collar (outside) 1 21 engine mounting collar (inside) 1 22 engine 1 tip remove the engine...

  • Page 280: Engine Removal

    Engine removal 5-7 eas23720 installing the engine 1. Install: • engine mounting collar (inside) “1” • engine mounting collar (outside) “2” • engine mounting collar (inside) “3” • engine mounting collar (outside) “4” • engine “5” • engine mounting bolt (rear lower side) “6” • engine mounting nut (rea...

  • Page 281: Engine Removal

    Engine removal 5-8 eas30360 installing the exup cables 1. Adjust: • exup servo motor pulley “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the exup servo motor coupler to the exup servo motor. B. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to “fue...

  • Page 282: Camshafts

    Camshafts 5-9 eas23760 camshafts removing the cylinder head covers order job/parts to remove q’ty remarks front exhaust pipes refer to “engine removal” on page 5-1. Engine bracket (front side) refer to “engine removal” on page 5-1. Radiator assembly refer to “radiators” on page 6-1. Thermostat inlet...

  • Page 283: Camshafts

    Camshafts 5-10 10 front cylinder head cover 1 11 cylinder head cover gasket 2 for installation, reverse the removal proce- dure. Removing the cylinder head covers order job/parts to remove q’ty remarks 1 4 3 2 (4) (4) 9 7 7 8 8 7 7 8 8 8 7 7 8 10 11 11 8 7 1 1 7 6 3 2 3 2 8 5 ls new new new new lt l...

  • Page 284: Camshafts

    Camshafts 5-11 removing the camshafts order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Generator cover plate refer to “generator and starter clutch” on page 5-37. 1 exhaust camshaft cap (rear cylinders) 2 2 exhaust camshaft (rear cylinders) 1 3 timing chain tensione...

  • Page 285: Camshafts

    Camshafts 5-12 12 timing chain tensioner (front cylinders) 1 13 timing chain tensioner gasket (front cylinders) 1 14 front cylinder timing chain guide (exhaust side) 1 15 intake camshaft cap (front cylinders) 2 16 intake camshaft (front cylinders) 1 17 intake camshaft sprocket (front cylinders) 1 18...

  • Page 286: Camshafts

    Camshafts 5-13 eas23820 removing the camshafts rear cylinders 1. Position: • piston #1 (at tdc) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position piston #1 at tdc by turning the crankshaft counterclockwise until the “t1” mark “a” on the generator rotor is aligned with the stationary poin...

  • Page 287: Camshafts

    Camshafts 5-14 tip while holding the camshaft sprocket and cam- shaft gear with the rotor holding tool “1”, loosen the camshaft sprocket bolts and camshaft gear bolts. Front cylinders tip when removing the front cylinder camshafts, re- peat the rear cylinder camshaft removal proce- dure. However, no...

  • Page 288: Camshafts

    Camshafts 5-15 3. Measure: • camshaft runout out of specification → replace. 4. Measure: • camshaft-journal-to-camshaft-cap clearance out of specification → measure the camshaft journal diameter. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshaft into the cylinder head (withou...

  • Page 289: Camshafts

    Camshafts 5-16 eas2s31035 checking the camshaft gears 1. Check: • intake camshaft gear (front cylinders) • intake camshaft gear (rear cylinders) damage/wear → replace the camshaft gears as a set. Eas23980 checking the decompression system 1. Check: • decompression system tip • check that the decompr...

  • Page 290: Camshafts

    Camshafts 5-17 b. Install the timing chain tensioner spring, tim- ing chain tensioner spring seat, and timing chain tensioner rod. C. Squeeze timing chain tensioner clip 2 “1”, and then push the timing chain tensioner rod “3” into the timing chain tensioner housing. Tip do not release timing chain t...

  • Page 291: Camshafts

    Camshafts 5-18 2. Install: • intake camshaft sprocket “1” tip • install the camshaft sprocket so that the bolt hole next to the “f” mark “a” is aligned with the bolt hole on the camshaft. • while holding the camshaft sprocket with the rotor holding tool “2”, tighten the camshaft sprocket bolts. 3. F...

  • Page 292: Camshafts

    Camshafts 5-19 5. Install: • intake camshaft cap bolts notice eca2s31035 the camshaft cap bolts must be tightened evenly; otherwise, the cylinder head, cam- shaft caps, and camshaft will be damaged. Tip • lubricate the camshaft cap bolt mating surface with molybdenum disulfide oil. • tighten the cam...

  • Page 293: Camshafts

    Camshafts 5-20 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: • exhaust camshaft “1” • exhaust camshaft caps “2” notice eca2s31034 do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. Tip • make sure the punch mark “a” on the intake camshaf...

  • Page 294: Camshafts

    Camshafts 5-21 tip • install the camshaft gear onto the left side of the camshaft. • install the camshaft gear so that the bolt hole next to the “r” mark “a” is aligned with the bolt hole on the camshaft. • while holding the camshaft gear with the rotor holding tool “2”, tighten the camshaft gear bo...

  • Page 295: Camshafts

    Camshafts 5-22 notice eca2s31034 do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. Tip • be sure to install the timing chain so that the in- take side of the chain is taut and the exhaust side is slack. • make sure each camshaft cap is installed in its...

  • Page 296: Camshafts

    Camshafts 5-23 9. Check that the timing chain is taut. If the chain is slack, reinstall the timing chain ten- sioner. Rear cylinders-exhaust side 1. Find: • rear cylinders-exhaust camshaft installation position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Make sure that the “r” mark on the g...

  • Page 297: Camshafts

    Camshafts 5-24 tip • check that the “i” mark “a” on the intake cam- shaft gear (rear cylinders) is aligned with the edge of the cylinder head “b”. • check that the “i” mark “c” on the intake cam- shaft gear (front cylinders) is above the edge of the cylinder head “d”. Out of alignment → adjust. Refe...

  • Page 298: Camshafts

    Camshafts 5-25 9. Install: • ignition coils “1” tip when installing the ignition coils, make sure that the ignition coil couplers are positioned at the angles shown in the illustration. A. Front cylinders b. Rear cylinders 1 30 30 a fwd 1 1 b 90 90 fwd 1 1.

  • Page 299: Cylinder Heads

    Cylinder heads 5-26 eas24110 cylinder heads removing the cylinder heads order job/parts to remove q’ty remarks camshafts refer to “camshafts” on page 5-9. Oil pipe 1 refer to “generator and starter clutch” on page 5-37. 1 coolant temperature sensor 1 2 front cylinder head 1 3 rear cylinder head 1 4 ...

  • Page 300: Cylinder Heads

    Cylinder heads 5-27 eas24140 removing the cylinder heads 1. Remove: • cylinder head bolts tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24170 checking the cylinder heads the following pro...

  • Page 301: Cylinder Heads

    Cylinder heads 5-28 tip pass the timing chains through the timing chain cavity. 2. Tighten: • cylinder head bolts warning ewa2s31032 replace the bolts with new ones. Tip tighten the bolts using the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lubricate the cylinder head ...

  • Page 302: Valves and Valve Springs

    Valves and valve springs 5-29 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks the following procedure applies to both cyl- inders. Cylinder heads refer to “cylinder heads” on page 5-26. 1 valve lifter 8 2 valve pad 8 3 valve cotter 16 4 ...

  • Page 303: Valves and Valve Springs

    Valves and valve springs 5-30 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifte...

  • Page 304: Valves and Valve Springs

    Valves and valve springs 5-31 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve 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. ▼▼▼ ▼ ▼ ▼...

  • Page 305: Valves and Valve Springs

    Valves and valve springs 5-32 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replac...

  • Page 306: Valves and Valve Springs

    Valves and valve springs 5-33 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 307: Valves and Valve Springs

    Valves and valve springs 5-34 eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 2. Measure: • compressed valve spring force “a” out of specification → replace th...

  • Page 308: Valves and Valve Springs

    Valves and valve springs 5-35 2. Lubricate: • valve stem “1” • valve stem seal “2” (with the recommended lubricant) • valve stem end (with the recommended lubricant) 3. Install: • valve spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • valve spring retainer “5” (into the cylinde...

  • Page 309: Valves and Valve Springs

    Valves and valve springs 5-36 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 (with the recommended lubricant) • valve lifter (with the ...

  • Page 310: Generator and Starter Clutch

    Generator and starter clutch 5-37 eas24480 generator and starter clutch removing the stator coil order job/parts to remove q’ty remarks front exhaust pipes refer to “engine removal” on page 5-1. Fuel tank protector refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page ...

