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Yamaha 2009 YZF-R1 (Y) Service Manual

Summary of 2009 YZF-R1 (Y)

  • Page 1

    Service manual yzf-r1(y) 2009 14b-28197-e0

  • Page 2

    Eas20040 yzf-r1(y) service manual ©2008 by yamaha motor co., ltd. First edition, november 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Important

    Eas20071 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on y...

  • Page 4: How To Use This Manual

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

  • Page 5: Symbols

    Eas20100 symbols the following symbols are used in this manual for easier understanding. 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

    1 2 3 4 5 6 7 8 9 eas20110 table of contents general information specifications periodic checks and adjustments chassis engine cooling system fuel system electrical system troubleshooting.

  • 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 seat rail reinforcement under the passenger seat. This informat...

  • 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 opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor...

  • Page 12: Features

    Features 1-3 eas14b1017 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 324 kpa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ecu energizes the fuel...

  • Page 13: Features

    Features 1-4 eas14b1076 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 14: Features

    Features 1-5 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 sys- tem to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake volume control gives ...

  • Page 15: Features

    Features 1-6 ycc-t/ycc-i system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. Ecu (engine control unit) 5. Etv main cpu (32 bit) 6. Fi cpu (32 bit) 7. Throttle servo motor driver 8. Throttle servo motor driver operation sens- ing/shut off circuit 9. Th...

  • Page 16: Features

    Features 1-7 ycc-t/ycc-i control outline 1. Accelerator position sensor 2. Throttle position sensor 3. Crankshaft position sensor 4. Speed sensor 5. D-mode switch 6. Coolant temperature sensor 7. Neutral switch 8. Atmospheric pressure sensor 9. Accelerator position (two signals) 10.Throttle position...

  • Page 17: Features

    Features 1-8 eas14b1019 instrument functions multi-function meter unit warning ewa14b1014 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function ...

  • Page 18: Features

    Features 1-9 clock and stopwatch modes to set the clock 1. Push the “select” button and “reset” button together for at least two seconds. 2. When the hour digits start flashing, push the “reset” button to set the hours. 3. Push the “select” button, and the minute digits start flashing. 4. Push the “...

  • Page 19: Features

    Features 1-10 odometer, tripmeter, instantaneous fuel consumption and average fuel consump- tion modes push the “select” button to switch the dis- play between the odometer mode “odo”, the tripmeter modes “trip 1” and “trip 2”, the instantaneous fuel consumption mode “km/l” or “l/100 km”, and the av...

  • Page 20: Features

    Features 1-11 average fuel consumption mode the average fuel consumption display can be set to either “av_ _._ km/l”, “av_ _._ l/100 km” or “av_ _._ mpg” (for the uk only). This display shows the average fuel consump- tion since it was last reset. • when the display is set to “av_ _._ km/l”, the ave...

  • Page 21: Features

    Features 1-12 drive mode display this display indicates which drive mode has been selected: “std”, “a” or “b”. For more details on the modes and on how to select them, refer to “d-mode (drive mode)”. Coolant temperature display the coolant temperature display indicates the temperature of the coolant...

  • Page 22: Features

    Features 1-13 this model is equipped with a self-diagnosis device for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light comes on and the display indicates an error code. The self-diagnosis device also detects prob- lems in the immobilize...

  • Page 23: Features

    Features 1-14 tip the display shows the current setting for each function, except the shift timing indicator light activity function. To adjust the brightness of the multifunction meter displays and tachometer 1. Turn the key to “off”. 2. Push and hold the “select” button. 3. Turn the key to “on”, a...

  • Page 24: Features

    Features 1-15 d-mode (drive mode) d-mode is an electronically controlled engine performance system with three mode selec- tions (“std”, “a”, and “b”). Push the drive mode switch “mode” to switch between modes. Tip before using d-mode, make sure you under- stand its operation along with the operation...

  • Page 25: Important Information

    Important information 1-16 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools” on page 1-20. 3. When disasse...

  • Page 26: Important Information

    Important information 1-17 eas20230 bearings and oil seals install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if a...

  • Page 27: Checking The Connections

    Checking the connections 1-18 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 severa...

  • Page 28: 1-19

    Handling the electronic parts 1-19 eas14b1120 handling the electronic parts electronic parts is very sensitive. Handle with care and do not give impact. Mankind has static electricity and it’s voltage is very high and electronic parts is very sensitive. It has possibility that inside small parts of ...

  • Page 29: Special Tools

    Special tools 1-20 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 inappropri- ate tools or improvised techniques. Special tools, part numbers...

  • Page 30: Special Tools

    Special tools 1-21 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-23, 4-72 damper rod holder 90890-01506 ym-01506 4-63, 4-65 oil filter wrench 90890-01426 yu-38411 3-29 rod holder 90890-01434 damper rod holder double ended ym-01434 4-62, 4-67 rod puller 90890-01437 universal da...

  • Page 31: Special Tools

    Special tools 1-22 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-66, 4-67 fork spring compressor 90890-01441 ym-01441 4-62, 4-67 fork seal driver 90890-01442 adjustable fork seal driver (36–46 mm) ym-01442 4-65, 4-66 vacuum gauge 90890-03094 carburetor sy...

  • Page 32: Special Tools

    Special tools 1-23 thickness gauge 90890-03180 feeler gauge set yu-26900-9 3-7 valve spring compressor 90890-04019 ym-04019 5-30, 5-36 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym-04108 5-30, 5-36 middle driven shaft bearing driver 90890-04058 bearing drive...

  • Page 33: Special Tools

    Special tools 1-24 valve guide remover (ø5) 90890-04097 valve guide remover (5.0 mm) ym-04097 5-32 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-32 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-32 valve guide installer (ø4.5) 90890-...

  • Page 34: Special Tools

    Special tools 1-25 pivot shaft wrench adapter 90890-01476 5-10 valve lapper 90890-04101 valve lapping tool ym-a8998 3-8 oil pressure adapter h 90890-03139 3-30 pressure gauge 90890-03153 yu-03153 3-30, 7-18 fuel pressure adapter 90890-03176 ym-03176 7-18 fuel injector pressure adapter 90890-03210 yu...

  • Page 35: Special Tools

    Special tools 1-26 damper rod holder (22 mm) 90890-01365 4-81, 4-82 drive chain cut & rivet tool 90890-01550 ym-01550 4-84, 4-85 piston installing tool 90890-04161 ym-04161 5-83 rotor puller 2k7-85555-00 5-38 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-38, 5-41, 5- 42, 5-44 pocket t...

  • Page 36: Special Tools

    Special tools 1-27 test harness-speed sensor (3p) 90890-03208 yu-03208 8-137, 8-141 test harness-lean angle sensor (6p) 90890-03209 yu-03209 8-133 test harness s-pressure sensor (3p) 90890-03207 yu-03207 8-140, 8-142 yamaha bond no. 1215 (three bond no. 1215®) 90890-85505 5-24, 5-39, 5- 45, 5-73 too...

  • Page 37: Specifications

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

  • Page 38: General Specifications

    General specifications 2-1 eas20280 general specifications model model 14b1 (aus, bel, che, cze, dnk, fin, gbr, grc, hun, irl, nld, nor, pol, prt, svn, swe, zaf) 14b2 (bel, fra) 14b3 (aus) dimensions overall length 2070 mm (81.5 in) overall width 715 mm (28.1 in) overall height 1130 mm (44.5 in) sea...

  • Page 39: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 998.0 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 78.0 × 52.2 mm (3.07 × 2.06 in) compression ratio 12.70 : 1 standard compression pressure (at sea le...

  • Page 40: Engine Specifications

    Engine specifications 2-3 thermostat valve opening temperature 71 °c (159.8 °f) valve full open temperature 85 °c (185.0 °f) valve lift (full open) more than 8 mm (0.31 in) radiator core width 383.0 mm (15.08 in) height 250.6 mm (9.87 in) depth 24.0 mm (0.94 in) water pump water pump type single suc...

  • Page 41: Engine Specifications

    Engine specifications 2-4 timing chain tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.11–0.20 mm (0.0043–0.0079 in) exhaust 0.23–0.27 mm (0.0091–0.0106 in) valve dimensions valve head diameter a (intake) 30.90–31.10 mm (1.2165–1.2244 in) valve head diamete...

  • Page 42: Engine Specifications

    Engine specifications 2-5 valve spring inner spring free length (intake) 39.33 mm (1.55 in) limit 37.36 mm (1.47 in) free length (exhaust) 37.96 mm (1.49 in) limit 36.06 mm (1.42 in) installed length (intake) 34.50 mm (1.36 in) installed length (exhaust) 33.00 mm (1.30 in) spring rate k1 (intake) 41...

  • Page 43: Engine Specifications

    Engine specifications 2-6 end gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) limit 0.50 mm (0.0197 in) ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) limit 0.115 mm (0.0045 in) 2nd ring ring type taper dimensions (b × t) 0.80 × 2.75 mm (0.03 × 0.11 in) end gap (installed) 0.30–0.45 mm (0.011...

  • Page 44: Engine Specifications

    Engine specifications 2-7 clutch clutch type wet, multiple-disc clutch release method outer pull, rack and pinion pull clutch lever free play 10.0–15.0 mm (0.39–0.59 in) friction plate thickness 2.92–3.08 mm (0.115–0.121 in) wear limit 2.82 mm (0.111 in) plate quantity 9 pcs clutch plate thickness 1...

  • Page 45: Engine Specifications

    Engine specifications 2-8 throttle position sensor throttle position sensor resistance 1.2–2.8 k Ω accelerator position sensor resistance 1.2–2.8 k Ω output voltage (at idle) 0.63–0.73 v fuel injection sensor crankshaft position sensor resistance 248–372 Ω at 20 °c (68 °f) cylinder identification se...

  • Page 46: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 24.0 ° trail 102.0 mm (4.02 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel ...

  • Page 47: Chassis Specifications

    Chassis specifications 2-10 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 diameter 16.00 mm (0.63 in) caliper cylinder inside diameter 24.05 mm × 3 (0.95 in × 3) recommended...

  • Page 48: Chassis Specifications

    Chassis specifications 2-11 rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 60.0 mm (2.36 in) spring free length 159.5 mm (6.28 in) installed length 147.5 mm (5.81 in) spring rate k1 98.10 n/mm (10.00 kgf/mm, 5...

  • Page 49: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci (digital) ignition timing (b.T.D.C.) 5.0 °/1200 r/min engine control unit model/manufacturer tbdf64/denso (14b1, 14b3) tbdf65/denso (14b2) ignition coil minimum ignition ...

  • Page 50: Electrical Specifications

    Electrical specifications 2-13 fuel level warning light led coolant temperature warning light led engine trouble warning light led steering damper warning light led immobilizer system indicator light led shift timing indicator light led electric starting system system type constant mesh starter moto...

  • Page 51: Electrical Specifications

    Electrical specifications 2-14 fuses main fuse 50.0 a headlight fuse 20.0 a signaling system fuse 7.5 a ignition fuse 15.0 a radiator fan fuse 15.0 a × 2 turn signal light fuse 7.5 a fuel injection system fuse 15.0 a steering damper fuse 7.5 a backup fuse 7.5 a etv (electronic throttle valve) fuse 7...

  • Page 52: Tightening Torques

    Tightening torques 2-15 eas20320 tightening torques eas20330 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each cha...

  • Page 53: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plugs m10 4 13 nm (1.3 m·kgf, 9.4 ft·lbf) cylinder head nut m10 2 see tip. Cylinder head nut m10 8 see tip. Cylinder head bolt m6 2 12 nm (1.2 m·kgf, 8.7 ft·lbf) camshaft cap bolt m6 20 1...

  • Page 54: Tightening Torques

    Tightening torques 2-17 throttle body and throttle body joint clamp m5 4 3 nm (0.3 m·kgf, 2.2 ft·lbf) throttle position sensor screw m5 2 3.5 nm (0.35 m·kgf, 2.5 ft·lbf) accelerator position sensor screw m5 2 3.5 nm (0.35 m·kgf, 2.5 ft·lbf) secondary injector assembly bolt m5 7 4 nm (0.4 m·kgf, 2.9 ...

  • Page 55: Tightening Torques

    Tightening torques 2-18 generator rotor cover bolt m6 8 12 nm (1.2 m·kgf, 8.7 ft·lbf) drive sprocket cover bolt m6 3 10 nm (1.0 m·kgf, 7.2 ft·lbf) clutch cover bolt m6 8 12 nm (1.2 m·kgf, 8.7 ft·lbf) clutch cover bolt m6 1 12 nm (1.2 m·kgf, 8.7 ft·lbf) pickup rotor cover 2 bolt m6 6 12 nm (1.2 m·kgf...

  • Page 56: Tightening Torques

    Tightening torques 2-19 tip cylinder head nut use new nuts and washers. 1. Apply engine oil to bolt thread and mating surface. 2. Tighten the bolt to 10 nm (1.0 m·kgf, 7.2 ft·lbf). 3. Tighten the bolt to 25 nm (2.5 m·kgf, 18 ft·lbf). 4. Tighten the bolts 1–7 and 10 to 115 °–125° and bolts 8 and 9 to...

  • Page 57: Tightening Torques

    Tightening torques 2-20 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (front side) m12 2 70 nm (7.0 m·kgf, 50 ft·lbf) engine mounting nut (rear side) m10 2 51 nm (5.1 m·kgf, 37 ft·lbf) engine mount adjusting bolt m18 2 7 nm (0.7 m·kgf, 5.1 f...

  • Page 58: Tightening Torques

    Tightening torques 2-21 handlebar end grip bolt m6 2 4 nm (0.4 m·kgf, 2.9 ft·lbf) front brake hose joint bracket bolt m6 2 11 nm (1.1 m·kgf, 8.0 ft·lbf) coolant reservoir bolt m6 2 5 nm (0.5 m·kgf, 3.6 ft·lbf) air chamber bracket bolt m6 4 7 nm (0.7 m·kgf, 5.1 ft·lbf) left lower cowling bracket bolt...

  • Page 59: Tightening Torques

    Tightening torques 2-22 tip lower ring nut 1. First, tighten the lower ring nut approximately 52 nm (5.2 m·kgf, 37 ft·lbf) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut 18 nm (1.8 m·kgf, 13 ft·lbf). Tip lower bracket pinch bolt tighten each bolt to ...

  • Page 60: Tightening Torques

    Tightening torques 2-23 at this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork. 4. In the order from the pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 nm (2.1 m·kgf, 15 ft·lbf) without performing temporary tight...

  • Page 61: 2-24

    Lubrication points and lubricant types 2-24 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part silicon fluid bearings camshaft lobes and journals (intake and exhaust) valve stem seal (installed on valve guide)...