  • Page 311: Generator and Starter Clutch

    Generator and starter clutch 5-38 10 crankshaft position sensor/stator assembly lead holder 1 1 11 crankshaft position sensor 1 12 stator coil 1 for installation, reverse the removal proce- dure. Removing the stator coil order job/parts to remove q’ty remarks lt lt new lt new new new new 10 nm (1.0 ...

  • Page 312: Generator and Starter Clutch

    Generator and starter clutch 5-39 removing the generator rotor and starter clutch order job/parts to remove q’ty remarks 1 generator rotor 1 2 washer 1 3 starter clutch 1 4 woodruff key 1 5 starter clutch gear 1 6 starter idle gear shaft 1 7 starter idle gear 1 8 starter clutch idle gear shaft 1 9 s...

  • Page 313: Generator and Starter Clutch

    Generator and starter clutch 5-40 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer • starter clutch bolts “2” tip • while holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt and starter clutch bolts. • do not allow the sheave hold...

  • Page 314: Generator and Starter Clutch

    Generator and starter clutch 5-41 4. Check: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the starter clutch gear “1” and starter clutch onto the generator rotor “2” and hold the generator rotor. B. When turning the starter clutch gear clock- wise “a”, the s...

  • Page 315: Generator and Starter Clutch

    Generator and starter clutch 5-42 3. Apply: • sealant (onto the crankshaft position sensor/stator assembly lead grommet) 4. Install: • stator coil • crankshaft position sensor • crankshaft position sensor/stator assembly lead holder 1 tip • route the crankshaft position sensor lead “1” to the inside...

  • Page 316: Generator and Starter Clutch

    Generator and starter clutch 5-43 a 1.

  • Page 317: Electric Starter

    Electric starter 5-44 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks front exhaust pipes refer to “engine removal” on page 5-1. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure. 1 2 ls new 20 ...

  • Page 318: Electric Starter

    Electric starter 5-45 disassembling the starter motor order job/parts to remove q’ty remarks 1 circlip 1 2 pinion gear 1 3 starter motor front cover 1 4 bearing 1 5 oil seal 1 6 circlip 1 7 starter motor rear cover 1 8 brush seat (along with brushes) 1 9 brush spring 4 10 brush 2 11 bearing 1 12 o-r...

  • Page 319: Electric Starter

    Electric starter 5-46 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 320: Electric Starter

    Electric starter 5-47 7. Check: • pinion gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” tip align the projection “a” on the starter motor rear cover with the slo...

  • Page 321: Clutch

    Clutch 5-48 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. 1 clutch cover 1 2 clutch cover gasket 1 3 dowel pin 2 4 clutch cover damper plate 1 5 clutch cover damper 1 for installation, reverse the r...

  • Page 322: Clutch

    Clutch 5-49 removing the clutch order job/parts to remove q’ty remarks clutch release cylinder refer to “removing the clutch re- lease cylinder” on page 5-62. 1 clutch spring plate retainer 1 2 clutch spring plate 1 3 clutch spring plate seat 1 4 pressure plate 1 5 short clutch push rod 1 6 ball 1 7...

  • Page 323: Clutch

    Clutch 5-50 17 thrust washer 1 18 clutch housing 1 19 collar 1 20 bearing 1 21 circlip 1 22 oil pump drive gear 1 23 dowel pin 3 24 thrust washer 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks new ls e e e e e e lt 24 19 20 21 22 23 23...

  • Page 324: Clutch

    Clutch 5-51 removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-13. 1 left rearview mirror 1 2 clutch master cylinder reservoir cap 1 3 clutch master cylinder reservoir diaphragm holder 1 4 clutch ma...

  • Page 325: Clutch

    Clutch 5-52 13 clutch master cylinder 1 for installation, reverse the removal proce- dure. Removing the clutch master cylinder order job/parts to remove q’ty remarks 30 nm (3.0 m • kgf, 22 ft • ibf) t.R. 14 nm (1.4 m • kgf, 10 ft • ibf) t.R. S s 10 9 11 8 6 7 12 1 5 13 2 3 4 new.

  • Page 326: Clutch

    Clutch 5-53 disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 clutch master cylinder kit 1 3 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 3 2 1 new s.

  • Page 327: Clutch

    Clutch 5-54 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-13. Generator cover refer to “generator and starter clutch” on page 5-37. 1 clutch hose union bolt 1 2 clutch hose gasket 2 3 clutch h...

  • Page 328: Clutch

    Clutch 5-55 disassembling the clutch release cylinder order job/parts to remove q’ty remarks 1 boot 1 2 clutch release cylinder piston 1 3 clutch release cylinder spring 1 4 clutch release cylinder piston seal 1 5 bleed screw 1 for assembly, reverse the disassembling procedure. S 5 3 4 2 1 new new s...

  • Page 329: Clutch

    Clutch 5-56 eas25070 removing the clutch 1. Remove: • clutch cover “1” 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: • clutch spring plate retainer “1” • clutch spring plate “2” • clutch sprin...

  • Page 330: Clutch

    Clutch 5-57 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 331: Clutch

    Clutch 5-58 eas25130 checking the clutch spring plate 1. Check: • clutch spring plate damage → replace. 2. Check: • clutch spring plate seat damage → replace. 3. Measure: • clutch spring free height out of specification → replace the clutch spring plate. Eas25150 checking the clutch housing 1. Check...

  • Page 332: Clutch

    Clutch 5-59 eas25260 installing the clutch 1. Install: • clutch boss plate “1” • clutch boss “2” tip assemble the clutch boss and clutch boss plate so that the rivets “a” in the clutch boss are aligned with the notches “b” in the clutch boss plate. 2. Install: • clutch boss “1” • springs • clutch bo...

  • Page 333: Clutch

    Clutch 5-60 6. Install: • clutch cover damper “1” • clutch cover damper plate “2” tip align the arrow mark “a” on the clutch cover 3 with the arrow mark “b” on the clutch cover damper and the arrow mark “c” on the clutch cover damper plate. 7. Install: • clutch cover “1” tip tighten the clutch cover...

  • Page 334: Clutch

    Clutch 5-61 eas25290 checking the clutch master cylinder 1. Check: • clutch master cylinder body cracks/damage → replace. • clutch fluid delivery passage (clutch master cylinder body) obstruction → blow out with compressed air. 2. Check: • clutch master cylinder kit rust/scratches/wear → replace. 3....

  • Page 335: Clutch

    Clutch 5-62 3. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) warning ewa13370 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the...

  • Page 336: Clutch

    Clutch 5-63 1. Check: • clutch release cylinder body cracks/damage → replace the clutch re- lease cylinder. 2. Check: • clutch release cylinder • clutch release cylinder piston rust/scratches/wear → replace the clutch release cylinder and clutch release cylinder piston as a set. Eas25340 assembling ...

  • Page 337: Clutch

    Clutch 5-64 4. Bleed: • clutch system refer to “bleeding the hydraulic clutch system” on page 3-13. 5. Check: • clutch fluid level below the minimum level mark “a” → add the recommended clutch fluid to the proper level. Refer to “checking the clutch fluid level” on page 3-13. 6. Check: • clutch leve...

  • Page 338: Shift Shaft

    Shift shaft 5-65 eas25410 shift shaft removing the shift arm and shift shaft order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-48. Crankcase cover refer to “water pump” on page 6-11. 1 shift rod 1 tip the shift rod locknut (shift pedal side) has left-hand threads. 2 s...

  • Page 339: Shift Shaft

    Shift shaft 5-66 13 bearing 2 for installation, reverse the removal proce- dure. Removing the shift arm and shift shaft order job/parts to remove q’ty remarks 1 ls new new e 2 3 4 12 13 5 10 9 7 8 6 13 11 lt lt e e 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 7 nm (0...

  • Page 340: Shift Shaft

    Shift shaft 5-67 eas25420 checking the shift shaft 1. Check: • shift shaft • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • stopper lever spring damage/wear → replace....

  • Page 341: Oil Pump

    Oil pump 5-68 eas24921 oil pump removing the oil pan and oil pump assembly order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Front exhaust pipes refer to “engine removal” on page 5-1. Sidestand refer to “engine removal” on page 5-1. Clutch hous...

  • Page 342: Oil Pump

    Oil pump 5-69 10 relief valve assembly 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump assembly order job/parts to remove q’ty remarks ls lt (10) 10 fwd 4 6 2 1 3 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, ...

  • Page 343: Oil Pump

    Oil pump 5-70 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 2 oil pump inner rotor 1 3 oil pump outer rotor 1 4 pin 1 5 washer 1 6 oil pump driven gear 1 7 oil pump housing 1 for assembly, reverse the disassembly pro- cedure. 2 4 1 5 6 7 3 ls.

  • Page 344: Oil Pump

    Oil pump 5-71 eas24930 removing the oil pan 1. Remove: • oil level switch lead holder • oil pan • 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 the oil pump 1. Check: • o...

  • Page 345: Oil Pump

    Oil pump 5-72 eas2s31038 checking the oil pipe 2 1. Check: • oil pipe 2 damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas25010 assembling the oil pump 1. Lubric...

  • Page 346: Crankcase

    Crankcase 5-73 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 heads” on page 5-26. Starter clutch refer to “generator and starter clutch” on page 5-37. Clutch housing refer to “clutch” ...

  • Page 347: Crankcase

    Crankcase 5-74 9 middle drive pinion gear bearing retainer 1 10 middle drive pinion gear shim refer to “aligning the middle gear” on page 5-114. 11 lower crankcase 1 12 dowel pin 3 13 timing chain guide assembly bracket 1 14 dowel pin 2 15 timing chain guide assembly 1 for installation, reverse the ...

  • Page 348: Crankcase

    Crankcase 5-75 removing the plate, oil pipe 3, and damper order job/parts to remove q’ty remarks connecting rod/piston refer to “connecting rods and pis- tons” on page 5-81. Crankshaft/balancer shaft refer to “crankshaft and balancer” on page 5-92. Transmission refer to “transmission” on page 5-98. ...

  • Page 349: Crankcase

    Crankcase 5-76 eas25550 disassembling the crankcase 1. Remove: • crankcase bolts • washers 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 numerical order (refer to the n...

  • Page 350: Crankcase

    Crankcase 5-77 eas2s31040 checking the timing chain guide assembly 1. Check: • timing chain guide assembly damage/wear → replace. Eas2s31096 checking the oil nozzles the following procedure applies to all of the oil nozzles. 1. Check: • oil nozzle damage/wear → replace the oil nozzle. • oil passage ...

  • Page 351: Crankcase

    Crankcase 5-78 tip • lubricate the washers with engine oil. • lubricate the bolts “1”–“8” thread and washers with engine oil. • lubricate the bolts “9”–“42” thread part and mating surface with engine oil. • finger tighten the crankcase bolts. • m10 × 150 mm bolts: “1” – “8” • m8 × 90 mm bolts: “9”, ...

  • Page 352: Crankcase

    Crankcase 5-79 warning ewa2s31013 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. Notice eca2s31043 • do not use a torque wrench to tighten the bolt to the specified an...

  • Page 353: Crankcase

    Crankcase 5-80 9. Install: • middle drive pinion gear bearing retainer “1” tip install the middle drive pinion gear bearing re- tainer with its arrow mark “a” facing up. 10.Install: • main axle bearing retainer “1” tip install the main axle bearing retainer with its “out” mark “a” facing outward. A....

  • Page 354: Connecting Rods and Pistons

    Connecting rods and pistons 5-81 eas2s31041 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-73. Balancer shaft refer to “crankshaft and balancer” on page 5-92. 1 oil nozzle 4 2 connecting r...

  • Page 355: Connecting Rods and Pistons

    Connecting rods and pistons 5-82 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” tip identify the position of each connecting rod cap so that it can be reinstalled in its original place...

  • Page 356: Connecting Rods and Pistons

    Connecting rods and pistons 5-83 1. Check: • piston wall • cylinder wall vertical scratches → replace the upper crankcase, and replace the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “c” with ...

  • Page 357: Connecting Rods and Pistons

    Connecting rods and pistons 5-84 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 oi...

  • Page 358: Connecting Rods and Pistons

    Connecting rods and pistons 5-85 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas2s31042 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bea...

  • Page 359: Connecting Rods and Pistons

    Connecting rods and pistons 5-86 notice eca2s31044 tighten the connecting rod bolts using the plastic-region tightening angle method. Al- ways install new bolts. F. Clean the connecting rod bolts. G. After installing the big end bearing, assemble the connecting rod and connecting rod cap without ins...

  • Page 360: Connecting Rods and Pistons

    Connecting rods and pistons 5-87 warning ewa2s31038 • when a 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 per- form the procedure again. • if the connecting rod and cap are not flush with each other, remove the con...

  • Page 361: Connecting Rods and Pistons

    Connecting rods and pistons 5-88 for example, if the connecting rod “p 1 ” and the crankshaft web “p 1 ” numbers are “4” and “1” respectively, then the bearing size for “p 1 ” is: eas26170 installing the connecting rods and pistons the following procedure applies to all of the con- necting rods and ...

  • Page 362: Connecting Rods and Pistons

    Connecting rods and pistons 5-89 tip be sure to install the piston rings so that the manufacturer marks face up. 4. Install: • piston “1” (onto its respective connecting rod “2”) • piston pin “3” • piston pin clips “4” tip • apply engine oil onto the piston pin. • make sure that the “y” mark “a” on ...

  • Page 363: Connecting Rods and Pistons

    Connecting rods and pistons 5-90 9. Install: • connecting rod assembly (into the cylinder and onto the crankshaft pin) tip • while compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. • make sure the “y” mark “a” on the #1 and #3 conn...

  • Page 364: Connecting Rods and Pistons

    Connecting rods and pistons 5-91 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a.

  • Page 365: Crankshaft and Balancer

    Crankshaft and balancer 5-92 eas25950 crankshaft and balancer removing the crankshaft and balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-73. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-81. 1 balancer shaft 1 2 balancer sh...

  • Page 366: Crankshaft and Balancer

    Crankshaft and balancer 5-93 eas2s31094 removing the balancer shaft journal bearings 1. Remove: • balancer shaft journal upper bearings (from the upper crankcase) • balancer shaft journal lower bearings (from the lower crankcase) tip identify the position of each balancer shaft jour- nal bearing so ...

  • Page 367: Crankshaft and Balancer

    Crankshaft and balancer 5-94 tip do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bearings “3” into the lower crankcase and assemble the crankcase halves. Tip • align the projections “d” of the crankshaft jour- nal lower bearings with t...

  • Page 368: Crankshaft and Balancer

    Crankshaft and balancer 5-95 for example, if the lower crankcase j 1 and crankshaft web j 1 numbers are 5 and 1 re- spectively, then the bearing size for j 1 is: eas26120 checking the balancer 1. Check: • balancer shaft cracks/damage/wear → replace the balanc- er shaft and bearings. Dirt → clean. • ...

  • Page 369: Crankshaft and Balancer

    Crankshaft and balancer 5-96 f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. Refer to “crankcase” on page 5-73. G. Remove the lower crankcase and the balanc- er shaft journal lower bearings. H. Measure the compressed plastigauge® width “g” on each balancer s...

  • Page 370: Crankshaft and Balancer

    Crankshaft and balancer 5-97 tip • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • be sure to install each crankshaft journal bear- ing in its original place. 2. Install: • timing chains “1” (onto the crankshaft sprocket) • crankshaft “2” t...

  • Page 371: Transmission

    Transmission 5-98 eas26241 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-73. 1 drive axle/middle drive pinion gear assembly 1 2 main axle assembly 1 3 shift drum retainer 2 4 long...

  • Page 372: Transmission

    Transmission 5-99 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 bearing 1 2 circlip 1 3 2nd pinion gear 1 4 toothed lock washer 1 5 toothed lock washer retainer 1 6 5th pinion gear 1 7 toothed spacer 1 8 toothed washer 1 9 circlip 1 10 3rd pinion gear 1 11 circlip 1 1...

  • Page 373: Transmission

    Transmission 5-100 disassembling the drive axle/middle drive pinion gear assembly order job/parts to remove q’ty remarks middle drive pinion gear assembly refer to “middle gear” on page 5-105. 1 bearing 1 2 washer 1 3 1st wheel gear 1 4 collar 1 5 4th wheel gear 1 6 circlip 1 7 toothed washer 1 8 3r...

  • Page 374: Transmission

    Transmission 5-101 17 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle/middle drive pinion gear assembly order job/parts to remove q’ty remarks 2 4 5 1 3 6 7 8 17 10 9 11 12 13 14 15 16 e new new m m m m m m m m.