  • Page 62: 2-25

    Lubrication points and lubricant types 2-25 crankcase mating surface yamaha bond no.1215 (three bond no.1215®) crankcase cover (lead grommet) yamaha bond no.1215 (three bond no.1215®) lubrication point lubricant.

  • Page 63: 2-26

    Lubrication points and lubricant types 2-26 eas20380 chassis lubrication point lubricant steering bearings and bearing races (upper and lower) throttle grip inner surface and throttle cable end brake lever pivoting point and metal-to-metal moving parts clutch lever pivoting point and metal-to-metal ...

  • Page 64: 2-27

    Lubrication system chart and diagrams 2-27 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 65: 2-28

    Lubrication system chart and diagrams 2-28 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Sub gallery 6. Oil filter cartridge 7. Main gallery 8. Mission shower 9. Drive axle 10.Main axle 11.Shift fork (upper) 12.Crankshaft 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.In...

  • Page 66: 2-29

    Lubrication system chart and diagrams 2-29 eas20410 lubrication diagrams.

  • Page 67: 2-30

    Lubrication system chart and diagrams 2-30 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil filter cartridge 5. Oil level switch.

  • Page 68: 2-31

    Lubrication system chart and diagrams 2-31.

  • Page 69: 2-32

    Lubrication system chart and diagrams 2-32 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Crankshaft 5. Balancer shaft 6. Oil cooler 7. Relief valve 8. Oil pipe 9. Oil strainer 10.Oil/water pump assembly.

  • Page 70: 2-33

    Lubrication system chart and diagrams 2-33.

  • Page 71: 2-34

    Lubrication system chart and diagrams 2-34 1. Oil filter cartridge 2. Oil level switch 3. Oil strainer 4. Oil pipe 5. Relief valve 6. Oil cooler.

  • Page 72: 2-35

    Lubrication system chart and diagrams 2-35.

  • Page 73: 2-36

    Lubrication system chart and diagrams 2-36 1. Main axle 2. Oil/water pump assembly.

  • Page 74: 2-37

    Lubrication system chart and diagrams 2-37.

  • Page 75: 2-38

    Lubrication system chart and diagrams 2-38 1. Main axle 2. Oil delivery pipe 2 3. Drive axle.

  • Page 76: 2-39

    Lubrication system chart and diagrams 2-39.

  • Page 77: 2-40

    Lubrication system chart and diagrams 2-40 1. Shift fork guide bar 2. Shift fork-c 3. Shift drum assembly 4. Shift fork-r 5. Drive axle 6. Shift fork-l.

  • Page 78: 2-41

    Lubrication system chart and diagrams 2-41.

  • Page 79: 2-42

    Lubrication system chart and diagrams 2-42 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil nozzle 5. Crankshaft.

  • Page 80: 2-43

    Lubrication system chart and diagrams 2-43.

  • Page 81: 2-44

    Lubrication system chart and diagrams 2-44 1. Balancer shaft 2. Crankshaft.

  • Page 82: Cooling System Diagrams

    Cooling system diagrams 2-45 eas20420 cooling system diagrams.

  • Page 83: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Oil/water pump assembly 2. Radiator 3. Radiator fan 4. Thermostat 5. Oil cooler.

  • Page 84: Cooling System Diagrams

    Cooling system diagrams 2-47.

  • Page 85: Cooling System Diagrams

    Cooling system diagrams 2-48 1. Radiator cap 2. Radiator 3. Radiator fan 4. Oil cooler.

  • Page 86: Cable Routing

    Cable routing 2-49 eas20430 cable routing.

  • Page 87: Cable Routing

    Cable routing 2-50 1. Meter lead 2. Ground lead 3. Meter 4. Meter bracket 5. Right auxiliary light lead 6. Headlight sub-wire harness 7. Headlight lead 8. Intake air temperature sensor 9. Left auxiliary light lead 10.Right air intake air duct cover 11.Turn signal relay 12.Headlight relay 13.Left air...

  • Page 88: Cable Routing

    Cable routing 2-51.

  • Page 89: Cable Routing

    Cable routing 2-52 1. Clutch cable 2. Main switch lead 3. Left handlebar switch lead 4. Steering damper lead 5. Horn lead 6. Horn 7. Brake hose 8. Front brake light switch lead 9. Throttle cable (decelerator cable) 10.Throttle cable (accelerator cable) 11.Right handlebar switch lead 12.Throttle cabl...

  • Page 90: Cable Routing

    Cable routing 2-53.

  • Page 91: Cable Routing

    Cable routing 2-54 1. Headlight sub-wire harness 2. Right radiator fan motor lead 3. Ac magneto lead 4. Crankshaft position sensor 5. Coolant reservoir hose 6. Throttle cable 7. Right handlebar switch lead 8. Clutch cable 9. Main harness 10.Rectifier/regulator 11.Rectifier/regulator bracket 12.Right...

  • Page 92: Cable Routing

    Cable routing 2-55.

  • Page 93: Cable Routing

    Cable routing 2-56 1. Ignition coil lead 2. Crankshaft position sensor lead 3. Rear brake light switch lead 4. O 2 sensor lead a. Route the rear brake light switch lead out- side of the o 2 sensor lead and push it to the occluding surface of the clutch cover..

  • Page 94: Cable Routing

    Cable routing 2-57.

  • Page 95: Cable Routing

    Cable routing 2-58 1. Union bolt 2. Washer 3. Exhaust chamber cover 4. Right footrest assembly 5. Brake caliper 6. Brake hose 7. Brake hose holder 8. Brake master cylinder 9. Footrest plate 10.Brake fluid reservoir hose 11.Clamp 12.Right muffler pipe cover 13.Pin 14.Washer 15.Cotter pin a. 12–18 mm ...

  • Page 96: Cable Routing

    Cable routing 2-59.

  • Page 97: Cable Routing

    Cable routing 2-60 1. Immobilizer unit lead 2. Left radiator fan motor lead 3. Radiator fan motor relay 4. Ecu (engine control unit) 5. Cable guide 6. Radiator inlet pipe 7. Ecu (engine control unit) bracket a. Insert the clamp winding the main harness into the ecu (engine control unit) bracket hole...

  • Page 98: Cable Routing

    Cable routing 2-61.

  • Page 99: Cable Routing

    Cable routing 2-62 1. Oil level switch lead 2. Gear position sensor lead 3. Speed sensor lead 4. Sidestand switch lead 5. Fuel tank breather hose 6. Fuel tank overflow hose 7. Coolant reservoir breather hose 8. Sidestand switch 9. Ac magneto lead 10.Frame 11.Main harness holder 12.Main harness 13.Dr...

  • Page 100: Cable Routing

    Cable routing 2-63.

  • Page 101: Cable Routing

    Cable routing 2-64 1. Right handlebar switch lead 2. Headlight sub-wire harness 3. Right radiator fan motor lead 4. Ac magneto lead 5. Atmospheric pressure sensor 6. Throttle position sensor (for throttle cable pulley) 7. Throttle servo motor 8. O 2 sensor lead 9. Rear brake light switch lead 10.Ign...

  • Page 102: Cable Routing

    Cable routing 2-65.

  • Page 103: Cable Routing

    Cable routing 2-66 ae.Install the water pump bypass hose with its clamp opening facing right of the vehicle. Af.Clamp the secondary injector sub-wire har- ness and throttle sub-wire harness at the protector. Face the end of the clamp down- ward..

  • Page 104: Cable Routing

    Cable routing 2-67.

  • Page 105: Cable Routing

    Cable routing 2-68 1. Rear frame 2. Right upper tail cover bracket 3. License plate light lead 4. Right turn signal light lead 5. Left turn signal light lead 6. Battery box 2 7. Tail/brake light lead 8. Lean angle sensor lead 9. Left upper tail cover bracket 10.Main harness 11.Starter relay 12.Front...

  • Page 106: Cable Routing

    Cable routing 2-69.

  • Page 107: Cable Routing

    Cable routing 2-70 1. Fuel tank upper cover 2. Fuel tank breather hose 3. Fuel tank overflow hose 4. Fuel tank 5. Fuel pump 6. Frame 7. Fuel hose connector cover 8. Clip 9. Fuel hose a. Install the lip on the fuel pump gasket upward. B. Pump positioning punch mark c. Install the fuel pump with the p...

  • Page 108: Cable Routing

    Cable routing 2-71.

  • Page 109: Cable Routing

    Cable routing 2-72 1. Upper air filter case 2. Fuel hose (secondary injector fuel rail side) 3. Fuel hose (primary injector fuel rail side) 4. Primary injector fuel rail 5. Secondary injector sub-wire harness 6. Throttle cable (pull side) 7. Throttle cable (return side) 8. Black coating 9. White coa...

  • Page 110: Cable Routing

    Cable routing 2-73.

  • Page 111: Cable Routing

    Cable routing 2-74 1. Cap case 2. Upper air filter case 3. Sub-wire harness 4. Secondary injector holder 5. Grommet 6. Plastic locking tie 7. Fuel rail a. Sub-wire harness should not be pinched under the bearing surface of the bolt. B. #4 purple tape c. Pinch the sub-wire harness with the hook. When...

  • Page 112: Cable Routing

    Cable routing 2-75.

  • Page 113

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

  • Page 114

    Checking the coolant level .................................................... 3-31 checking the cooling system ................................................. 3-31 changing the coolant ................................................................ 3-32 checking the front brake light switch ......

  • Page 116: 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 longer service life and redu...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-2 eas14b1034 general maintenance and lubrication chart no. Item check or maintenance job odometer reading annual check 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) 1 air filter element • replace. √ 2 clutch • check operation. ...

  • Page 118: Periodic Maintenance

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

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-4 eas21030 checking the fuel line (primary injec- tor) the following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • rider seat refer to “general chassis” on page 4-1. 2. Remove: • fuel tank refer to “fuel tank” on page 7-1. • air filter case refe...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-5 2. Remove: • fuel tank refer to “fuel tank” on page 7-1. 3. Remove: • air filter case refer to “air filter case” on page 7- 5. 4. Disconnect: • ignition coil 5. Remove: • spark plug eca13320 before removing the spark plugs, blow away any dirt accumulated in the spark plug we...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-6 • air cut-off valve refer to “air induction system” on page 7-21. • radiator • radiator fan motor refer to “radiator” on page 6-1. 2. Remove: • ignition coils • spark plugs • cylinder head cover • cylinder head cover gasket refer to “camshafts” on page 5-13. 3. Remove: • pic...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-7 c. Measure the valve clearance #1 with a thickness gauge “1”. D. Turn the crankshaft 270 degrees in clock- wise and position the pickup rotor i mark “a” downward. E. Measure the valve clearance #3 with a thickness gauge. F. Turn the crankshaft 180 degrees in clock- wise and ...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-8 tip • refer to “camshafts” on page 5-13. • when removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the va...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-9 example: valve pad number = 158 rounded value = 160 new valve pad number = 160 f. Install the new valve pad “1” and the valve lifter “2”. Tip • lubricate the valve pad with molybdenum disulfide oil. • lubricate the valve lifter with engine oil. • the valve lifter must turn s...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-10 4. Install: • vacuum gauge “1” • digital tachometer (use goods on the market) 5. Install: • air filter case refer to “air filter case” on page 7- 5. • fuel tank refer to “fuel tank” on page 7-1. 6. Check: • throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Sta...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-11 4. Install: • fuel tank • fuel tank side cover refer to “fuel tank” on page 7-1. • rider seat refer to “general chassis” on page 4-1. Eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Remov...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-12 7. Check: • tightening torque 8. Install: • radiator lower bracket refer to “radiator” on page 6-1. 9. Install: • rear brake master cylinder refer to “rear brake” on page 4-43. 10. Install: • side cowlings refer to “general chassis” on page 4-1. 11. Install: • passenger sea...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-13 5. Press the “select” and “reset” buttons to select a cylinder. Tip the selected cylinder number appears on the odometer, tripmeter and fuel reserve trip lcd. • to decrease the selected cylinder number, press the “reset” button. • to increase the selected cylinder number, p...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-14 6. Install: • air filter case cover refer to “air filter case” on page 7- 5. Eca14401 never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air fi...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-15 c. Tighten the locknuts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas14b1088 checking the brake operation 1. Check: • brake operation brake not working properly → check the brake system. Refer to “front brake” on page 4-30 and “rear brake” on page 4-43. Tip drive on the dry road,...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-16 eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) tip • while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • adjust the groove ...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-17 warning ewa13070 after adjusting the brake pedal position, check that the end of the adjusting bolt “c” is visible through the hole “d”. C. Tighten the locknut “1” to specification. Warning ewa13050 a soft or spongy feeling in the brake lever can indicate the presence of ai...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-18 tip bleeding order of the front hydraulic brake sys- tem is the following order: • front brake master cylinder • front brake calipers d. Place the other end of the hose into a con- tainer. E. Slowly apply the brake several times. F. Fully pull the brake lever or fully press...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-19 eas21290 checking the rear brake hose 1. Check: • brake hose “1” cracks/damage/wear → replace. 2. Check: • brake hose clamp “2” loose connection → tighten the clamp bolt. 3. Hold the vehicle upright and apply rear brake several times. 4. Check: • brake hose brake fluid leak...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-20 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. Warning ewa14090 after extensive tests, the tires listed below have been approv...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-21 eas14b1089 checking the wheel bearings the following procedure applies to all of the wheel bearings. 1. Check: • wheel bearings refer to “checking the front wheel” on page 4-20 and “checking the rear wheel” on page 4-27. Eas14b1090 checking the swingarm operation 1. Check: ...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-22 tip to maintain the proper wheel alignment, adjust both sides evenly. C. Tighten the wheel axle nut to specification. D. Tighten the locknuts to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting p...

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-23 c. Loosen the lower ring nut “6” completely, then tighten it to specification. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remov...

  • Page 139: Periodic Maintenance

    Periodic maintenance 3-24 2. Adjust: • installed shift rod length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “a” or “b” to obtain the correct shift pedal position. C. Tighten both locknuts. D. Make sure the installed shift rod length is within ...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-25 spring preload warning ewa14b1026 always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Eca13570 • grooves are provided to indicate the adjustment position. • never go beyond the maximum or mini- mum adjustment pos...

  • Page 141: Periodic Maintenance

    Periodic maintenance 3-26 compression damping eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping (left side) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas14b1096 checking ...

  • Page 142: Periodic Maintenance

    Periodic maintenance 3-27 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression damping (for fast compres- sion damping) eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping...