  • Page 375: Transmission

    Transmission 5-102 eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • shift fork pawl “2” bends/damage/scoring/wear → replace the shift fork. 2. Check: • shift fork guide bar roll the shift fork guide bar on a flat s...

  • Page 376: Transmission

    Transmission 5-103 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect ...

  • Page 377: Transmission

    Transmission 5-104 eas26350 installing the transmission 1. Install: • shift drum assembly • shift fork-l • shift fork-r • short shift fork guide bar • shift fork-c • long shift fork guide bar tip the embossed marks on the shift forks should face towards the right side of the engine and be in the fol...

  • Page 378: Middle Gear

    Middle gear 5-105 eas25711 middle gear removing the middle driven pinion gear order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. 1 circlip 4 2 bearing 4 3 universal joint (middle gear side) 1 4 middle driven pinion gear assembly 1 5 middle driven pinion gear shim re...

  • Page 379: Middle Gear

    Middle gear 5-106 15 bearing race 2 16 middle driven pinion gear bearing housing 1 for installation, reverse the removal proce- dure. Removing the middle driven pinion gear order job/parts to remove q’ty remarks ls ls ls ls 5 3 5 9 7 8 6 1 4 2 2 2 12 15 11 10 16 14 13 15 new new new new ls ls lt 30 ...

  • Page 380: Middle Gear

    Middle gear 5-107 removing the middle drive pinion gear order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-73. 1 middle drive pinion gear bearing retainer 1 2 middle drive pinion gear shim refer to “aligning the middle gear” on page 5-114. 3 drive axle/middle d...

  • Page 381: Middle Gear

    Middle gear 5-108 14 middle drive pinion gear bearing housing 1 for installation, reverse the removal proce- dure. Removing the middle drive pinion gear order job/parts to remove q’ty remarks (4) 2 8 2 4 5 1 11 13 14 3 7 12 6 9 10 m e new e e lt m 24 nm (2.4 m • kgf, 17 ft • ibf) t.R. 110 nm (11.0 m...

  • Page 382: Middle Gear

    Middle gear 5-109 eas2s31047 removing the middle driven pinion gear assembly 1. Remove: • universal joint (middle gear side) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the circlips “1”. B. Place the universal joint in a press. C. With a pipe “2” of the proper diameter posi- tioned b...

  • Page 383: Middle Gear

    Middle gear 5-110 tip wrap the middle drive pinion gear in a folded rag, and then secure it in a vise. C. Loosen the middle drive pinion gear nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas2s31052 checking the middle driven pinion gear assembly 1. Check: • middle driven pinion gear gallin...

  • Page 384: Middle Gear

    Middle gear 5-111 tip while compressing the spring with the damper spring compressor “2”, install the washer and spring retainers. Eas2s31055 assembling the middle driven pinion gear assembly 1. Install: • oil seal “1” (to the middle driven pinion gear bearing housing) 2. Install: • washer “1” tip i...

  • Page 385: Middle Gear

    Middle gear 5-112 b. Remove the universal joint holder, and then turn the nut with a torque wrench to check the starting torque. C. Out of specification → tighten the nut further. D. Repeat steps (a) to (c) until the starting torque is within specification. Tip • be careful not to exceed the specifi...

  • Page 386: Middle Gear

    Middle gear 5-113 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • universal joint operation rough operation → replace the universal joint or bearing. Tip lift the universal joint “1” and make sure that it falls freely when released. Eas25880 measuring the middle gear backlash 1. Remove...

  • Page 387: Middle Gear

    Middle gear 5-114 tip • tighten the middle driven pinion gear bearing housing bolts carefully, one thread turn at a time only. Push in the middle driven pinion gear bearing housing and then tighten the bolts to specification. • clearance between the crankcase and the middle driven pinion gear bearin...

  • Page 388: Middle Gear

    Middle gear 5-115 tip select the middle driven pinion gear shim(s) “2” by calculating the middle drive pinion gear shim thickness and then measuring the middle gear backlash. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the middle gears with the appropri- ate shim(s) that has had it...

  • Page 389: Middle Gear

    Middle gear 5-116 “e”= a numeral on the middle driven pinion gear, to be divided by 100 and either added to or subtracted from “12.00” “f”= a numeral on the middle driven pinion gear, to be divided by 100 and either added to or subtracted from “62.00” “g”= a numeral on the upper crankcase, to be div...

  • Page 390: Middle Gear

    Middle gear 5-117.

  • Page 391: Cooling System

    6 cooling system radiators .................................................................................................... 6-1 checking the radiators ................................................................. 6-4 installing the radiator assembly .............................................

  • Page 392: Radiators

    Radiators 6-1 eas2s31078 radiators removing the radiator assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-19. Throttle bodies refer to “throttle bodies” on page 7-11. Front exhaust pipes refer to “engine removal” on page 5-1. 1 radiator cap 1 2...

  • Page 393: Radiators

    Radiators 6-2 12 thermostat outlet hose 1 13 oil cooler outlet hose 1 14 lower radiator outlet hose 1 15 radiator fan motor sub-wire harness coupler 1 disconnect. 16 right lower radiator bracket 1 17 left lower radiator bracket 1 18 radiator assembly 1 19 upper radiator bracket 1 20 upper/lower radi...

  • Page 394: Radiators

    Radiators 6-3 disassembling the radiators order job/parts to remove q’ty remarks 1 upper radiator side panel 2 2 sub radiator fan motor coupler 1 disconnect. 3 upper radiator cover 1 4 sub radiator fan 1 5 upper radiator 1 6 left lower radiator inlet hose 1 7 right lower radiator inlet hose 1 8 lowe...

  • Page 395: Radiators

    Radiators 6-4 eas26390 checking the radiators 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage...

  • Page 396: Oil Cooler

    Oil cooler 6-5 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Coolant drain. Refer to “changing the coolant” on page 3-19. Radiator assembly refer to “radiators” on page 6-1. 1 oil cooler outlet ho...

  • Page 397: Oil Cooler

    Oil cooler 6-6 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose • oil cooler adapter cracks/damage/wear → replace. Eas26430 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the oil c...

  • Page 398: Thermostat

    Thermostat 6-7 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-19. Throttle bodies refer to “throttle bodies” on page 7-11. Brake hose holder refer to “abs (anti-lock brake sys- tem)” on page 4-55. 1...

  • Page 399: Thermostat

    Thermostat 6-8 11 battery box bracket 1 12 thermostat inlet pipe (rear cylinders) 1 13 thermostat housing 1 14 thermostat housing bracket 1 for installation, reverse the removal proce- dure. Removing the thermostat assembly order job/parts to remove q’ty remarks 11 12 10 6 13 4 2 5 1 3 14 9 8 7 10 n...

  • Page 400: Thermostat

    Thermostat 6-9 eas26450 checking the thermostat 1. Check: • thermostat “1” does not open at 69–73 °c (156.2–163.4 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer ...

  • Page 401: Thermostat

    Thermostat 6-10 4. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-19. 5. Check: • cooling system leaks → repair or replace any faulty part. 6. Measure: • radiator cap opening pressure below the specified pressure → replace th...

  • Page 402: Water Pump

    Water pump 6-11 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Coolant drain. Refer to “changing the coolant” on page 3-19. Clutch cover refer to “clutch” on page 5-48. 1 water pump outlet pipe 1 2...

  • Page 403: Water Pump

    Water pump 6-12 11 water pump driven gear 1 12 gear stopper pin 1 13 washer 1 14 impeller shaft 1 15 water pump seal 1 16 bearing 1 17 oil seal 1 for installation, reverse the removal proce- dure. Removing the water pump order job/parts to remove q’ty remarks lt lt 3 (6) (15) 14 15 17 16 5 7 6 6 4 1...

  • Page 404: Water Pump

    Water pump 6-13 eas26510 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the crankcase cover “2”. 2. Remove: • bearing “1” • oil seal “2” tip remove the bearing and oil seal from the out- side of the crankcase cover “3”. Eas26540 checki...

  • Page 405: Water Pump

    Water pump 6-14 3. Install: • impeller “1” • washer • water pump driven gear • circlip tip after installation, check that the impeller shaft ro- tates smoothly. Eas26590 installing the water pump 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing th...

  • Page 406: Water Pump

    Water pump 6-15.

  • Page 407: Fuel System

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

  • Page 408: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks mudguard 2 refer to “general chassis” on page 4-1. 1 fuel tank breather hose (fuel tank to rollover valve) 1 2 rollover valve 1 3 fuel tank breather hose (rollover valve to canis- ter) 1 for california onl...

  • Page 409: Fuel Tank

    Fuel tank 7-2 13 brake fluid reservoir 1 14 exup servo motor assembly 1 15 rear frame 1 16 fuel tank bracket 1 17 fuel tank 1 18 fuel tank cap 1 19 filler neck 1 20 fuel pump 1 21 fuel tank protector 1 for installation, reverse the removal proce- dure. Removing the fuel tank order job/parts to remov...

  • Page 410: Fuel Tank

    Fuel tank 7-3 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Disconnect: • fuel pump coupler • fuel hose warning ewa2s31026 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could ca...

  • Page 411: Fuel Tank

    Fuel tank 7-4 • align the projection “b” on the fuel tank with the slot in the fuel pump bracket. • tighten the fuel pump nuts in the proper tight- ening sequence as shown. Eas2s31081 installing the filler neck 1. Install: • filler neck gasket • filler neck • fuel tank breather hose holder • filler ...

  • Page 412: Fuel Tank

    Fuel tank 7-5 c. Connect the pressure gauge “2” and adapter “3” to the fuel hose “1”. D. Start the engine. E. Measure the fuel pressure. Faulty → replace the fuel pump. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pressure gauge 90890-03153 yu-03153 fuel pressure adapter 90890-03176 ym-03176 fu...

  • Page 413: Air Filter Case

    Air filter case 7-6 eas2s31001 air filter case removing the air filter case and intake funnels order job/parts to remove q’ty remarks intake duct assemblies/battery box refer to “general chassis” on page 4-1. 1 air filter case cover 1 2 air filter element 1 3 intake funnel servo motor coupler 1 disc...

  • Page 414: Air Filter Case

    Air filter case 7-7 15 variable intake funnel lever shaft 1 16 bushing 2 1 for installation, reverse the removal proce- dure. Removing the air filter case and intake funnels order job/parts to remove q’ty remarks 3.5 nm (0.35 m • kgf, 2.5 ft • ibf) t.R. 2 (8) (10) 1 6 11 (3) 12 9 3 12 6 nm (0.6 m • ...

  • Page 415: Air Filter Case

    Air filter case 7-8 eas2s31005 checking the intake funnels 1. Check: • intake funnel servo motor operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply current to the intake funnel servo motor and check that the variable intake funnel seals mates with the fixed intake funnels (il- lust...

  • Page 416: Air Filter Case

    Air filter case 7-9 eas2s31007 installing the air filter case and intake funnels 1. Install: • variable intake funnel lever shaft tip • to install the variable intake funnel lever shaft into the lower air filter case, slide the bushing 1 “1” in the direction of the arrow. • face the cutout “a” in bu...

  • Page 417: Air Filter Case

    Air filter case 7-10 5. Install: • upper air filter case tip tighten the upper air filter case screws in proper sequence as shown. T r . . Upper air filter case screw 2.5 nm (0.25 m·kgf, 1.8 ft·lbf) 1 1 1 1 1 1 1 1 1 1 2.

  • Page 418: Throttle Bodies

    Throttle bodies 7-11 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks lower air filter case refer to “air filter case” on page 7-6. 1 accelerator position sensor coupler 1 disconnect. 2 throttle position sensor coupler 1 disconnect. 3 throttle servo motor ...

  • Page 419: Throttle Bodies

    Throttle bodies 7-12 14 throttle body joint cover 2 for installation, reverse the removal proce- dure. Removing the throttle bodies order job/parts to remove q’ty remarks 1 8 10 11 12 3 4 5 7 6 14 13 13 2 9 9 9 13 13 9 (8) 14 3 nm (0.3 m • kgf, 2.2 ft • ibf) t.R. 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R...

  • Page 420: Throttle Bodies

    Throttle bodies 7-13 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor 1 2 accelerator position sensor 1 3 intake air pressure sensor 1 4 cylinder-#2 injector coupler 1 disconnect. 5 cylinder-#1 injector coupler 1 disconnect. 6 cylinder-#4 injector coupler 1 di...

  • Page 421: Throttle Bodies

    Throttle bodies 7-14 eas26980 checking the 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 rem...

  • Page 422: Throttle Bodies

    Throttle bodies 7-15 pressure drops → properly install or replace the injector ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas2s31095 checking and cleaning the throttle bodies tip clean the throttle bodies only if they cannot be synchronized using the bypass air screws. Be- fore cleaning the t...

  • Page 423: Throttle Bodies

    Throttle bodies 7-16 warning ewa2s31034 when cleaning the throttle bodies, be careful not to injure yourself on the throttle valves or other components of the throttle bodies. Notice eca2s31074 do not open the throttle valves by supplying electrical power to the throttle bodies. D. Apply a petroleum...

  • Page 424: Throttle Bodies

    Throttle bodies 7-17 2. Adjust: • throttle position sensor angle ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporary tighten the throttle position sen- sor. B. Check that the throttle valves are fully closed. C. Connect the throttle position sensor, acceler- ator position sensor and throt...

  • Page 425: Throttle Bodies

    Throttle bodies 7-18 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1.

  • Page 426: Air Induction System

    Air induction system 7-19 eas27040 air induction system a a 6 5 4 5 6 1 4 3 3 2 1 a b c d.

  • Page 427: Air Induction System

    Air induction system 7-20 1. Air induction system hose (air cut-off valve to rear reed valve cover) 2. Air induction system hose (air filter case to air chamber) 3. Air chamber 4. Air induction system hose (air chamber to air cut-off valve) 5. Air cut-off valve 6. Air induction system hose (air cut-...

  • Page 428: Air Induction System

    Air induction system 7-21 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks lower air filter case refer to “air filter case” on page 7-6. 1 air induction system hose (air filter case to air chamber) 1 2 air chamber 1 3 air induction system hose (air filter case...

  • Page 429: Air Induction System

    Air induction system 7-22 removing the reed valves order job/parts to remove q’ty remarks cylinder head covers refer to “camshafts” on page 5-9. 1 reed valve cover 2 2 reed valve assembly 4 3 reed valve plate 4 for installation, reverse the removal proce- dure. 1 (3) 2 3 lt 1 (3) 2 3 lt fwd 10 nm (1...

  • Page 430: Air Induction System

    Air induction system 7-23 eas27060 checking the air induction system air induction 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 431: Electrical System

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

  • Page 432

    Abs (anti-lock brake system) ........................................................... 8-73 circuit diagram ................................................................................ 8-73 abs components chart ................................................................. 8-75 abs coupler ...

  • Page 434: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / w r...

  • Page 435: Ignition System

    Ignition system 8-2 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 14.Relay unit 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle sensor 30.Ecu (engine control unit) 32.Cylinder-#1 ignition coil 33.Cylinder-#2 ignition coil 34.Cylinder-#3 ignition coil 35.Cylinder-#4 ignition ...

  • Page 436: Ignition System

    Ignition system 8-3 eas2s31057 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the gear position...

  • Page 437: Ignition System

    Ignition system 8-4 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check th...

  • Page 438: Ignition System

    Ignition system 8-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 9. Check the gear position switch. Refer to “checking the switches” on page 8-121. Replace the gear position switch. 10.Check the sidestand switch. Refer to “checking the switches” on page 8-121. Replace the sidestand switch. 11.C...

  • Page 439: Ignition System

    Ignition system 8-6.

  • Page 440: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b ...

  • Page 441: Electric Starting System

    Electric starting system 8-8 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 19.Sidestand switch 63.Gear position switch 68.Clutch switch 83.Engine stop switch 84.Start switch 89.Ignition fuse.

  • Page 442: Electric Starting System

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

  • Page 443: Electric Starting System

    Electric starting system 8-10 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and ignition)...

  • Page 444: Electric Starting System

    Electric starting system 8-11 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 9. Check the engine stop switch. Refer to “checking the switches” on page 8-121. Replace the right handlebar switch. 10.Check the gear position switch. Refer to “checking the switches” on page 8-121. Replace th...

  • Page 445: Electric Starting System

    Electric starting system 8-12.

  • Page 446: Charging System

    Charging system 8-13 eas27200 charging system eas27210 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / w ...

  • Page 447: Charging System

    Charging system 8-14 1. Ac magneto 2. Rectifier/regulator 6. Main fuse 8. Battery 9. Frame ground.