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-28 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas14b1097 checking the connecting arm and relay arm refer to “checking the connecting arm and relay arm” on page 4-76. Eas20730 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • place the vehicle on a suitable stand...

  • Page 144: Periodic Maintenance

    Periodic maintenance 3-29 tip before checking the engine oil level, wait a few minutes until the oil has settled. Eas20790 changing the engine oil 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • lower cowli...

  • Page 145: Periodic Maintenance

    Periodic maintenance 3-30 9. Install: • engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: • engine (for engine oil leaks) 12. Install: • lower cowlings refer to “general chassis” on page 4-1. 13. Check: • engine oil level refer to “checking ...

  • Page 146: Periodic Maintenance

    Periodic maintenance 3-31 6. Install: • main gallery bolt eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Check: • coolant level the coolant level should be between the maximum level mark...

  • Page 147: Periodic Maintenance

    Periodic maintenance 3-32 eas21130 changing the coolant 1. Remove: • lower cowlings • side cowlings refer to “general chassis” on page 4-1. 2. Disconnect: • coolant reservoir cap “1” 3. Drain: • coolant (from the coolant reservoir) 4. Remove: • radiator cap “2” warning ewa13030 a hot radiator is und...

  • Page 148: Periodic Maintenance

    Periodic maintenance 3-33 • if coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • if coolant is swallowed, induce vomiting and get immediate medical attention. Eca13480 • adding water instead of coolant lowers the antifreeze content of the coolant. If w...

  • Page 149: Periodic Maintenance

    Periodic maintenance 3-34 replace damaged outer cable and inner cables as soon as possible. 1. Check: • outer cable damage → replace. 2. Check: • cable operation rough movement → lubricate. Tip hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubri...

  • Page 150: Periodic Maintenance

    Periodic maintenance 3-35 2. Disconnect: • headlight coupler “1” 3. Remove: • headlight bulb holder “1” • headlight bulb “2” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: • headlight bulb ...

  • Page 151: Periodic Maintenance

    Periodic maintenance 3-36 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲.

  • Page 152: Periodic Maintenance

    Periodic maintenance 3-37.

  • Page 153: Chassis

    4 chassis general chassis....................................................................................4-1 removing the quick fastener (screw type)....................... 4-11 installing the quick fastener (screw type)...................... 4-11 removing the quick fastener (push type) ...........

  • Page 154

    Checking the front brake calipers ..................................... 4-38 assembling the front brake calipers ................................. 4-39 installing the front brake calipers.................................... 4-39 removing the front brake master cylinder..................... 4-40 chec...

  • Page 155

    Swingarm ................................................................................................ 4-78 removing the swingarm ............................................................. 4-80 checking the swingarm ............................................................. 4-81 installing ...

  • Page 156: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats and battery order job/parts to remove q’ty remarks 1 rider seat 1 2 passenger seat 1 3 battery negative lead 1 disconnect. 4 battery positive lead 1 disconnect. 5 tool band 1 6 tool 1 7 upper tail cover bracket 2 8 battery cover 1 9 bat...

  • Page 157: General Chassis

    General chassis 4-2 removing the side cowlings order job/parts to remove q’ty remarks 1 front cowling inner panel 2 2 side cowling 2 3 front turn signal light coupler 2 disconnect. 4 front turn signal light 2 5 lower cowling 2 6 side cowling inner panel 2 for installation, reverse the removal proce-...

  • Page 158: General Chassis

    General chassis 4-3 removing the ecu and rectifier/regulator order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. 1 ecu coupler 2 disconnect. 2 ecu 1 3 radiator fan motor relay coupler 1 disconnect. 4 radiator fan motor relay 1 5 ecu bracket 1 6 rectifier/regul...

  • Page 159: General Chassis

    General chassis 4-4 removing the air ducts order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Ecu and rectifier/regulator refer to “general chassis” on page 4-1. 1 air chamber cover 2 2 air chamber 2 3 air chamber bracket 2 4 air intake air duct cover 2 5 rea...

  • Page 160: General Chassis

    General chassis 4-5 removing the front cowling assembly order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Ecu and rectifier/regulator refer to “general chassis” on page 4-1. Air duct refer to “general chassis” on page 4-1. 1 intake air temperature sensor cou...

  • Page 161: General Chassis

    General chassis 4-6 removing the meter and headlight order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Ecu and rectifier/regulator refer to “general chassis” on page 4-1. Air duct refer to “general chassis” on page 4-1. Front cowling assembly refer to “gener...

  • Page 162: General Chassis

    General chassis 4-7 removing the meter and headlight order job/parts to remove q’ty remarks 12 windshield 1 13 intake air temperature sensor 1 14 headlight assembly 1 15 front cowling 1 for installation, reverse the removal proce- dure..

  • Page 163: General Chassis

    General chassis 4-8 disassembling the headlight assembly order job/parts to remove q’ty remarks 1 auxiliary light socket 2 2 auxiliary light bulb 2 3 headlight bulb cover 2 4 headlight bulb 2 5 headlight harness 1 6 headlight grille 2 for installation, reverse the removal proce- dure..

  • Page 164: General Chassis

    General chassis 4-9 removing the rear fender order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Passenger seat refer to “general chassis” on page 4-1. Upper tail cover bracket refer to “general chassis” on page 4-1. 1 upper tail cover 1 2 muffler 2 refer to “en...

  • Page 165: General Chassis

    General chassis 4-10 disassembling the license plate/turn signal light assembly order job/parts to remove q’ty remarks 1 license plate/turn signal light stay 1 2 license plate/turn signal light stay plate 1 3 cover 1 4 rear turn signal light 2 5 license plate light 1 6 rear reflector 1 7 mudguard 1 ...

  • Page 166: General Chassis

    General chassis 4-11 eas14b1029 removing the quick fastener (screw type) tip to remove the quick fastener, turn its center with a screwdriver counterclockwise, then pull the fastener out. Eas14b1030 installing the quick fastener (screw type) tip to install the quick fastener, turn its screw counterc...

  • Page 167: General Chassis

    General chassis 4-12 eas14b1104 installing the quick fastener (pull type) tip to install the quick fastener, pull the pin, then insert the fastener into the cover and push the pin “a”. Make sure to insert the fastener until it is locked. Eas14b1037 installing the passenger seat lock cylinder 1. Inst...

  • Page 168: General Chassis

    General chassis 4-13 eas14b1040 removing the lower cowlings 1. Remove: • lower cowling “1” tip slide the lower cowling to the forward and remove. Eas14b1041 installing the lower cowlings 1. Install: • lower cowling “1” tip insert the lower cowling tab “a” into the inner panel hole “b” and slide back...

  • Page 169: General Chassis

    General chassis 4-14 eas14b1045 installing the air chamber covers 1. Install: • air chamber cover “1” tip insert the air chamber cover tab “a” downward into the hole “b” of the air chamber “2”. Eas14b1046 removing the intake air duct cov- ers 1. Remove: • intake air duct cover “1” tip press the uppe...

  • Page 170: General Chassis

    General chassis 4-15 eas14b1049 removing the windshield 1. Remove: • windshield “1” tip • slide the windshield to the back and remove from the front cowling. • remove the rear view mirror and then remove the windshield. Eas14b1050 installing the windshield 1. Install: • windshield “1” tip insert the...

  • Page 171: General Chassis

    General chassis 4-16 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas14b1002 installing the upper tail cover 1. Install: • upper tail cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the upper tail cover from the front of the lower tail cover “2” and slide to the back. B. Put the upper tail cover down, align t...

  • Page 172: General Chassis

    General chassis 4-17 c. Adjusting the right rider footrest “1”. D. Adjusting the left rider footrest “1”. Eca14b1024 route the rear brake light switch lead through the groove “1” of the right rider footrest and groove “2” of the exhaust chamber cover. Tip when adjusting the left and right rider foot...

  • Page 173: Front Wheel

    Front wheel 4-18 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 left brake hose holder 1 2 right brake hose holder 1 3 left front brake caliper 1 4 right front brake caliper 1 5 front wheel axle pinch bolt 4 loosen. 6 front wheel axle bolt 1 7 ...

  • Page 174: Front Wheel

    Front wheel 4-19 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal (left and right) 2 2 wheel bearing (left and right) 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 175: Front Wheel

    Front wheel 4-20 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • ri...

  • Page 176: Front Wheel

    Front wheel 4-21 c. Remove the wheel bearings “3” with a gen- eral bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Eca14b1001 do not contact the wheel bearing inner race “4” or balls “5”. Contact should be made only with the outer race “6”. Tip us...

  • Page 177: Front Wheel

    Front wheel 4-22 tip start with the lightest weight. B. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 178: Front Wheel

    Front wheel 4-23 warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to “cable routing” on page 2-49. Tip make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs..

  • Page 179: Rear Wheel

    Rear wheel 4-24 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-43. 1 locknut (left and right) 2 loosen. 2 adjusting bolt (left and right) 2 loosen. 3 rear wheel axle nut 1 4 washer 1 5 rear wheel axle 1 6 adjustin...

  • Page 180: Rear Wheel

    Rear wheel 4-25 removing the brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sprocket 1 3 collar 2 4 dust cover 2 5 oil seal 1 6 bearing 1 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 rear wheel 1 for installation, reverse the ...

  • Page 181: Rear Wheel

    Rear wheel 4-26 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 182: Rear Wheel

    Rear wheel 4-27 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper “1” tip do n...

  • Page 183: Rear Wheel

    Rear wheel 4-28 eas22110 checking the rear wheel drive hub 1. Check: • rear wheel drive hub “1” cracks/damage → replace. • rear wheel drive hub dampers “2” damage/wear → replace. Eas14b1003 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → ...

  • Page 184: Rear Wheel

    Rear wheel 4-29 3. Tighten: • rear wheel axle nut • rear brake caliper bolts warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to “cable routing” on page 2-49. Rear wheel axle nut 150 nm (15 m·kgf, 110 ft·lbf) rear brake caliper bolt (front side) 27 nm (...

  • Page 185: Front Brake

    Front brake 4-30 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 front brake caliper 1 3 brake pad clip 4 4 brake pad pin 2 5 brake pad spring 2 6 brake pad kit 1 7 ...

  • Page 186: Front Brake

    Front brake 4-31 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-17. 1 stopper 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid reservoir diaphragm 1 5 ...

  • Page 187: Front Brake

    Front brake 4-32 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 bleed screw 1 3 brake master cylinder body 1 for installation, reverse the removal proce- dure..

  • Page 188: Front Brake

    Front brake 4-33 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-17. 1 union bolt 1 2 washer 2 3 brake hose 1 4 brake caliper 1 fo...

  • Page 189: Front Brake

    Front brake 4-34 disassembling the front brake calipers order job/parts to remove q’ty remarks 1 brake pad clip 4 2 brake pad pin 2 3 brake pad spring 2 4 brake pad kit 1 5 brake caliper piston 6 6 brake caliper piston dust seal 6 7 brake caliper piston seal 6 8 bleed screw 1 for installation, rever...

  • Page 190: Front Brake

    Front brake 4-35 eas22220 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...

  • Page 191: Front Brake

    Front brake 4-36 tip • when installing the brake disc, align the arrow “1” on the brake disc and arrow “2” on the wheel in the direction of wheel rotation. • tighten the brake disc bolts in stages and in a crisscross pattern. D. Measure the brake disc deflection. E. If out of specification, repeat t...

  • Page 192: Front Brake

    Front brake 4-37 5. Install: • brake pads • brake pad springs tip always install new brake pads and a new brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the ...

  • Page 193: Front Brake

    Front brake 4-38 eas22300 removing the front brake calipers the following procedure applies to both of the brake calipers. Tip before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt “1” • washers “2” • brake hose “3” tip put the end of the brak...

  • Page 194: Front Brake

    Front brake 4-39 • brake caliper cylinders “2” scratches/wear → replace the brake cal- iper assembly. • brake caliper body “3” cracks/damage → replace the brake caliper assembly. • brake fluid delivery passages (brake caliper body) obstruction → blow out with compressed air. Warning ewa14b1003 whene...

  • Page 195: Front Brake

    Front brake 4-40 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful che...

  • Page 196: Front Brake

    Front brake 4-41 2. Check: • brake fluid reservoir tank “1” cracks/damage → replace. • brake fluid reservoir diaphragm “2” damage/wear → replace. • brake fluid reservoir diaphragm holder “3” cracks/damage → replace. 3. Check: • brake hose “4” cracks/damage/wear → replace. Eas22520 assembling the fro...

  • Page 197: Front Brake

    Front brake 4-42 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type...

  • Page 198: Rear Brake

    Rear brake 4-43 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad shim 4 5 brake pad kit 1 6 bleed screw 1 7 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 199: Rear Brake

    Rear brake 4-44 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-17. 1 footrest plate 1 2 brake fluid reservoir cap 1 3 rear brake fluid reservoir diaphragm holder 1 4 rear brake fluid reservoir...

  • Page 200: Rear Brake

    Rear brake 4-45 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 adjusting nut 1 3 brake master cylinder kit 1 4 dust cover 1 5 circlip 1 6 hose joint 1 7 o-ring 1 8 brake master cylinder body 1 for installation, reverse the removal...

  • Page 201: Rear Brake

    Rear brake 4-46 removing the rear brake calipers order job/parts to remove q’ty remarks 1 union bolt 1 2 washer 2 3 brake hose 1 4 brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 202: Rear Brake

    Rear brake 4-47 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad kit 1 4 brake pad shim 4 5 brake pad spring 1 6 brake caliper piston 1 7 brake caliper piston dust seal 1 8 brake caliper piston seal 1 9 bleed screw 1 for install...

  • Page 203: Rear Brake

    Rear brake 4-48 eas22560 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the enti...

  • Page 204: Rear Brake

    Rear brake 4-49 3. Measure: • brake pad wear limit “a” out of specification → replace the brake pads as a set. 4. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring tip always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 205: Rear Brake

    Rear brake 4-50 eas22590 removing the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt “1” • copper washers “2” • brake hose “3” • brake caliper “4” tip put the end of the brake hose into a container and pump o...

  • Page 206: Rear Brake

    Rear brake 4-51 warning ewa14b1005 whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. 2. Check: • brake caliper bracket “1” cracks/damage → replace. Eas22650 assembling the rear brake caliper warning ewa14b1006 • before installation, a...

  • Page 207: Rear Brake

    Rear brake 4-52 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type ...

  • Page 208: Rear Brake

    Rear brake 4-53 2. Check: • brake fluid reservoir tank “1” cracks/damage → replace. • brake fluid reservoir diaphragm “2” cracks/damage → replace. • brake fluid reservoir diaphragm holder “3” cracks/damage → replace. 3. Check: • brake hoses “1” cracks/damage/wear → replace. Eas22730 assembling the r...