  • Page 448: Charging System

    Charging system 8-15 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Passenger seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page 8-125. Replac...

  • Page 449: Charging System

    Charging system 8-16.

  • Page 450: Lighting System

    Lighting system 8-17 eas27240 lighting system eas27250 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / w ...

  • Page 451: Lighting System

    Lighting system 8-18 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 30.Ecu (engine control unit) 53.Multi-function meter 58.Meter light 61.High beam indicator light 66.Headlight relay 69.Dimmer switch 76.Front right turn signal/position light 77.Front left turn signal/position light 79.Auxil...

  • Page 452: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, auxiliary light, position light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Rear...

  • Page 453: Lighting System

    Lighting system 8-20 ng → ok ↓ 7. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-17. Properly connect or repair the lighting sys- tem wiring. Replace the ecu or meter assembly 1..

  • Page 454: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / ...

  • Page 455: Signaling System

    Signaling system 8-22 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 10.Backup fuse (odometer and clock) 14.Relay unit 18.Fuel sender 26.Coolant temperature sensor 30.Ecu (engine control unit) 44.Rear wheel sensor 47.Abs ecu (electronic control unit) 50.Neutral indicator light 52.Shift timin...

  • Page 456: Signaling System

    Signaling system 8-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. • the shift indicator fails to come on. • the fuel meter fails to come on. • the coolant temperature meter fails to come on. • the spe...

  • Page 457: Signaling System

    Signaling system 8-24 ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Check the horn. Refer to “checking the horn” on page 8-134. Replace the horn. 3. C...

  • Page 458: Signaling System

    Signaling system 8-25 ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the shift indicator fails to come on. Ng → ok ↓ 4. Check the turn signal/hazard relay. Refer to “checking the turn signal/hazard relay” on page 8-130. Replace the turn signal/hazard ...

  • Page 459: Signaling System

    Signaling system 8-26 ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter, fuel level warning light, or both fail to come on. Ng → ok ↓ ng → ok ↓ the coolant temperature meter, coolant temperature warning light, or both fail to come on. Ng → ok ↓ 2. Check the e...

  • Page 460: Signaling System

    Signaling system 8-27 ng → ok ↓ the shift timing indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ tip repair or replace if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white–white) (black–black...

  • Page 461: Signaling System

    Signaling system 8-28.

  • Page 462: Cooling System

    Cooling system 8-29 eas27300 cooling system eas27310 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / w r ...

  • Page 463: Cooling System

    Cooling system 8-30 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 26.Coolant temperature sensor 30.Ecu (engine control unit) 89.Ignition fuse 92.Radiator fan motor relay 93.Main radiator fan motor fuse 94.Main radiator fan motor 95.Sub radiator fan motor fuse 96.Sub radiator fan motor.

  • Page 464: Cooling System

    Cooling system 8-31 eas27320 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Rear fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, ma...

  • Page 465: Cooling System

    Cooling system 8-32.

  • Page 466: Fuel Injection System

    Fuel injection system 8-33 eas27330 fuel injection system eas27340 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch...

  • Page 467: Fuel Injection System

    Fuel injection system 8-34 3. Fuel injection system fuse 5. Electric throttle valve fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 12.Starter relay 14.Relay unit 15.Starting circuit cut-off relay 16.Fuel pump relay 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Atmosp...

  • Page 468: Fuel Injection System

    Fuel injection system 8-35 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 469: Fuel Injection System

    Fuel injection system 8-36 ecu detects an abnormal signal from a sensor if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for...

  • Page 470: Fuel Injection System

    Fuel injection system 8-37 the engine operation is not normal but the engine trouble warning light does not come on. 1. Check the operation of following sensors and actuators in the diagnostic mode. Refer to “sensor operation table” and “actuator oper- ation table”. If a malfunction is detected in t...

  • Page 471: Fuel Injection System

    Fuel injection system 8-38 • to increase the selected diagnostic code number, press the “select” button. Press the “select” button for 1 second or longer to automatically increase the diagnostic code numbers. 6. Verify the operation of the sensor or actuator. • sensor operation the data representing...

  • Page 472: Fuel Injection System

    Fuel injection system 8-39 d:07 vehicle speed pulse 0–999 check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. D:08 lean angle sensor remove the lean angle sensor and incline it more than 65 degrees. • upright...

  • Page 473: Fuel Injection System

    Fuel injection system 8-40 d:60 eeprom fault code dis- play — • no history 00 • history exists 01–04 (cylinder fault code) • (if more than one cylinder is defective, the display alter- nates every two seconds to show all the detected cylin- der numbers. When all cyl- inder numbers are shown, the dis...

  • Page 474: Fuel Injection System

    Fuel injection system 8-41 actuator operation table d:70 control number 0–254 [-] — diag- nostic code no. Item meter display checking method diag- nostic code no. Item actuation checking method d:30 cylinder-#1 ignition coil actuates the cylinder-#1 igni- tion coil five times at one- second interval...

  • Page 475: Fuel Injection System

    Fuel injection system 8-42 d:39 injector #4 actuates the injector #4 five times at one-second inter- vals. Illuminates the engine trou- ble warning light. Check the operating sound of the injector #4 five times. D:48 air induction system sole- noid actuates the air induction system solenoid five tim...

  • Page 476: Fuel Injection System

    Fuel injection system 8-43 eas27461 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 477: Fuel Injection System

    Fuel injection system 8-44 diagnostic code no. — meter display — checking method — probable cause of malfunction check or maintenance job 1 installed condition of crankshaft position sensor. • check for looseness or pinching. 2 connections • crankshaft position sensor coupler • wire harness ecu coup...

  • Page 478: Fuel Injection System

    Fuel injection system 8-45 3 defective intake air pressure sensor. • execute the diagnostic mode. (code no. D:03) • replace if defective. Refer to “checking the intake air pressure sensor” on page 8-139. Reinstatement method turning the main switch to “on”. Fault code no. 14 item intake air pressure...

  • Page 479: Fuel Injection System

    Fuel injection system 8-46 d:13 meter display throttle position sensor signal 2 • 15–16 (fully closed position) • 97–102 (fully opened position) checking method • check with throttle valve fully closed. • check with throttle valve fully opened. Probable cause of malfunction check or maintenance job ...

  • Page 480: Fuel Injection System

    Fuel injection system 8-47 2 open or short circuit in wire harness. • repair or replace if there is an open or short circuit. • between exup servo motor coupler and ecu coupler. (blue–blue) (white/red–white/red) (black/blue–black/blue) 3 defective exup servo motor (potentiom- eter circuit). • execut...

  • Page 481: Fuel Injection System

    Fuel injection system 8-48 fault code no. 19 item sidestand switch: a break or disconnection of the blue/yellow lead of the ecu is detected. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:20 meter display sidestand switch • on (stand retracted) • off (stand ext...

  • Page 482: Fuel Injection System

    Fuel injection system 8-49 1 defective intake air pressure sensor or atmospheric pressure sensor. • execute the diagnostic mode. (code no. D:03 and/or d:02) • replace if defective. Refer to “checking the intake air pressure sensor” on page 8-139 or “checking the atmospheric pres- sure sensor” on pag...

  • Page 483: Fuel Injection System

    Fuel injection system 8-50 fault code no. 22 item intake air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. D:05 meter display displays the intake air temperature. Checking method compare the actually measured intak...

  • Page 484: Fuel Injection System

    Fuel injection system 8-51 3 open or short circuit in wire harness. • repair or replace if there is an open or short circuit. • between atmospheric pressure sensor coupler and ecu coupler. (blue–blue) (pink–pink) (black/blue–black/blue) 4 defective atmospheric pressure sensor. • execute the diagnost...

  • Page 485: Fuel Injection System

    Fuel injection system 8-52 fault code no. 30 item latch up detected. No normal signal is received from the lean angle sensor. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:08 meter display lean angle sensor • 0.4–1.4 (upright) • 3.8–4.2 (overturned) checking m...

  • Page 486: Fuel Injection System

    Fuel injection system 8-53 2 open or short circuit in wire harness and/or ignition coil sub-wire harness 1. • repair or replace if there is an open or short circuit. • between cylinder-#1 ignition coil coupler and ignition coil sub-wire harness 1 coupler. (black/orange–black/orange) (white–white) • ...