  • Page 209: Rear Brake

    Rear brake 4-54 • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance. • when refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly low...

  • Page 210: Handlebars

    Handlebars 4-55 eas22850 handlebars removing the handlebars order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Ecu and rectifier/regulator refer to “general chassis” on page 4-1. Air duct refer to “general chassis” on page 4-1. Front cowling refer to “general...

  • Page 211: Handlebars

    Handlebars 4-56 removing the handlebars order job/parts to remove q’ty remarks 9 throttle grip 1 10 brake switch connector 2 11 right handlebar switch 1 12 handlebar pinch bolt 2 loosen. 13 handlebar bolt 2 loosen. 14 upper bracket pinch bolt 2 loosen. 15 steering stem nut 1 16 main switch coupler 2...

  • Page 212: Handlebars

    Handlebars 4-57 eas22870 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: • grip end • handlebar grip “1” tip blow compressed air between the handlebar and the handlebar grip, and g...

  • Page 213: Handlebars

    Handlebars 4-58 4. Install: • throttle grip • throttle cable housing “1” • throttle cables tip align the projection “a” on the throttle cable housing with the hole “b” in the right handlebar. 5. Install: • clutch lever holder “1” tip align the slit on the clutch lever holder with the punch mark “a” ...

  • Page 214: Front Fork

    Front fork 4-59 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies both of the front fork legs. Side cowling refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-18. 1 front fender 1 2 upper bracket ...

  • Page 215: Front Fork

    Front fork 4-60 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 washer 1 4 nut 1 5 spacer 1 6 upper spring seat 1 7 fork spring 1 8 lower spring seat 1 9 outer tube 1 10 dust seal 1 11 ...

  • Page 216: Front Fork

    Front fork 4-61 disassembling the front fork legs order job/parts to remove q’ty remarks 14 damper rod assembly 1 15 damper adjusting rod 1 16 damper adjusting valve 1 17 damper adjusting valve spring 1 18 inner tube 1 for installation, reverse the removal proce- dure..

  • Page 217: Front Fork

    Front fork 4-62 eas14b1006 removing the front fork legs the following procedure applies to both of the front fork legs. Tip each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipp...

  • Page 218: Front Fork

    Front fork 4-63 tip use the side of the rod holder that is marked “b”. C. Hold the spring preload adjusting bolt “6” and loosen the nut “3”. Eca14b1005 when loosening the nut “3”, be sure not to break the projections “a” on the cap bolt collar “7” of the cap bolt “1”. Tip loosen the nut using a prop...

  • Page 219: Front Fork

    Front fork 4-64 eas23010 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube “1” • outer tube “2” bends/damage/scratches → replace. Warning ewa13650 do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Me...

  • Page 220: Front Fork

    Front fork 4-65 2. Lubricate: • inner tube’s outer surface 3. Tighten: • damper rod assembly tip tighten the damper rod assembly with the damper rod holder “1”. 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” eca14b1007 make sure the numbered side of the oil seal faces bo...

  • Page 221: Front Fork

    Front fork 4-66 8. Install: • dust seal “1” (with the fork seal driver weight “2”) 9. Install: • rod puller “1” • rod puller attachment “2” (onto the damper rod “3”) 10. Fully compress the front fork leg. 11. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) eca14b1008...

  • Page 222: Front Fork

    Front fork 4-67 tip be sure to bleed the front fork leg of any resid- ual air. 14. Measure: • front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) out of specification → correct. 15. Install: • lower spring seat “1” • fork sp...

  • Page 223: Front Fork

    Front fork 4-68 j. Remove the rod puller and rod puller attachment. K. Install the nut “1” all the way onto the damper rod assembly. L. Install the damper adjusting valve spring, the damper adjusting valve and the damper adjusting rod. M. Install the washer and cap bolt, and then finger tighten the ...

  • Page 224: Front Fork

    Front fork 4-69 3. Tighten: • cap bolt “1” • handlebar bolt “2” • handlebar pinch bolt “3” • upper bracket pinch bolt “4” 4. Check: • cable routing tip make sure the brake hose, throttle cables, clutch cable, and handlebar switch leads are routed properly. Refer to “cable routing” on page 2-49. 5. I...

  • Page 225: Steering Head

    Steering head 4-70 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Air duct refer to “general chassis” on page 4-1. Front fork legs refer to “front fork” on page 4-59. Handlebars refer to “handlebars” on pa...

  • Page 226: Steering Head

    Steering head 4-71 removing the lower bracket order job/parts to remove q’ty remarks 13 lower ring nut 1 14 lower bracket 1 15 upper bearing cover 1 16 upper bearing inner race 1 17 upper bearing 1 18 lower bearing 1 19 lower bearing inner race 1 20 lower bearing dust seal 1 21 upper bearing outer r...

  • Page 227: Steering Head

    Steering head 4-72 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut “1” (with the steering nut wrench “2”) warning ewa13730 securely support the lower ...

  • Page 228: Steering Head

    Steering head 4-73 eas23140 installing the steering head 1. Lubricate: • upper bearing • lower bearing • bearing races 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 3-22. 3. Install: • upper bra...

  • Page 229: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-74 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Passenger seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-...

  • Page 230: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-75 eas14b1010 handling the rear shock absorber warning ewa14b1013 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held r...

  • Page 231: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-76 • spring damage/wear → replace the rear shock absorber assembly. • bearing damage/wear → replace. • bolts bends/damage/wear → replace. Eas23260 checking the connecting arm and relay arm 1. Check: • connecting arm “1” • relay arm “2” damage/wear → replace. 2. Check: ...

  • Page 232: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-77 • rear shock absorber assembly lower nut 4. Install: • connecting arm tip when installing the connecting arm, lift up the swingarm. 5. Tighten: • connecting arm and swingarm nut rear shock absorber assembly bracket and frame nut 92 nm (9.2 m·kgf, 66 ft·lbf) rear sho...

  • Page 233: Swingarm

    Swingarm 4-78 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-24. Rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-74. 1 drive chain guard 1 2 rear fender 1 3 left footrest 1 4 drive chain guide 1...

  • Page 234: Swingarm

    Swingarm 4-79 removing the swingarm order job/parts to remove q’ty remarks 14 oil seal 1 15 circlip 1 16 bearing 1 17 bearing 2 for installation, reverse the removal proce- dure..

  • Page 235: Swingarm

    Swingarm 4-80 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. Remove: • connecting arm and swingarm bo...

  • Page 236: Swingarm

    Swingarm 4-81 eas23360 checking the swingarm 1. Check: • swingarm bends/cracks/damage → replace. 2. Check: • pivot shaft roll the pivot shaft on a flat surface. Bends → replace. Warning ewa13770 do not attempt to straighten a bent pivot shaft. 3. Wash: • pivot shaft • dust cover • spacer • washers •...

  • Page 237: Swingarm

    Swingarm 4-82 3. Install: • pivot shaft “1” tip tighten the pivot shaft with the damper rod holder (22 mm) “2”. 4. Install: • pivot shaft ring nut “1” tip tighten the pivot shaft ring nut with the ring nut wrench “2”. 5. Install: • pivot shaft nut “1” 6. Adjust: • drive chain slack refer to “adjusti...

  • Page 238: Chain Drive

    Chain drive 4-83 eas23400 chain drive removing the drive sprocket and drive chain order job/parts to remove q’ty remarks drive chain refer to “adjusting the drive chain slack” on page 3-21. 1 locknut 2 2 shift rod 1 3 shift arm 1 4 shift pedal 1 5 drive sprocket cover 1 6 drive sprocket nut 1 7 wash...

  • Page 239: Chain Drive

    Chain drive 4-84 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain tip cut the ...

  • Page 240: Chain Drive

    Chain drive 4-85 use only kerosene to clean the drive chain. • do not soak the drive chain in kerosene for more than ten minutes, otherwise the o-rings can be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • o-rings “1” damage → replace the drive chain. • drive chain rollers “2” damage/wear → rep...

  • Page 241: Chain Drive

    Chain drive 4-86 b. After riveting, make sure the diameter between the edges “b” of the connecting pin “2” is 5.7–6.0 mm (0.22–0.24 in). C. After riveting, make sure the space “c”, which is inside of the connecting link “3” and inside of the connecting plate “1”, is 16.3–16.5 mm (0.64–0.65 in). ▲▲▲▲...

  • Page 242: Chain Drive

    Chain drive 4-87.

  • Page 243: Engine

    5 engine engine inspection..................................................................................5-1 measuring the compression pressure .................................5-1 engine removal ......................................................................................5-3 installing ...

  • Page 244

    Oil pump ................................................................................................... 5-51 removing the oil pan ................................................................... 5-54 checking the sprocket and chain ......................................... 5-54 checking the ...

  • Page 245

    Transmission......................................................................................... 5-92 removing the transmission ...................................................... 5-96 checking the shift forks .......................................................... 5-96 checking the shift...

  • Page 246: Engine Inspection

    Engine inspection 5-1 eas14b1052 engine inspection eas14b1053 measuring the compression pres- sure the following procedure applies to all of the cylinders. Tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer t...

  • Page 247: Engine Inspection

    Engine inspection 5-2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: • spark plugs • ignition coils 8. Install: • all removed parts tip for installation, reverse the removal proce- dure. Compression pressure (with oil applied into the cylinder) reading diagnosis higher than without oil piston ring(s) we...

  • Page 248: Engine Removal

    Engine removal 5-3 eas23711 engine removal removing the exhaust pipe and muffler order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Passenger seat refer to “general chassis” on page 4-1. Upper tail cover refer to “general chassis” on page 4-1. Side cowling refe...

  • Page 249: Engine Removal

    Engine removal 5-4 removing the exhaust pipe and muffler order job/parts to remove q’ty remarks 10 left muffler 1 11 left muffler gasket 1 12 right muffler clamp 1 loosen. 13 right muffler 1 14 right muffler gasket 1 15 rear brake light switch coupler 1 disconnect. 16 right footrest assembly 1 17 ex...

  • Page 250: Engine Removal

    Engine removal 5-5 removing the exhaust pipe and muffler order job/parts to remove q’ty remarks 25 exhaust chamber protector 1 26 exhaust chamber pipe protector clamp 1 loosen. 27 exhaust chamber pipe protector 1 28 exhaust chamber bracket 1 29 exhaust pipe 1 30 exhaust pipe gasket 4 for installatio...

  • Page 251: Engine Removal

    Engine removal 5-6 disconnecting the leads and hoses order job/parts to remove q’ty remarks battery negative lead refer to “general chassis” on page 4-1. Battery positive lead refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Side cowling air duct refer to “general ...

  • Page 252: Engine Removal

    Engine removal 5-7 disconnecting the leads and hoses order job/parts to remove q’ty remarks 5 speed sensor lead coupler 1 disconnect. 6 oil level switch lead coupler 1 disconnect. 7 gear position sensor coupler 2 disconnect. 8 engine ground lead 2 disconnect. 9 clutch cable 1 disconnect. For install...

  • Page 253: Engine Removal

    Engine removal 5-8 removing the engine order job/parts to remove q’ty remarks 1 left lower cowling bracket 1 2 right lower cowling bracket 1 3 left inner panel bracket 1 4 right inner panel bracket 1 5 sidestand assembly 1 6 sidestand switch 1 7 holder 1 8 sidestand switch bracket 1 9 engine mountin...

  • Page 254: Engine Removal

    Engine removal 5-9 removing the engine order job/parts to remove q’ty remarks 16 engine mount nut (rear lower side) 1 17 engine mount bolt (rear upper side) 1 18 engine mount bolt (rear lower side) 1 19 engine 1 20 engine mount adjusting bolt 2 for installation, reverse the removal proce- dure..

  • Page 255: Engine Removal

    Engine removal 5-10 eas23720 installing the engine eca14b1021 do not hold the radiator inlet pipe when removing the engine and moving the engine by itself. 1. Install: • engine mounting adjust bolts (temporary tighten) 2. Install: • engine 3. Install: • engine mounting bolt (rear upper side) “1” • e...

  • Page 256: Engine Removal

    Engine removal 5-11 7. Tighten: • engine mounting nut (rear lower side) “1” • engine mounting nut (rear upper side) “2” tip first tighten the engine mounting nut (rear lower side), and then tighten the engine mounting nut (rear upper side). 8. Tighten: • engine mounting bolt (front left side) “1” 9....

  • Page 257: Engine Removal

    Engine removal 5-12 installed depth of gasket “c” 3.5 mm (0.14 in).

  • Page 258: Camshafts

    Camshafts 5-13 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Side cowling refer to “general chassis” on page 4-1. Radiator refer to “radiator” on page 6-1....

  • Page 259: Camshafts

    Camshafts 5-14 for installation, reverse the removal proce- dure. Removing the cylinder head cover order job/parts to remove q’ty remarks.

  • Page 260: Camshafts

    Camshafts 5-15 removing the camshafts order job/parts to remove q’ty remarks pickup coil cover 2 refer to “pickup rotor” on page 5-43. Generator cover refer to “generator” on page 5-37. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft cap 3 4 exhaust camshaft cap 3 5 in...

  • Page 261: Camshafts

    Camshafts 5-16 removing the camshafts order job/parts to remove q’ty remarks 14 crankshaft sprocket 1 15 collar 1 16 straight key 1 for installation, reverse the removal proce- dure..

  • Page 262: Camshafts

    Camshafts 5-17 eas23810 removing the camshafts 1. Remove: • pickup rotor cover 2 refer to “pickup rotor” on page 5-43. 2. Align: • “k” mark “a” on the pickup rotor (with the crankcase mating surface “b”) eca14b1034 when turning the crankshaft with a tool, remove all the spark plugs. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 263: Camshafts

    Camshafts 5-18 7. Remove: • dowel pins • timing chain guide (intake side) • timing chain guide (exhaust side) 8. Remove: • pickup rotor refer to “pickup rotor” on page 5-43. • timing chain • crankshaft sprocket “1” • collar “2” • straight key “3” eas23850 checking the camshafts 1. Check: • camshaft ...

  • Page 264: Camshafts

    Camshafts 5-19 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance out of specification → measure the cam- shaft journal diameter. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head (without the camshaft caps). B. Position strip of plastigauge® “1” onto the camshaft...

  • Page 265: Camshafts

    Camshafts 5-20 eas23950 checking the timing chain guides 1. Check: • timing chain guide (exhaust side) “1” • timing chain guide (intake side) “2” • timing chain guide (top side) “3” damage/wear → replace the defective part(s). Eas23960 checking the timing chain ten- sioner 1. Check: • timing chain t...

  • Page 266: Camshafts

    Camshafts 5-21 2. Install: • pickup rotor refer to “pickup rotor” on page 5-43. 3. Install: • timing chain guide (exhaust side) • timing chain guide (intake side) • dowel pins 4. Align: • “k” mark “a” on the pickup rotor (with the crankcase mating surface “b”) eca14b1034 when turning the crankshaft ...

  • Page 267: Camshafts

    Camshafts 5-22 6. Install: • exhaust camshaft “1” • intake camshafts “2” tip • hang the timing chain on the sprocket from the exhaust camshaft to the intake camshaft, and then put it on the cylinder head. • the intake camshaft sprocket timing mark “a” and exhaust camshaft sprocket timing mark “b” sh...

  • Page 268: Camshafts

    Camshafts 5-23 b. Keep pressing the timing chain tensioner rod, mount clip “5” into groove “6”, and lock the timing chain tensioner rod. C. In the status of step “b”, install the rod assembly in the cylinder block. Tip always use a new gasket. D. Unlock the timing chain tensioner by turn- ing the cr...

  • Page 269: Camshafts

    Camshafts 5-24 • tighten the cylinder head cover bolts stages and in a crisscross pattern. Yamaha bond no.1215 (three bond no.1215®) 90890-85505.

  • Page 270: Cylinder Head

    Cylinder head 5-25 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Intake camshaft refer to “camshafts” on page 5-13. Exhaust camshaft refer to “camshafts” on page 5-13. 1 coolant temperature sensor 1 2 cylinder h...

  • Page 271: Cylinder Head

    Cylinder head 5-26 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the cam- shafts” on page 5-17. 2. Remove: • cylinder head nuts • cylinder head bolts tip • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a t...

  • Page 272: Cylinder Head

    Cylinder head 5-27 3. Install: • cylinder head • washers • cylinder head nuts • cylinder head bolts tip • pass the timing chain through the timing chain cavity. • lubricate the cylinder head nuts and wash- ers with engine oil. 4. Tighten: • cylinder head nuts “1”–“10” • cylinder head bolts “11”, “12...

  • Page 273: Valves and Valve Springs

    Valves and valve springs 5-28 eas24270 valves and valve springs * silicon fluid removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-25. 1 intake valve lifter 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve sprin...

  • Page 274: Valves and Valve Springs

    Valves and valve springs 5-29 * silicon fluid removing the valves and valve springs order job/parts to remove q’ty remarks 10 exhaust valve lifter 8 11 exhaust valve pad 8 12 exhaust valve cotter 16 13 exhaust valve spring retainer 8 14 exhaust valve spring 8 15 exhaust valve 8 16 exhaust valve stem...

  • Page 275: 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 cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lif...

  • Page 276: Valves and Valve Springs

    Valves and valve springs 5-31 eas24290 checking the valves and valve guides the following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide tip to ease valve guide remov...

  • Page 277: 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 → replace the valve. 5. Mea...

  • Page 278: Valves and Valve Springs

    Valves and valve springs 5-33 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. 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 impression. D. Measure the valve seat width. T...

  • Page 279: Valves and Valve Springs

    Valves and valve springs 5-34 e. Apply a fine lapping compound to the valve face and repeat the above steps. F. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Inst...

  • Page 280: Valves and Valve Springs

    Valves and valve springs 5-35 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head....

  • Page 281: Valves and Valve Springs

    Valves and valve springs 5-36 4. Install: • valve cotters “1” tip install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attach- ment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft...

  • Page 282: Generator

    Generator 5-37 eas24480 generator removing the generator order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Side cowling refer to “general chassis” on page 4-1. Stator coil lead coupler refer to “general chassis”...

  • Page 283: Generator

    Generator 5-38 eas24490 removing the generator 1. Remove: • generator cover • generator cover gasket • dowel pins 2. Remove: • generator rotor bolt “1” • washer tip while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 3. Remove: • generator rotor “1” (wi...

  • Page 284: Generator

    Generator 5-39 4. Apply: • sealant (onto the stator coil lead grommet “1”) yamaha bond no.1215 (three bond no.1215®) 90890-85505.

  • Page 285: Starter Clutch

    Starter clutch 5-40 eas24550 starter clutch removing the starter clutch order job/parts to remove q’ty remarks clutch housing assembly refer to “clutch” on page 5-59. 1 starter clutch gear 1 2 bearing 1 3 starter clutch assembly 1 4 starter idle gear 1 for installation, reverse the removal proce- du...

  • Page 286: Starter Clutch

    Starter clutch 5-41 eas24560 removing the starter clutch 1. Remove: • starter clutch bolt “1” tip • while holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt. • fix the flat surface of the clutch housing assembly with the sheave holder. Eas24570 checkin...

  • Page 287: Starter Clutch

    Starter clutch 5-42 • fix the flat surface of the clutch housing assembly with the sheave holder. Sheave holder 90890-01701 primary clutch holder ys-01880-a.

  • Page 288: Pickup Rotor

    Pickup rotor 5-43 eas14b1058 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Generator cover refer to “generator” on page 5-37. Air filter case refer to “air filter case” on page 7-5. 1 timing check bolt 1 2 pickup rotor cover...

  • Page 289: Pickup Rotor

    Pickup rotor 5-44 eas14b1059 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer • pickup rotor tip while holding the generator rotor “2” with the sheave holder “3”, loosen the pickup rotor bolt. Eas14b1060 installing the pickup rotor 1. Install: • pickup rotor “1” • washer • picku...

  • Page 290: Pickup Rotor

    Pickup rotor 5-45 yamaha bond no.1215 (three bond no.1215®) 90890-85505.

  • Page 291: Electric Starter

    Electric starter 5-46 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks battery negative lead refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Throttle body refer to “...

  • Page 292: Electric Starter

    Electric starter 5-47 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 lock washer 1 4 washer 1 5 starter motor yoke 1 6 armature assembly 1 7 gasket 2 8 brush holder 1 9 o-ring 1 10 rear cover 1 for installation, reverse the removal proce- dure..

  • Page 293: Electric Starter

    Electric starter 5-48 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 294: Electric Starter

    Electric starter 5-49 6. Measure: • brush spring force out of specification → replace the brush holder. 7. Check: • gear teeth damage/wear → replace the gear. Eas24800 assembling the starter motor 1. Install: • brush holder • armature assembly • o-ring ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull both the...

  • Page 295: Electric Starter

    Electric starter 5-50 tip align the match marks “a” on the starter motor yoke with the match marks “b” on the front and rear covers..

  • Page 296: Oil Pump

    Oil pump 5-51 eas24921 oil pump removing the oil pan and oil/water pump assembly order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Lower cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-29. Fuel t...

  • Page 297: Oil Pump

    Oil pump 5-52 removing the oil pan and oil/water pump assembly order job/parts to remove q’ty remarks 6 dowel pin 2 7 drain pipe 1 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 1 11 relief valve assembly 1 12 oil/water pump assembly drive chain guide 1 13 collar 1 14 oil/water pump assembly d...

  • Page 298: Oil Pump

    Oil pump 5-53 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil/water pump driven sprocket 1 2 circlip 1 3 oil pump housing 1 4 bearing 1 5 dowel pin 2 6 oil pump outer rotor 1 7 oil pump inner rotor 1 8 pin 1 for installation, reverse the removal proce- dure..

  • Page 299: Oil Pump

    Oil pump 5-54 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil level switch lead holder “2” • oil pan “3” • gasket • dowel pins tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas14b1021...

  • Page 300: Oil Pump

    Oil pump 5-55 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas24970 checking the relief valve 1. Check: • relief valve body “1” • relief valve “2” • spring “3” • damage/wear → replace the defective part(s). Eas24980 checking the oil deliv...

  • Page 301: Oil Pump

    Oil pump 5-56 eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • pin “1” • inner rotor “2” • outer rotor “3” • oil pump housing “4” • oil pump housing bolt tip when installing the inner rotor, align the pin “1” i...

  • Page 302: Oil Pump

    Oil pump 5-57 eca14b1018 after installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 3. Install: • oil/water pump assembly drive chain guide “1” tip “up” mark of the oil/water pump assembly drive chain guide is upward. 4. Install: • oil...

  • Page 303: Oil Pump

    Oil pump 5-58 • engine oil drain bolt • gasket tip tighten the oil pan bolts in stages and in a crisscross pattern. Oil pan bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) oil level switch bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) engine oil drain bolt 43 nm (4.3 m·kgf, 31 ft·lbf) new.

  • Page 304: Clutch

    Clutch 5-59 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. 1 pull lever cover 1 2 clutch cable 1 disconnect. 3 clutch cover 1 4 clutch cover gasket 1 5 dowel pin 3 6 oil filler cap 1 for installation, reverse the removal proce- dure..

  • Page 305: Clutch

    Clutch 5-60 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 1 2 pull lever 1 3 pull lever spring 1 4 circlip 1 5 pull lever shaft 1 6 oil seal 1 7 bearing 1 8 bearing 1 for installation, reverse the removal proce- dure..

  • Page 306: Clutch

    Clutch 5-61 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 1 3 pull rod 1 4 bearing 1 5 friction plate 1 1 6 clutch plate 1 1 7 friction plate 2 7 8 clutch plate 2 1 9 clutch plate 3 6 10 friction plate 1 1 11 clutch boss nut 1 12 spring 3 13 clu...

  • Page 307: Clutch

    Clutch 5-62 removing the clutch order job/parts to remove q’ty remarks 16 thrust washer 1 17 clutch housing assembly 1 18 bearing 1 19 washer 1 for installation, reverse the removal proce- dure..

  • Page 308: Clutch

    Clutch 5-63 eas25080 removing the clutch 1. Remove: • pull lever cover “1” • clutch cover “2” • gasket tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compression ...

  • Page 309: Clutch

    Clutch 5-64 • pressure plate 2 • conical spring washer • thrust washer • clutch housing assembly eas25100 checking the friction plates the following procedure applies to all of the friction plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction ...

  • Page 310: Clutch

    Clutch 5-65 tip when adjusting the clutch assembly width [by replacing the clutch plate(s)], be sure to replace the clutch plate “1” fast. After replacing the clutch plate “1”, if specifica- tions cannot be met, replace the clutch plate “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas25140 checking the clutc...

  • Page 311: Clutch

    Clutch 5-66 eas25170 checking the pressure plate 1. Check: • pressure plate 1 “1” • pressure plate 2 “2” cracks/damage → replace. • bearing “3” damage/wear → replace. Eas25200 checking the primary drive gear 1. Check: • primary drive gear damage/wear → replace the crankshaft and clutch housing as a ...

  • Page 312: Clutch

    Clutch 5-67 2. Install: • pressure plate 2 “1” • clutch boss “2” tip fit the groove “a” of the pressure plate 2 to the projection “b” of the clutch boss to assemble. 3. Install: • springs “1” • clutch boss nut “2” tip • lubricate the clutch boss nut threads with engine oil. • while holding the clutc...

  • Page 313: Clutch

    Clutch 5-68 6. Install: • bearing (into the pressure plate 1) • pull rod • pressure plate 1 7. Install: • clutch springs • clutch spring bolts “1” tip tighten the clutch spring bolts in stages and in a crisscross pattern. 8. Install: • dowel pins • clutch cover gasket • clutch cover “1” tip • positi...

  • Page 314: Shift Shaft

    Shift shaft 5-69 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks shift arm refer to “chain drive” on page 4-83. Clutch assembly refer to “clutch” on page 5-59. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 circlip 1 6 washer 1 7 stopper le...

  • Page 315: Shift Shaft

    Shift shaft 5-70 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” • collar damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stop- per leve...

  • Page 316: Crankcase

    Crankcase 5-71 eas25540 crankcase * following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. Separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Cylinder head refer to “cylinder head” on page 5-...

  • Page 317: Crankcase

    Crankcase 5-72 * following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. Separating the crankcase order job/parts to remove q’ty remarks 8 crankcase breather cover 1 9 crankcase breather cover gasket 1 10 crankcase breather case 1 11 crankcase breathe...

  • Page 318: Crankcase

    Crankcase 5-73 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts tip • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in increasing numerical ...

  • Page 319: Crankcase

    Crankcase 5-74 6. Install: • crankcase bolts tip • lubricate the bolts “1”– 18” thread, mating surfaces and washers with engine oil. • lubricate the bolts “19”–“40” thread and mat- ing surfaces with engine oil (except “31”). • apply loctite® to the screw of the bolt “31” and engine oil to the bearin...

  • Page 320: Connecting Rods And Pistons

    Connecting rods and pistons 5-75 eas14b1024 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-71. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 connecting rod 4 5 p...

  • Page 321: Connecting Rods And Pistons

    Connecting rods and pistons 5-76 eas26030 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap “1” • connecting rod • big end bearings tip • identify the position of each big end bear- ing so that it can b...

  • Page 322: Connecting Rods And Pistons

    Connecting rods and pistons 5-77 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “c” with the cylinder bore gauge. Tip measure cylinder bore “c” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the me...

  • Page 323: Connecting Rods And Pistons

    Connecting rods and pistons 5-78 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 324: Connecting Rods And Pistons

    Connecting rods and pistons 5-79 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas14b1023 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end b...

  • Page 325: Connecting Rods And Pistons

    Connecting rods and pistons 5-80 • after installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. Tip install by carrying out the following procedures in order to assemble in the most suitable con- dition. E. Tighten the connecti...

  • Page 326: Connecting Rods And Pistons

    Connecting rods and pistons 5-81 warning ewa13400 if the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. Eca13950 do not use a torque wrench to tight...

  • Page 327: Connecting Rods And Pistons

    Connecting rods and pistons 5-82 eas26190 installing the connecting rod and piston the following procedure applies to all of the connecting rods and pistons. 1. Install: • big end bearings • connecting rod cap (onto the connecting rod) tip • be sure to reinstall each big end bearing in its original ...

  • Page 328: Connecting Rods And Pistons

    Connecting rods and pistons 5-83 4. Install: • piston “1” (onto the respective connecting rod “2”) • piston pin “3” • piston pin clip “4” tip • apply engine oil onto the piston pin. • make sure that the “y” mark “a” on the con- necting rod faces left when the punch mark “b” on the piston is pointing...

  • Page 329: Connecting Rods And Pistons

    Connecting rods and pistons 5-84 tip fit the projection “a” of the piston installing tool “3” and blunt-edged part “b” of the cylinder, fix the position of the piston installing tool, and then push the piston down to the cylinder. 10. Install: • cylinder gasket • dowel pin • cylinder assembly • conn...