  • Page 487: Fuel Injection System

    Fuel injection system 8-54 2 open or short circuit in wire harness and/or ignition coil sub-wire harness 2. • repair or replace if there is an open or short circuit. • between cylinder-#2 ignition coil coupler and ignition coil sub-wire harness 2 coupler. (black/orange–black/orange) (white–white) • ...

  • Page 488: Fuel Injection System

    Fuel injection system 8-55 2 open or short circuit in wire harness and/or ignition coil sub-wire harness 1. • repair or replace if there is an open or short circuit. • between cylinder-#3 ignition coil coupler and ignition coil sub-wire harness 1 coupler. (black/orange–black/orange) (black–black) • ...

  • Page 489: Fuel Injection System

    Fuel injection system 8-56 2 open or short circuit in wire harness and/or ignition coil sub-wire harness 2. • repair or replace if there is an open or short circuit. • between cylinder-#4 ignition coil coupler and ignition coil sub-wire harness 2 coupler. (black/orange–black/orange) (black–black) • ...

  • Page 490: Fuel Injection System

    Fuel injection system 8-57 2 open or short circuit in wire harness and/or sub-wire harness. • repair or replace if there is an open or short circuit. • between injector coupler and sub-wire har- ness coupler. (red–red) #1: (red/yellow–red/yellow) #2: (green–green) #3: (blue/black–blue/black) #4: (or...

  • Page 491: Fuel Injection System

    Fuel injection system 8-58 probable cause of malfunction check or maintenance job 1 connections • lean angle sensor coupler • wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and con...

  • Page 492: Fuel Injection System

    Fuel injection system 8-59 fault code no. 42 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. A fail-safe system able to start engine able to drive vehicl...

  • Page 493: Fuel Injection System

    Fuel injection system 8-60 fault code no. 42 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. B fail-safe system able to start engine able to drive vehicl...

  • Page 494: Fuel Injection System

    Fuel injection system 8-61 probable cause of malfunction check or maintenance job 1 connections • relay unit coupler • wire harness ecu coupler • right handlebar switch coupler • battery terminal • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. •...

  • Page 495: Fuel Injection System

    Fuel injection system 8-62 fault code no. 46 item power supply to the fuel injection system is not normal. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — checking method — probable cause of malfunction check or maintenance job 1 connections • wire h...

  • Page 496: Fuel Injection System

    Fuel injection system 8-63 probable cause of malfunction check or maintenance job 1 malfunction in ecu. • replace the ecu. Tip do not perform this procedure with the main switch turned to “on”. Reinstatement method turning the main switch to “on”. Fault code no. 59 item accelerator position sensor: ...

  • Page 497: Fuel Injection System

    Fuel injection system 8-64 4 defective accelerator position sensor. • execute the diagnostic mode. (code no. D:14 and/or d:15) • replace if defective. Refer to “checking the accelerator position sensor” on page 8-138. Reinstatement method turning the main switch to “on”. Fault code no. 60 item throt...

  • Page 498: Fuel Injection System

    Fuel injection system 8-65 reinstatement method turning the main switch to “on”. Fault code no. 70 item engine idling stop: engine has been left idling. (the ecu auto- matically stops the engine after 20 minutes if it is left idling.) fail-safe system able to start engine able to drive vehicle diagn...

  • Page 499: Fuel Injection System

    Fuel injection system 8-66 fault code no. Er-2 item ecu internal malfunction (output signal error): no signals are received from the ecu within the specified duration. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — checking method — probable cause o...

  • Page 500: Fuel Injection System

    Fuel injection system 8-67 4 malfunction in ecu. • replace the ecu. Reinstatement method turning the main switch to “on”. Fault code no. Er-4 item ecu internal malfunction (input signal error): non-registered data has been received from the meter. Fail-safe system able to start engine able to drive ...

  • Page 501: Fuel Injection System

    Fuel injection system 8-68.

  • Page 502: Fuel Pump System

    Fuel pump system 8-69 eas27550 fuel pump system eas27560 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) y br / b dg ch br g r / ...

  • Page 503: Fuel Pump System

    Fuel pump system 8-70 3. Fuel injection system fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 14.Relay unit 16.Fuel pump relay 17.Fuel pump 30.Ecu (engine control unit) 83.Engine stop switch 89.Ignition fuse.

  • Page 504: Fuel Pump System

    Fuel pump system 8-71 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and fu...

  • Page 505: Fuel Pump System

    Fuel pump system 8-72.

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

    Abs (anti-lock brake system) 8-73 eas28790 abs (anti-lock brake system) eas27730 circuit diagram w (gray) ww r b sb g b / r g / w wl w g / w b / r g sb l y b g / r sb r / w r / w sb / w g / b b / w y r r r br / l r br l / y1 l / b lr bb y br / b wg y (black) b2 w2 (black) wg y (black) b1 w1 (black) ...

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

    Abs (anti-lock brake system) 8-74 4. Abs solenoid fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 11.Abs motor fuse 12.Starter relay 14.Relay unit 15.Starting circuit cut-off relay 30.Ecu (engine control unit) 44.Rear wheel sensor 45.Front wheel sensor 46.Abs test coupler 47.Abs ecu (ele...

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

    Abs (anti-lock brake system) 8-75 eas27740 abs components chart 1 5 3,4 a 6 7 9 10 11 8 12 13 3,4 a 2 1. Abs ecu fuse 2. Abs test coupler 3. Hydraulic unit assembly 4. Abs solenoid fuse 5. Abs motor fuse 6. Abs warning light 7. Front wheel sensor 8. Front wheel sensor rotor 9. Right front brake cali...

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

    Abs (anti-lock brake system) 8-76.

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

    Abs (anti-lock brake system) 8-77 eas27750 abs coupler location chart b / w b br / r br b w ch l / w w / y lg / w b / l b w g / r lg / l y l / w ch g / y r / l (gray) w gy (black) b w (black) w gy (black) b w (black) r / w sb / w g / b b / w y lg b g / y lg / l lg / w 2 1 3 5 4.

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

    Abs (anti-lock brake system) 8-78 1. Meter assembly 1 coupler 2. Abs ecu coupler 3. Rear wheel sensor coupler 4. Abs test coupler 5. Front wheel sensor coupler.

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

    Abs (anti-lock brake system) 8-79 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 hoses that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler connection ...

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

    Abs (anti-lock brake system) 8-80 tip 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 be heard from under the seat, and if the brake lever or brake pedal are even slightly ap...

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

    Abs (anti-lock brake system) 8-81 eas27810 basic process for troubleshooting [a] turn the main switch to on, and 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 warni...

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

    Abs (anti-lock brake system) 8-82 warning ewa2s31022 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 8-115.) eas27830 [a] checking the abs warning li...

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

    Abs (anti-lock brake system) 8-83 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 517: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-84 • if the battery is defective, clean the battery terminals and recharge it, or replace the battery. 3. Main fuse • check the fuse for continuity. Refer to “checking the fuses” on page 8-125. • if the main fuse is blown, replace the fuse. 4. Circuit • check the meter...

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

    Abs (anti-lock brake system) 8-85 • if the t/c terminal is not short-circuited to the ground, the internal circuit of the meter assembly 1 is defective. Replace the meter assembly 1. Eas2s31074 [c-5] diagnosis using the fault codes connect the test coupler adapter to the abs test coupler, and then t...

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

    Abs (anti-lock brake system) 8-86 abs-22 start switch signal is not received prop- erly (start switch circuit or start switch monitor circuit). • wire harness • connection of the relay unit coupler and abs ecu coupler. Abs-24 brake light signal is not received prop- erly while vehicle is traveling (...

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

    Abs (anti-lock brake system) 8-87 * 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 centerstand). Tip fault codes no....

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

    Abs (anti-lock brake system) 8-88 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 prop- erly. Orde...

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

    Abs (anti-lock brake system) 8-89 fault code no. Abs-12 symptom rear wheel sensor signal is not received proper- ly. 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 w...

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

    Abs (anti-lock brake system) 8-90 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 w...

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

    Abs (anti-lock brake system) 8-91 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 wh...

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

    Abs (anti-lock brake system) 8-92 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 wire...

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

    Abs (anti-lock brake system) 8-93 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 defect...

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

    Abs (anti-lock brake system) 8-94 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 wire...

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

    Abs (anti-lock brake system) 8-95 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 defectiv...

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

    Abs (anti-lock brake system) 8-96 fault code no. Abs-18 abs-46 symptom missing pulses detected in the rear wheel sen- sor signal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel bearings, axle, sensor housing, and sen...