  • Page 330: Connecting Rods And Pistons

    Connecting rods and pistons 5-85 warning ewa13400 if the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. Eca13950 do not use a torque wrench to tight...

  • Page 331: Crankshaft

    Crankshaft 5-86 eas25960 crankshaft removing the crankshaft order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-71. Connecting rod refer to “removing the connecting rods and pistons” on page 5-76. 1 balancer shaft 1 2 balancer shaft journal lower bearing 4 3 balance...

  • Page 332: Crankshaft

    Crankshaft 5-87 eas25980 removing the crankshaft and bal- ancer shaft 1. Remove: • balancer shaft “1” • balancer shaft journal bearings • crankshaft assembly “2” • crankshaft journal bearings tip identify the position of each balancer shaft journal bearings and crankshaft journal bear- ings so that ...

  • Page 333: Crankshaft

    Crankshaft 5-88 d. Put a piece of plastigauge® “1” on each crankshaft journal. Tip do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bear- ings “1” into the lower crankcase and assemble the crankcase halves. Tip • align the projections “...

  • Page 334: Crankshaft

    Crankshaft 5-89 eas14b1027 checking the balancer shaft 1. Measure: • balancer shaft runout out of specification → replace the bal- ancer shaft. 2. Check: • balancer shaft journal surfaces • bearing surfaces scratches/wear → replace the balancer shaft. 3. Measure: • balancer shaft-journal-to-balancer...

  • Page 335: Crankshaft

    Crankshaft 5-90 tip • align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in the lower crankcase. • do not move the balancer shaft until the clearance measurement has been com- pleted. F. Tighten the bolts to specification in the tightening sequence cast on th...

  • Page 336: Crankshaft

    Crankshaft 5-91 tip • align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcases. • be sure to install each crankshaft journal bearing in its original place. Eas14b1028 installing the balancer assembly 1. Install: • balancer journal upper bearings (into t...

  • Page 337: Transmission

    Transmission 5-92 eas26241 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase separate. Refer to “crankcase” on page 5-71. 1 drive axle assembly 1 2 shift drum retainer 2 3 spring 2 4 shift fork guide bar 2 5 shift fork...

  • Page 338: Transmission

    Transmission 5-93 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd/4th pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 col...

  • Page 339: Transmission

    Transmission 5-94 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 circlip 1 2 bearing 1 3 washer 1 4 1st wheel gear 1 5 collar 1 6 5th wheel gear 1 7 circlip 1 8 washer 1 9 3rd wheel gear 1 10 collar 1 11 toothed lock washer 1 12 toothed lock washer retainer 1 13 4th w...

  • Page 340: Transmission

    Transmission 5-95 disassembling the drive axle assembly order job/parts to remove q’ty remarks 16 circlip 1 17 6th wheel gear 1 18 circlip 1 19 washer 1 20 2nd wheel gear 1 21 collar 1 22 collar 1 23 oil seal 1 24 circlip 1 25 bearing 1 26 drive axle 1 for installation, reverse the removal proce- du...

  • Page 341: Transmission

    Transmission 5-96 eas26250 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • main axle assembly “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “2” of t...

  • Page 342: Transmission

    Transmission 5-97 3. Check: • shift fork movement (along the shift fork guide bar) rough movement → replace the shift forks and shift fork guide bar as a set. Eas26270 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear → replace the shift drum assembly. • shift drum...

  • Page 343: Transmission

    Transmission 5-98 5. Check: • transmission gear movement rough movement → replace the defec- tive part(s). 6. Check: • circlips bends/damage/looseness → replace. Eas29020 assembling the main axle and drive axle 1. Install: • toothed washer “1” • circlip “2” tip • be sure the circlip sharp-edged corn...

  • Page 344: Transmission

    Transmission 5-99 3. Install: • shift fork-c “1” • shift drum assembly “2” • shift fork guide bar “3” tip • the embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “r”, “c”, “l”. • carefully position the shift forks so that they are in...

  • Page 345: Cooling System

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

  • Page 346: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-32. Ecu refer to “general chassis” on page 4-1. Side cowling refer to “general chassis” on page 4-1. Rectifier/regulator refer to “general chassis” on ...

  • Page 347: Radiator

    Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 12 radiator bracket 1 13 radiator fan 2 14 thermostat bypass hose 2 1 disconnect. 15 thermostat bypass hose 3 1 16 radiator inlet pipe 1 17 radiator inlet hose 1 for installation, reverse the removal proce- dure..

  • Page 348: Radiator

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

  • Page 349: Radiator

    Radiator 6-4 b. Apply 137.3 kpa (1.37 kgf/cm 2 , 19.9 psi) of pressure. C. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3..

  • Page 350: Oil Cooler

    Oil cooler 6-5 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-32. Engine oil drain. Refer to “changing the engine oil” on page 3-29. Side cowling refer to “general chassis” on page 4-1. Lower cowling refer t...

  • Page 351: Oil Cooler

    Oil cooler 6-6 removing the oil cooler order job/parts to remove q’ty remarks 8 water jacket joint 1 9 o-ring 1 10 water pump outlet pipe 1 11 o-ring 1 12 o-ring 1 for installation, reverse the removal proce- dure..

  • Page 352: Oil Cooler

    Oil cooler 6-7 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear → replace. 3. Check: • water jacket joint inlet hose • water jacket joint • water pump outlet pipe cracks/damage/wear → replac...

  • Page 353: Thermostat

    Thermostat 6-8 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-32. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. Throttle body refer to “throttle bodies” ...

  • Page 354: Thermostat

    Thermostat 6-9 removing the thermostat order job/parts to remove q’ty remarks 12 thermostat bypass hose 2 1 13 water pump bypass hose 1 14 joint 1 15 thermostat bypass hose 1 1 16 engine outlet pipe 1 17 o-ring 1 for installation, reverse the removal proce- dure..

  • Page 355: Thermostat

    Thermostat 6-10 eas26450 checking the thermostat 1. Check: • thermostat “1” does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in the water. ...

  • Page 356: Thermostat

    Thermostat 6-11 eas26480 installing the thermostat assem- bly 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-32. 2. Check: • cooling system leaks → repair or replace any faulty part. Refer to “installing the radiator” on p...

  • Page 357: Water Pump

    Water pump 6-12 eas26500 water pump disassembling the water pump order job/parts to removes q’ty remarks oil/water pump assembly refer to “oil pump” on page 5-51. Oil pump rotor refer to “oil pump” on page 5-51. 1 water pump cover 1 2 o-ring 1 3 pin 2 4 impeller shaft (along with the impeller) 1 5 w...

  • Page 358: Water Pump

    Water pump 6-13 eas26520 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 2. Remove: • oil seal “1” (with a thin, flat-head screwdriver) tip remove the oil seal from the inside of the water pump housing “2”. 3...

  • Page 359: Water Pump

    Water pump 6-14 3. Install: • rubber damper holder “1” • rubber damper “2” tip before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Eca14090 make sure the rubber damper and rubber da...

  • Page 360: Water Pump

    Water pump 6-15.

  • Page 361: Fuel System

    7 fuel system fuel tank .................................................................................................. 7-1 removing the fuel tank side covers ...................................... 7-3 removing the fuel tank ................................................................ 7-3 rem...

  • Page 362: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank and fuel pump order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. 1 fuel tank side cover 2 2 bolt 1 3 bolt/collar/washer 2/2/2 4 fuel tank breather hose 1 disconnect. 5 fuel tank overflow hose 1 disconnect....

  • Page 363: Fuel Tank

    Fuel tank 7-2 removing the fuel tank and fuel pump order job/parts to remove q’ty remarks 15 fuel pump bracket 1 16 fuel pump 1 17 fuel pump gasket 1 for installation, reverse the removal proce- dure..

  • Page 364: Fuel Tank

    Fuel tank 7-3 eas14b1078 removing the fuel tank side covers the following procedure applies to both of the fuel tank side covers. 1. Remove: • fuel tank side cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the screw on the fuel tank side cover. B. Slide the fuel tank side cover to the front and t...

  • Page 365: Fuel Tank

    Fuel tank 7-4 tip • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • install the fuel pump gasket so that the lip side turns to the inside of the fuel tank. • install the fuel pump as shown in the illustra- tion. • align t...

  • Page 366: Air Filter Case

    Air filter case 7-5 eas14b1062 air filter case removing the air filter case and secondary injectors order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. 1 crankcase breather hose 1 disconnect. 2 sub-wire harness coupler 1 disconnect. 3 fuel hose (secondary injector fuel...

  • Page 367: Air Filter Case

    Air filter case 7-6 removing the air filter case and secondary injectors order job/parts to remove q’ty remarks 15 intake funnel servo motor rod assembly 1 16 intake funnel assembly 1 17 intake funnel servo motor 1 for installation, reverse the removal proce- dure..

  • Page 368: Air Filter Case

    Air filter case 7-7 eas14b1105 checking the secondary injectors (before removing) 1. Check: • injectors use the diagnostic code number “d:40– d:43”. Refer to “diagnostic mode” on page 8-38. Eas14b1063 removing the fuel hose (primary injector joint side and secondary injector joint side) 1. Remove: •...

  • Page 369: Air Filter Case

    Air filter case 7-8 4. Remove: • sub-wire harness • secondary injectors ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the fuel rail screws “1” as shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • fuel rails “1” • secondary injector joint “2” eas14b1065 removing the lower air filter case 1. Remove: • low...

  • Page 370: Air Filter Case

    Air filter case 7-9 2. Check: • injector resistance refer to “checking the fuel injec- tors” on page 8-144. Eas14b1113 checking the air filter case seal 1. Check: • air filter case seal “1” damage → replace. Eas14b1066 checking the intake funnel 1. Check: • intake funnel servo motor rod assembly dam...

  • Page 371: Air Filter Case

    Air filter case 7-10 eas14b1107 installing the secondary injec- tors eca14b1046 • always use new o-rings. • when checking the injectors, do not allow any foreign material to enter or adhere to the injectors, fuel rails, or o-rings. • be careful not to twist or pinch the o- rings when installing the ...

  • Page 372: Air Filter Case

    Air filter case 7-11 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas14b1069 installing the fuel hose (primary injector joint side and secondary injector joint side) 1. Connect: • fuel hose (primary injector joint side and secondary injector joint side) eca14b1033 when installing the fuel hose, make sure that it ...

  • Page 373: Throttle Bodies

    Throttle bodies 7-12 eas26970 throttle bodies removing the throttle body assembly order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. 1 throttle position sensor coupler 1 disconnect. 2 accelerator position sensor ...

  • Page 374: Throttle Bodies

    Throttle bodies 7-13 removing the throttle body assembly order job/parts to remove q’ty remarks 14 crankshaft position sensor coupler 1 disconnect. 15 heat protector 1 16 throttle body joint 2 for installation, reverse the removal proce- dure..

  • Page 375: Throttle Bodies

    Throttle bodies 7-14 removing the primary injectors order job/parts to remove q’ty remarks 1 primary injector coupler #1 1 disconnect. 2 primary injector coupler #2 1 disconnect. 3 primary injector coupler #3 1 disconnect. 4 primary injector coupler #4 1 disconnect. 5 sub-wire harness 1 6 intake air...

  • Page 376: Throttle Bodies

    Throttle bodies 7-15 eas14b1108 checking the primary injectors (before removing) 1. Check: • injectors use the diagnostic code number “d:36– d:39”. Refer to “diagnostic mode” on page 8-38. Eas14b1109 removing the primary injectors warning ewa14b1028 • check the injectors in a well-ventilated area fr...

  • Page 377: Throttle Bodies

    Throttle bodies 7-16 tip if the protector “a” is scratched or damaged, replace the throttle bodies as a set. 2. Clean: • throttle bodies eca14b1047 observe the following precautions; other- wise, the throttle bodies may not operate properly. • do not open the throttle valves quickly. • do not subjec...

  • Page 378: Throttle Bodies

    Throttle bodies 7-17 eca14b1029 • do not use a tool, such as a wire brush, to remove the carbon deposits; otherwise, the inside of the throttle bodies may be damaged. • do not allow carbon deposits or other for- eign materials to enter any of the pas- sages in each throttle body or in the space betw...

  • Page 379: Throttle Bodies

    Throttle bodies 7-18 c. Close the valve on the injector pressure adapter. D. Apply air pressure with the air compressor. E. Open the valve on the injector pressure adapter until the specified pressure is reached. Eca14b1037 never exceed the specified air pressure or damage could occur. F. Close the ...

  • Page 380: Throttle Bodies

    Throttle bodies 7-19 eas14b1073 adjusting the throttle position sensor warning ewa14b1023 • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: • throttle position sens...

  • Page 381: Throttle Bodies

    Throttle bodies 7-20 tip “diag” appears on the odometer lcd. F. Diagnostic code number “d:14” is selected. G. Adjust the position of the accelerator posi- tion sensor angle so that 12–22 can appear in the meter. H. After adjusting the accelerator position sen- sor angle, tighten the accelerator posi...

  • Page 382: Air Induction System

    Air induction system 7-21 eas27040 air induction system.

  • Page 383: Air Induction System

    Air induction system 7-22 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover).

  • Page 384: Air Induction System

    Air induction system 7-23 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 7-5. 1 side air filter case duct 2 2 atmospheric pressure sensor coupler 1 disconnect. 3 a...

  • Page 385: Air Induction System

    Air induction system 7-24 removing the reed valves order job/parts to remove q’ty remarks 1 reed valve cover 2 2 reed valve assembly 2 3 reed valve plate 4 for installation, reverse the removal proce- dure..

  • Page 386: Air Induction System

    Air induction system 7-25 eas27060 checking the air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emis- sion of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 387: Air Induction System

    Air induction system 7-26 4. Check: • air cut-off valve cracks/damage → replace. 5. Check: • air induction system solenoid refer to “checking the air induc- tion system solenoid” on page 8- 140. Eas27070 installing the air induction system 1. Install: • reed valves • reed valve stoppers • reed valve...

  • Page 388: Air Induction System

    Air induction system 7-27.

  • Page 389: Electrical System

    8 electrical system ignition system.......................................................................................8-1 circuit diagram................................................................................8-1 engine stopping due to sidestand operation .....................8-3 trouble...

  • Page 390

    Electrical components.................................................................8-117 checking the switches.............................................................8-121 checking the bulbs and bulb sockets...............................8-124 checking the fuses.................................

  • Page 392: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram.

  • Page 393: Ignition System

    Ignition system 8-2 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 15.Sidestand switch 21.Ecu (engine control unit) 22.Ignition coil #1 23.Ignition coil #2 24.Ignition coil #3 25.Ignition coil #4 26.Spark plug 41.Crankshaft position sensor 45.Cylinder identificati...

  • Page 394: Ignition System

    Ignition system 8-3 eas14b1082 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the neutral switc...

  • Page 395: Ignition System

    Ignition system 8-4 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. Ecu (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Gear position sensor 12.Battery negative lead 13.Engine ground.

  • Page 396: Ignition System

    Ignition system 8-5 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Air filter case duct 4. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ n...

  • Page 397: Ignition System

    Ignition system 8-6 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 7. Check the cylinder identification sensor. Refer to “checking the cylin- der identification sensor” on page 8-141. Replace the cylinder identification sensor. 8. Check the main switch. Refer to “che...

  • Page 398: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram.

  • Page 399: Electric Starting System

    Electric starting system 8-8 1. Main switch 4. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Relay unit 13.Starting circuit cut-off relay 15.Sidestand switch 64.Right handlebar switch 67.Engine stop switch 68.Start switch 69.Gear position sensor 71.Left handlebar switch 76.Clutch switch ...

  • Page 400: Electric Starting System

    Electric starting system 8-9 eas14b1036 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 neu...

  • Page 401: Electric Starting System

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

  • Page 402: Electric Starting System

    Electric starting system 8-11 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Heat protector 4. Side cowlings ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fu...

  • Page 403: Electric Starting System

    Electric starting system 8-12 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-121. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-121. Rep...

  • Page 404: Charging System

    Charging system 8-13 eas27200 charging system eas27210 circuit diagram.

  • Page 405: Charging System

    Charging system 8-14 2. Ac magneto 3. Rectifier/regulator 4. Main fuse 8. Battery 101.Engine ground 102.Battery negative lead.

  • Page 406: Charging System

    Charging system 8-15 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Right side cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fuses” on page 8-125. Rep...

  • Page 407: Charging System

    Charging system 8-16.

  • Page 408: Lighting System

    Lighting system 8-17 eas27240 lighting system eas27250 circuit diagram.

  • Page 409: Lighting System

    Lighting system 8-18 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 21.Ecu (engine control unit) 47.Meter assembly 59.High beam indicator light 62.Meter light 71.Left handlebar switch 73.Pass switch 74.Dimmer switch 83.Headlight 84.Auxiliary light 85.Ground (cord headlight) 86....

  • Page 410: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight or license plate light. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Left side cowling 3. Air intake air duct covers 4. Meter assembly ng ...

  • Page 411: Lighting System

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

  • Page 412: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram.

  • Page 413: Signaling System

    Signaling system 8-22 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 17.Fuel sender 21.Ecu (engine control unit) 39.Speed sensor 42.Coolant temperature sensor 47.Meter assembly 49.Fuel level warning light 50.Oil level warning light 51.Neutral indicator light 52.Ta...

  • Page 414: 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. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Side cowlings 5. Meter ass...

  • Page 415: Signaling System

    Signaling system 8-24 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 ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Properl...

  • Page 416: 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 oil level warning light 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...

  • Page 417: Signaling System

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

  • Page 418: Signaling System

    Signaling system 8-27 ng → ok ↓ the shift timing indicator light fails to come on. Ng → ok ↓ ng → ok ↓ 2. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Properly connect or repair the signal- ing system’s wiring. Replace the ecu or meter assembly. 1. Check that ...

  • Page 419: Signaling System

    Signaling system 8-28.

  • Page 420: Cooling System

    Cooling system 8-29 eas27300 cooling system eas27310 circuit diagram.

  • Page 421: Cooling System

    Cooling system 8-30 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 21.Ecu (engine control unit) 42.Coolant temperature sensor 90.Radiator fan motor relay 91.Right radiator fan motor fuse 92.Left radiator fan motor fuse 93.Right radiator fan motor 94.Left radiator fan motor 100....

  • Page 422: Cooling System

    Cooling system 8-31 eas27320 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, radiator fan motor and fuel injection system...

  • Page 423: Cooling System

    Cooling system 8-32.

  • Page 424: Fuel Injection System

    Fuel injection system 8-33 eas27330 fuel injection system eas27340 circuit diagram.

  • Page 425: Fuel Injection System

    Fuel injection system 8-34 1. Main switch 4. Main fuse 7. Etv (electronic throttle valve) fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 13.Starting circuit cut-off relay 14.Fuel pump relay 15.Sidestand switch 16.Fuel pump 18.Throttle position sensor 19.Accelerator position sensor 20.O ...

  • Page 426: 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 engine under substitute char...

  • Page 427: 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 illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate f...

  • Page 428: Fuel Injection System

    Fuel injection system 8-37 eas14b1115 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the faulty system with the fa...

  • Page 429: Fuel Injection System

    Fuel injection system 8-38 eas14b1084 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch...

  • Page 430: Fuel Injection System

    Fuel injection system 8-39 sensor operation table diag- nostic code no. Item meter display checking method d:01 throttle position sensor sig- nal 1 • fully closed position 12–21 check with throttle valves fully closed. • fully opened position 97–106 check with throttle valves fully open. D:02 atmosp...

  • Page 431: Fuel Injection System

    Fuel injection system 8-40 d:13 throttle position sensor sig- nal 2 • fully closed position 9–23 check with throttle valves fully closed. • fully opened position 94–108 check with throttle valves fully open. D:14 accelerator position sensor signal 1 • fully closed position 12–22 check with throttle ...

  • Page 432: Fuel Injection System

    Fuel injection system 8-41 d:61 malfunction history code display — • no history 00 • history exists fault codes 11–70 • (if more than one code number is detected, the dis- play alternates every two seconds to show all the detected code numbers. When all code numbers are shown, the display repeats th...

  • Page 433: Fuel Injection System

    Fuel injection system 8-42 actuator operation table 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-sec- ond intervals. Illuminates the engine trou- ble warning light. Check the spark five times. • connect...

  • Page 434: Fuel Injection System

    Fuel injection system 8-43 d:40 secondary injector #1 actuates the secondary injec- tor #1 five times at one-sec- ond intervals. Illuminates the engine trou- ble warning light. Check the operating sound of the secondary injector #1 five times. D:41 secondary injector #2 actuates the secondary injec-...

  • Page 435: Fuel Injection System

    Fuel injection system 8-44 d:51 radiator fan motor relay actuates the radiator fan motor relay for five cycles of five seconds. (on 2 sec- onds, off 3 seconds) illuminates the engine trou- ble warning light. Check the operating sound of the radiator fan motor relay five times. D:52 headlight relay a...

  • Page 436: Fuel Injection System

    Fuel injection system 8-45 eas14b1085 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the mal...

  • Page 437: Fuel Injection System

    Fuel injection system 8-46 5 sensor installation status - check the mounting section for loose or pinched mount- ing. Incorrect installation → rein- stall or repair the sensor. Crank the engine, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check ...

  • Page 438: Fuel Injection System

    Fuel injection system 8-47 3 continuity of wire harness open or short circuit → replace the wire harness. Gray–gray black/blue–black/blue crank the engine, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 4 sensor installation st...

  • Page 439: Fuel Injection System

    Fuel injection system 8-48 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 13 symptom open or short circuit of intake air pressure sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitor- ing ...

  • Page 440: Fuel Injection System

    Fuel injection system 8-49 5 intake air pressure sensor malfunction check in the diagnostic mode (code no. 03). When engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa 1000 m above sea level: approx. 90 kpa 2000 m...

  • Page 441: Fuel Injection System

    Fuel injection system 8-50 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 14 symptom the intake air pressure sensor has failed (due to clogging of hose or sensor disconnection). Fail-safe action engine startup: possible ridin...

  • Page 442: Fuel Injection System

    Fuel injection system 8-51 fault code no. 15 symptom open or short circuit of throttle position sensor lead fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitor- ing code no. D:01 d:13 d:01 meter display throttle position sen...

  • Page 443: Fuel Injection System

    Fuel injection system 8-52 5 supply voltage of throttle position sensor lead check the supply voltage. Throttle position sensor sig- nal 1 black/blue–white throttle position sensor sig- nal 2 black/blue–black refer to “checking the throttle position sen- sor” on page 8-138. Place the main switch to ...

  • Page 444: Fuel Injection System

    Fuel injection system 8-53 6 throttle position sensor mal- function check the throttle position sensor signal 1 diagnostic mode (code no. 01). When throttle is fully closed: a value of 12–21 is indicated. When throttle is fully opened: a value of 97–106 is indi- cated. Check the throttle position se...

  • Page 445: Fuel Injection System

    Fuel injection system 8-54 fault code no. 19 symptom open or short circuit of ecu input line (blue/yellow lead) fail-safe action engine startup: impossible riding: impossible diagnostic monitor- ing code no. D:20 meter display sidestand switch • on (stand retracted) • off (stand extended) checking m...

  • Page 446: Fuel Injection System

    Fuel injection system 8-55 5 sidestand switch malfunction diagnostic mode (code no. 20). Sidestand retracted: on indi- cation sidestand extended: off indication indication is incorrect. → replace the sidestand switch. Place the main switch to the on position, and check the fault code indication when...

  • Page 447: Fuel Injection System

    Fuel injection system 8-56 fault code no. 20 symptom when the main switch is on, there is a big difference in voltage value of the intake air pressure sensor and atmospheric pressure sensor fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. D:03 d:02 d:03 met...

  • Page 448: Fuel Injection System

    Fuel injection system 8-57 * check the sensor only when the engine is cold. 2 atmospheric pressure sensor malfunction check in the diagnostic mode (code no. 02). When engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101...

  • Page 449: Fuel Injection System

    Fuel injection system 8-58 fault code no. 21 symptom open or short circuit of coolant temperature sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. D:06 meter display when engine is cold: displays temperature closer to air temperature when engine...

  • Page 450: Fuel Injection System

    Fuel injection system 8-59 * check the sensor only when the engine is cold. 6 coolant temperature sensor malfunction check in the diagnostic mode (code no. 06). During cold starting: a tem- perature close to the ambient temperature is indicated. Indication is incorrect. → replace the coolant tempera...

  • Page 451: Fuel Injection System

    Fuel injection system 8-60 3 continuity of wire harness open or short circuit → replace the wire harness. Black/blue–black/blue brown/white–brown/white place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check t...

  • Page 452: Fuel Injection System

    Fuel injection system 8-61 fault code no. 23 symptom open or short circuit of atmospheric pressure sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. D:02 meter display displays the atmospheric pressure. Checking method compare the actually measur...

  • Page 453: Fuel Injection System

    Fuel injection system 8-62 4 atmospheric pressure sensor malfunction check in the diagnostic mode (code no. 02). Atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa 1000 m above sea level: approx. 90 kpa 2000 m above sea level: appro...

  • Page 454: Fuel Injection System

    Fuel injection system 8-63 fault code no. 24 symptom the o 2 sensor does not operate. Fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance job sensor inspection proce- d...

  • Page 455: Fuel Injection System

    Fuel injection system 8-64 6 o 2 sensor malfunction check the o 2 sensor for an abnormality. Refer to “engine removal” on page 5-3. O 2 sensor malfunction → replace the o 2 sensor either start and warm up the engine, and then racing it, or reset it with diagnostic code 63. No fault code indicated. →...

  • Page 456: Fuel Injection System

    Fuel injection system 8-65 3 lean angle sensor malfunc- tion diagnostic mode (code no. 08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-133. In vertical position: 0.4–1.4 v when turned over: 3.7–4.4 v indication is incorrect. → replace the lean angle sen- sor. Pla...

  • Page 457: Fuel Injection System

    Fuel injection system 8-66 2 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...

  • Page 458: Fuel Injection System

    Fuel injection system 8-67 6 ignition coil malfunction (check the resistance of igni- tion coil #1.) refer to “checking the ignition coils” on page 8- 132. Ignition coil inspection method start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indi...

  • Page 459: Fuel Injection System

    Fuel injection system 8-68 2 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or repair/replace the wire harness. Start and idle the engine for approxima...

  • Page 460: Fuel Injection System

    Fuel injection system 8-69 6 ignition coil malfunction (check the resistance of igni- tion coil #2.) refer to “checking the ignition coils” on page 8- 132. Ignition coil inspection method start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indi...

  • Page 461: Fuel Injection System

    Fuel injection system 8-70 2 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...

  • Page 462: Fuel Injection System

    Fuel injection system 8-71 6 ignition coil malfunction (check the resistance of igni- tion coil #3.) refer to “checking the ignition coils” on page 8- 132. Ignition coil inspection method start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indi...

  • Page 463: Fuel Injection System

    Fuel injection system 8-72 2 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or repair/replace the wire harness. Start and idle the engine for approxima...

  • Page 464: Fuel Injection System

    Fuel injection system 8-73 6 ignition coil malfunction (check the resistance of igni- tion coil #4.) refer to “checking the ignition coils” on page 8- 132. Ignition coil inspection method start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indi...

  • Page 465: Fuel Injection System

    Fuel injection system 8-74 fault code no. 39 symptom open or short circuit of primary injector lead fail-safe action engine startup: possible (depending on the number of failed cylin- ders) riding: possible (depending on the number of failed cylinders) diagnostic monitor- ing code no. D:36 d:37 d:38...

  • Page 466: Fuel Injection System

    Fuel injection system 8-75 4 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Start the engine and let it idle for ap...

  • Page 467: Fuel Injection System

    Fuel injection system 8-76 6 continuity of wire harness open or short circuit → replace the wire harness. Primary injector #1 red/blue–red/blue red/black–red/black primary injector #2 red/blue–red/blue green/black–green/black primary injector #3 red/blue–red/blue blue/black–blue/black primary inject...

  • Page 468: Fuel Injection System

    Fuel injection system 8-77 fault code no. 40 symptom open or short circuit of secondary injector lead fail-safe action engine startup: possible (depending on the number of failed cylin- ders) riding: possible (depending on the number of failed cylinders) diagnostic monitor- ing code no. D:40 d:41 d:...

  • Page 469: Fuel Injection System

    Fuel injection system 8-78 3 secondary injector malfunc- tion refer to “checking the fuel injectors” on page 8-144. Fuel injection inspection method. Check the injector’s operating noise by the diagnostic mode (code no.40–43). Injector’s operating noise → reset with the diagnostic code 63. Recovered...

  • Page 470: Fuel Injection System

    Fuel injection system 8-79 5 connection of secondary injector sub-wire harness coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking) poor connection → connect it securely, or repair/replace the wire harness. Check the injector’s...

  • Page 471: Fuel Injection System

    Fuel injection system 8-80 6 continuity of wire harness open or short circuit → replace the wire harness. Secondary injector #1 red/blue–red/blue white/blue–white/blue secondary injector #2 red/blue–red/blue sky blue/white–sky blue/ white secondary injector #3 red/blue–red/blue brown/yellow–brown/ye...