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

    Abs (anti-lock brake system) 8-97 fault code no. Abs-22 symptom start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 engine startability. Check the ...

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

    Abs (anti-lock brake system) 8-98 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 meth...

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

    Abs (anti-lock brake system) 8-99 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 “c...

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

    Abs (anti-lock brake system) 8-100 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 as- sembly. • turn the ...

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

    Abs (anti-lock brake system) 8-101 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 535: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-102 fault code no. Abs-34 symptom hydraulic unit abs motor relay is short-circuit- ed. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in abs motor relay. Replace the hydraulic unit as- sembly. • turn ...

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

    Abs (anti-lock brake system) 8-103 4 brake lines • check the brake lines for kinks and deterioration. Warning ewa2s31023 only use genuine yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • check that the connections of the brake lines from the brake master cyli...

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

    Abs (anti-lock brake system) 8-104 warning ewa2s31024 the front brakes will not function properly if the connections are reversed. • brake hose (front brake master cylinder to hydraulic unit) “1” inlet: from the front brake master cylinder • brake hose (hydraulic unit to left front brake caliper) “2...

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

    Abs (anti-lock brake system) 8-105 fault code no. Abs-42 abs-47 symptom rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the abs ecu to release the hy- draulic pressure. Order item/components and probable cause check or maintenance job r...

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

    Abs (anti-lock brake system) 8-106 warning ewa2s31025 the rear brake will not function properly if the connections are reversed. • brake hose (rear brake master cylinder to hydraulic unit) “1” inlet: from the rear brake master cylinder • brake hose (hydraulic unit to rear brake caliper) “2” outlet: ...

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

    Abs (anti-lock brake system) 8-107 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 541: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-108 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 542: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-109 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 3-34....

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

    Abs (anti-lock brake system) 8-110 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 3-34....

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

    Abs (anti-lock brake system) 8-111 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 545: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-112 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 cir- cuit between the white termi...

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

    Abs (anti-lock brake system) 8-113 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 cir- cuit between the white termin...

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

    Abs (anti-lock brake system) 8-114 eas2s31075 [d-1] deleting the fault codes 1. Connect the test coupler adapter “1” to the abs test coupler “2”. Refer to “[b-5] mal- function are currently detect- ed” on page 8-83. 2. Turn the main switch to “on”. Fault codes will be displayed in the multi- functio...

  • Page 548: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-115 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 pocket tester ...

  • Page 549: Abs (Anti-Lock Brake System)

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

  • Page 550: Electrical Components

    Electrical components 8-117 eas27972 electrical components 1 3 4 5 6 7 8 11 10 9 12 13 14 21 20 17 18 19 15 16 22 2 23.

  • Page 551: Electrical Components

    Electrical components 8-118 1. Main switch 2. Clutch switch 3. Battery 4. Main fuse 5. Starter relay 6. Abs motor fuse 7. Turn signal/hazard relay 8. Fuse box 1 9. Headlight relay 10.Radiator fan motor relay 11.Relay unit 12.Rear brake light switch 13.O 2 sensor 14.Sidestand switch 15.Cylinder-#1 ig...

  • Page 552: Electrical Components

    Electrical components 8-119 3 4 5 6 2 1 7 8 9 10 11 12 13 14 15 16 17 18 19.

  • Page 553: Electrical Components

    Electrical components 8-120 1. Air induction system solenoid 2. Atmospheric pressure sensor 3. Ecu (engine control unit) 4. Lean angle sensor 5. Hydraulic unit assembly 6. Fuse box 2 7. Rectifier/regulator 8. Exup servo motor 9. Fuel pump assembly 10.Gear position switch 11.Oil level switch 12.Crank...

  • Page 554: Electrical Components

    Electrical components 8-121 eas27980 checking the switches l r ch b / br dg l / b b g br y b br / w (black) on off b b dg br / w ch r br / l l / b l / y dg br / w ch r / w r / l b / w l / w r / w r / l w g / w b / r g sb l b b r br / l l / b l / y l / w b / w br b / br y l / b g b b (black) 5 6 1 4 ...

  • Page 555: Electrical Components

    Electrical components 8-122 1. Dimmer switch 2. Hazard switch 3. Turn signal switch 4. Horn switch 5. Engine stop switch 6. Start switch 7. Front brake light switch 8. Rear brake light switch 9. Gear position switch 10.Sidestand switch 11.Main switch 12.Clutch switch.

  • Page 556: Electrical Components

    Electrical components 8-123 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 557: Electrical Components

    Electrical components 8-124 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 continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or b...

  • Page 558: Electrical Components

    Electrical components 8-125 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in t...

  • Page 559: Electrical Components

    Electrical components 8-126 eas28030 checking and charging the battery warning ewa13290 batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear when...

  • Page 560: Electrical Components

    Electrical components 8-127 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Notice eca2s31053 • do not use a high-rate battery charger since it forces a high-amperage current into the ba...

  • Page 561: Electrical Components

    Electrical components 8-128 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 low...

  • Page 562: Electrical Components

    Electrical components 8-129 eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester ( Ω × 1) and battery (12 v) to the relay terminal...

  • Page 563: Electrical Components

    Electrical components 8-130 radiator fan motor relay eas2s31059 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must be repaired. ▼▼▼ ▼ ▼ ▼▼...

  • Page 564: Electrical Components

    Electrical components 8-131 tip the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the relay unit from the wire har- ness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminals as shown...

  • Page 565: Electrical Components

    Electrical components 8-132 c. Measure the primary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. ...

  • Page 566: Electrical Components

    Electrical components 8-133 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. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 567: Electrical Components

    Electrical components 8-134 eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the stator coil. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the...

  • Page 568: Electrical Components

    Electrical components 8-135 eas28190 checking the oil level switch 1. Drain: • engine oil 2. Remove: • oil level switch (from the oil pan) 3. Check: • oil level switch resistance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the oil level switch termina...

  • Page 569: Electrical Components

    Electrical components 8-136 eas29040 checking the fuel level warning light this model is equipped with a self-diagnosis de- vice for the fuel level detection circuit. 1. Check: • fuel level warning light “1” (turn the main switch to “on”.) warning light comes on for a few seconds, then goes off → wa...

  • Page 570: Electrical Components

    Electrical components 8-137 2. Check: • coolant temperature sensor resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the coolant temperature sensor terminals as shown. B. Immerse the coolant temperature sensor “1” ...

  • Page 571: Electrical Components

    Electrical components 8-138 eas29100 checking the accelerator position sensor 1. Remove: • accelerator position sensor (from the throttle body) warning ewa2s31017 • handle the accelerator position sensor with special care. • never subject the accelerator position sen- sor to strong shocks. If the ac...

  • Page 572: Electrical Components

    Electrical components 8-139 • never subject the atmospheric pressure sensor to strong shocks. If the atmospheric pressure sensor is dropped, replace it. 1. Check: • atmospheric pressure sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect...

  • Page 573: Electrical Components

    Electrical components 8-140 1. Check: • intake air pressure sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the in- take air pressure sensor coupler as shown. B. Turn the main switch to “on”. C. Measure...

  • Page 574: Electrical Components

    Electrical components 8-141.

  • Page 575: Troubleshooting

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

  • Page 576: Troubleshooting

    Troubleshooting 9-1 eas28451 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 577: Troubleshooting

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

  • Page 578: Troubleshooting

    Troubleshooting 9-3 eas28600 overheating engine 1. Clogged coolant passages • cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radi...

  • Page 579: Troubleshooting

    Troubleshooting 9-4 4. Swingarm • worn bearing or bushing • bent or damaged swingarm 5. Rear shock absorber assembly(-ies) • faulty rear shock absorber spring • leaking oil or gas 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect...

  • Page 580

    Eas28740 wiring diagram vmx17y(c) 2009 1. Ac magneto 2. Rectifier/regulator 3. Fuel injection system fuse 4. Abs solenoid fuse 5. Electric throttle valve fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 10. Backup fuse (odometer and clock) 11. Abs motor fuse 12. Starter relay 13. Starter ...

  • Page 582

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

  • Page 583

    Vmx17y(c) 2009 wiring diagram (gray) (black) (black) (black) (black) (black) (black) (gray) (gray) (black) (black) (black) (black) (black) (gray) (black) (gray) (dark gray) (gray) (dark gray) (dark blue) (black) (black) (black) (black) (dark blue) (dark blue) (black) (black) (black) (black) (black) ...