  • Page 472: Fuel Injection System

    Fuel injection system 8-81 fault code no. 41 symptom open or short circuit of lean angle sensor lead fail-safe action engine startup: impossible riding: impossible diagnostic monitor- ing code no. D:08 meter display lean angle sensor • 0.4–1.4 (upright) • 3.7–4.4 (overturned) checking method remove ...

  • Page 473: Fuel Injection System

    Fuel injection system 8-82 4 lean angle sensor malfunc- tion refer to “checking the lean angle sensor” on page 8-133. Rotate the main switch to the off position first, and then rotate it to the on position again. Then, check the fault code indication. No fault code indicated. → recovered. Fault code...

  • Page 474: Fuel Injection System

    Fuel injection system 8-83 fault code no. 42 symptom a. Normal signals are not received from the speed sensor. B. Open or short circuit of gear position sensor lead a fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. D:07 (speed sensor) meter display vehicle s...

  • Page 475: Fuel Injection System

    Fuel injection system 8-84 a. Speed sensor system malfunction item/components and probable cause check or maintenance job sensor inspection proce- dure 1 connection of speed sensor (meter) coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wea...

  • Page 476: Fuel Injection System

    Fuel injection system 8-85 b. Gear position sensor system malfunction item/components and probable cause check or maintenance job sensor inspection proce- dure 1 connection of gear position sensor coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend...

  • Page 477: Fuel Injection System

    Fuel injection system 8-86 c. Clutch switch system malfunction 5 shift drum (that detects the neutral position) malfunction check the gear shift drum (that detects the neutral posi- tion). Refer to “checking the shift drum assembly” on page 5-97. Malfunction → replace the shift drum. Start the engin...

  • Page 478: Fuel Injection System

    Fuel injection system 8-87 4 continuity of wire harness open short circuit → replace the wire harness. Black/yellow–black/yellow blue/yellow–blue/yellow start the engine, and check the secure connection of the coupler. Ride the vehicle at a low speed (approx. 20–30 km/h). Then, check the fault code ...

  • Page 479: Fuel Injection System

    Fuel injection system 8-88 2 connection of main harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Start and idle the engine for approxim...

  • Page 480: Fuel Injection System

    Fuel injection system 8-89 fault code no. 44 symptom an error is detected while reading or writing on eep-rom fail-safe action engine startup: under certain conditions riding: under certain conditions diagnostic monitor- ing code no. D:60 meter display the in self diagnostic code 44 detected eep-rom...

  • Page 481: Fuel Injection System

    Fuel injection system 8-90 4 “03” is indicated in diagnostic mode (code no. 60) eep-rom data error for adjustment of co concentra- tion of cylinder #3 change the co concentra- tion of cylinder #3, and rewrite in eep-rom. After this adjustment is made, the memory is not recovered when the main switch...

  • Page 482: Fuel Injection System

    Fuel injection system 8-91 fault code no. 46 symptom incorrect voltage is supplied to the ecu. Fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance job sensor inspection...

  • Page 483: Fuel Injection System

    Fuel injection system 8-92 fault code no. 50 symptom ecu memory malfunction fail-safe action engine startup: under certain conditions riding: under certain conditions diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance job sens...

  • Page 484: Fuel Injection System

    Fuel injection system 8-93 3 continuity of wire harness open or short circuit → replace the wire harness. Black/blue–black/blue white–white blue–blue black–black place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated....

  • Page 485: Fuel Injection System

    Fuel injection system 8-94 5 supply voltage of accelera- tor position sensor lead check the supply voltage. Accelerator position sensor signal 1 black/blue–white accelerator position sensor signal 2 black/blue–black refer to “checking the accelerator position sensor” on page 8-139. Place the main sw...

  • Page 486: Fuel Injection System

    Fuel injection system 8-95 6 accelerator position sensor malfunction check the accelerator posi- tion sensor signal 1 diagnos- tic mode (code no. 14). When throttle is fully closed: a value of 12–22 is indicated. When throttle is fully opened: a value of 97–107 is indi- cated. Check the accelerator ...

  • Page 487: Fuel Injection System

    Fuel injection system 8-96 fault code no. 60 symptom defect found in ycc-t drive fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check ...

  • Page 488: Fuel Injection System

    Fuel injection system 8-97 6 throttle body malfunction refer to “adjusting the throttle position sen- sor” on page 7-19. Throttle body malfunction → replace the throttle body. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault c...

  • Page 489: Fuel Injection System

    Fuel injection system 8-98 3 check the steering damper fuse. Abnormality → replace the steering damper fuse. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 4 continuity of wire harness ...

  • Page 490: Fuel Injection System

    Fuel injection system 8-99 fault code no. Er-1 symptom no signal is received from the ecu. Fail-safe action engine startup: impossible if ecu failure riding: impossible if ecu failure diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or mai...

  • Page 491: Fuel Injection System

    Fuel injection system 8-100 fault code no. Er-2 symptom no signal is sent from ecu. Fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance job sensor inspection proce- dur...

  • Page 492: Fuel Injection System

    Fuel injection system 8-101 fault code no. Er-3 symptom correct data cannot be received from the ecu. Fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance job sensor ins...

  • Page 493: Fuel Injection System

    Fuel injection system 8-102 fault code no. Er-4 symptom no registration data can be received from the meter unit. Fail-safe action engine startup: possible riding: possible diagnostic monitor- ing code no. — meter display — checking method — item/components and probable cause check or maintenance jo...

  • Page 494: Fuel Pump System

    Fuel pump system 8-103 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 495: Fuel Pump System

    Fuel pump system 8-104 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 16.Fuel pump 21.Ecu (engine control unit) 64.Right handlebar switch 67.Engine stop switch 100.Ignition fuse 101.Engine ground 102.Battery negative lead.

  • Page 496: Fuel Pump System

    Fuel pump system 8-105 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Passenger seat 4. Left side cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, igni...

  • Page 497: Fuel Pump System

    Fuel pump system 8-106 ng → ok ↓ 7. Check the entire fuel pump sys- tem’s wiring. Refer to “circuit diagram” on page 8-103. Properly connect or repair the fuel pump system’s wiring. Replace the ecu..

  • Page 498: Immobilizer System

    Immobilizer system 8-107 eas27640 immobilizer system eas27650 circuit diagram.

  • Page 499: Immobilizer System

    Immobilizer system 8-108 1. Main switch 4. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Battery 9. Fuel injection system fuse 21.Ecu (engine control unit) 47.Meter assembly 48.Immobilizer system indicator light 54.Multi-function meter 100.Ignition fuse 101.Engine ground 102.Battery negative lead.

  • Page 500: Immobilizer System

    Immobilizer system 8-109 eas27671 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 501: Immobilizer System

    Immobilizer system 8-110 eas27691 part replacement and key code registration requirements in the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Tip each standard key is registered during production...

  • Page 502: Immobilizer System

    Immobilizer system 8-111 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Tip do not start the engine with a standar...

  • Page 503: Immobilizer System

    Immobilizer system 8-112 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the los...

  • Page 504: Immobilizer System

    Immobilizer system 8-113 eas27701 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, backup and fuel injection system) refer to “checking the fuses” ...

  • Page 505: Immobilizer System

    Immobilizer system 8-114 eas27721 self-diagnosis fault code indication when a system failure occurs, the error code number is indicated in the lcd display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code. Fault code part s...

  • Page 506: Immobilizer System

    Immobilizer system 8-115 immobilizer system indicator light fault code indication digit of 10 : cycles of 1 sec. On and 1.5 sec. Off. Digit of 1 : cycles of 0.5 sec. On and 0.5 sec. Off. Example: fault code 52 55 immobilizer unit key code registra- tion malfunction. Same standard key was attempted t...

  • Page 507: Immobilizer System

    Immobilizer system 8-116.

  • Page 508: Electrical Components

    Electrical components 8-117 eas27972 electrical components.

  • Page 509: Electrical Components

    Electrical components 8-118 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Battery 7. Fuse box 8. Main fuse 9. Fuel injection system fuse 10.Starter relay 11.Rear brake light switch 12.Gear position sensor 13.Sidestand switch 14.O 2 sensor 15.Spee...

  • Page 510: Electrical Components

    Electrical components 8-119.

  • Page 511: Electrical Components

    Electrical components 8-120 1. Intake air temperature sensor 2. Headlight relay 3. Turn signal/hazard relay 4. Atmospheric pressure sensor 5. Intake air pressure sensor 6. Intake funnel servo motor 7. Fuel pump 8. Relay unit 9. Lean angle sensor 10.Coolant temperature sensor 11.Crankshaft position s...

  • Page 512: Electrical Components

    Electrical components 8-121 eas27980 checking the switches.

  • Page 513: Electrical Components

    Electrical components 8-122 1. Horn switch 2. Clutch switch 3. Main switch 4. Dimmer switch 5. Pass switch 6. Turn signal switch 7. Hazard switch 8. Sidestand switch 9. Gear position sensor 10.Oil level switch 11.Front brake light switch 12.Engine stop switch 13.Start switch 14.Rear brake light swit...

  • Page 514: 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. Eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from t...

  • Page 515: Electrical Components

    Electrical components 8-124 eas27990 checking the bulbs and bulb sock- ets 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 conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket ...

  • Page 516: Electrical Components

    Electrical components 8-125 tip check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. B. Connect the pocket tester probes to the respective leads of the bulb ...

  • Page 517: Electrical Components

    Electrical components 8-126 • do not smoke when charging or han- dling batteries. • keep batteries and electrolyte out of reach of children. • avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: external • skin — wash with ...

  • Page 518: Electrical Components

    Electrical components 8-127 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method illustration) warning ewa13300 do not quick charge a battery. Eca13670 • never remove the vrla (valve regulated lead acid) battery sealing caps. • do not use a high-rate battery ...

  • Page 519: Electrical Components

    Electrical components 8-128 tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charged and ammeter to the battery and start charging. Tip set the charging voltage at 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be o...

  • Page 520: Electrical Components

    Electrical components 8-129 9. Lubricate: • battery terminals 10. Install: • battery cover • rider seat refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, replace the relay. 1. Discon...

  • Page 521: Electrical Components

    Electrical components 8-130 headlight relay radiator fan motor relay eas14b1015 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 relay coupler is faulty and must be repai...

  • Page 522: Electrical Components

    Electrical components 8-131 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay out- put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Tip the pocket tester or the analog pocket tes...

  • Page 523: Electrical Components

    Electrical components 8-132 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continu- ity. ▲▲▲▲▲...

  • Page 524: Electrical Components

    Electrical components 8-133 b. Turn the main switch to “on” and engine stop switch to “ ”. C. Measure the ignition spark gap “a”. D. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap until a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28120 checking the cran...

  • Page 525: Electrical Components

    Electrical components 8-134 c. Set the main switch to “on”. D. Turn the lean angle sensor to 45 °. E. Measure the lean angle sensor output volt- age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28940 checking the starter motor opera- tion 1. Check: • starter motor operation does not operate → perform the elec...

  • Page 526: Electrical Components

    Electrical components 8-135 eas28170 checking the rectifier/regulator 1. Check: • rectifier/regulator input voltage out of specification → correct the stator coil condition. Refer to “checking the stator coil” on page 8-134. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition...

  • Page 527: Electrical Components

    Electrical components 8-136 b. Connect the pocket tester ( Ω × 1) to the horn terminals. C. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • horn sound faulty sound → replace. Eas28190 checking the oil level switch 1. Drain: • engine oil 2. Remove: • oil level switch (from the...

  • Page 528: Electrical Components

    Electrical components 8-137 b. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the test harness-speed sensor (3p) “1” to the speed s...

  • Page 529: Electrical Components

    Electrical components 8-138 c. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28260 checking the coolant temperature sensor 1. Remove: • coolant temperature sensor refer to “cylinder head” on page 5- 25. Warning ewa14130 • handle the coolant temperature sensor with specia...

  • Page 530: Electrical Components

    Electrical components 8-139 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1 k) to the throttle position sensor terminal as shown. B. Measure the throttle position sensor maxi- mum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • throttle position sensor tip when installin...

  • Page 531: Electrical Components

    Electrical components 8-140 tip do not use old batteries to operate the throttle servo motor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disc...

  • Page 532: Electrical Components

    Electrical components 8-141 c. Turn the main switch to “on”. D. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28390 checking the cylinder identifica- tion sensor 1. Remove: • fuel tank refer to “fuel tank” on page 7-1. • air filter case refer to “air filte...

  • Page 533: Electrical Components

    Electrical components 8-142 b. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor (3p). C. Turn the main switch to “on”. D. Measure the intake air pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28420 checking the intake air tempera- ture sensor 1. Remov...

  • Page 534: Electrical Components

    Electrical components 8-143 2. Check: • steering damper solenoid resistance out of specification → replace the steer- ing damper assembly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the steering damper lead cou- pler from wire harness. B. Connect the pocket tester ( Ω × 1) to the steering damper l...

  • Page 535: Electrical Components

    Electrical components 8-144 eas14b1101 checking the fuel injectors 1. Remove: • fuel tank refer to “fuel tank” on page 7-1. • air filter upper cover (for secondary injec- tor) refer to “air filter case” on page 7- 5. 2. Check: • fuel injector resistance out of specification → replace the fuel inject...

  • Page 536: Electrical Components

    Electrical components 8-145.

  • Page 537: Troubleshooting

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

  • Page 538: 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 troubleshooting. Refer to the relative proce- dure in this manual for checks, ad...

  • Page 539: 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 540: Troubleshooting

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

  • Page 541: Troubleshooting

    Troubleshooting 9-4 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose wheel axle • excessive wheel runout 8. Frame • bent frame • damaged steering head p...

  • Page 542: Wiring Diagram

    Eas28740 wiring diagram yzf-r1(y) 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Main fuse 5. Backup fuse 6. Immobilizer unit 7. Etv (electronic throttle valve) fuse 8. Battery 9. Fuel injection system fuse 10. Starter relay 11. Starter motor 12. Relay unit 13. Starting circuit cut-off relay...

  • Page 544

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

  • Page 545: Wiring Diagram

    Wiring diagram yzf-r1(y) schema de cablage yzf-r1(y) schaltplan yzf-r1(y) schema elettrico yzf-r1(y) diagrama de conexiones de yzf-r1(y).

  • Page 546: Wiring Diagram

    Wiring diagram yzf-r1(y) schema de cablage yzf-r1(y) schaltplan yzf-r1(y) schema elettrico yzf-r1(y) diagrama de conexiones de yzf-r1(y).