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Yamaha 2011 FZ8NA(C) Service Manual

Manual is about: Motorcycle Yamaha 2011 FZ8NA(C)

Summary of 2011 FZ8NA(C)

  • Page 1

    Service manual fz8na(c) 2011 39p-28197-10 lit-11616-24-07.

  • Page 2

    Eas20050 fz8na(c) service manual ©2010 by yamaha motor corporation, u.S.A. First edition, november 2010 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-24-07.

  • Page 3

    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

    Eas20091 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

    Eas20101 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 frame. This information will be needed to order spare parts..

  • Page 11: Features

    Features 1-2 eas20170 features eas39p1101 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 carburet...

  • Page 12: Features

    Features 1-3 eas39p1102 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ecu energizes the...

  • Page 13: Features

    Features 1-4 eas39p1103 instrument functions multi-function meter unit warning ewa12422 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 me...

  • Page 14: Features

    Features 1-5 5. Push the “reset” button to set the min- utes. 6. Push the “select” button and then release it to start the clock. Odometer and tripmeter modes push the “select” button to switch the dis- play between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” in the followi...

  • Page 15: Features

    Features 1-6 self-diagnosis device 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 will come on and the display will indicate an error code. Eca11590 if the display indicates an e...

  • Page 16: Important Information

    Important information 1-7 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 1-14. 3. When disassem...

  • Page 17: Important Information

    Important information 1-8 eas20231 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if ap...

  • Page 18: Basic Service Information

    Basic service information 1-9 eas30380 basic service information eas30390 quick fasteners rivet type 1. Remove: • quick fastener tip to remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • quick fastener tip to install the quick fastener, push its pin...

  • Page 19: Basic Service Information

    Basic service information 1-10 eca16750 when disconnecting the battery leads from the battery, be sure to disconnect the nega- tive battery lead first, then the positive bat- tery lead. If a tool or similar item contacts the vehicle while only the negative battery lead is connected, a spark could be...

  • Page 20: Basic Service Information

    Basic service information 1-11 eca16630 electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the contacts clean. Tip when resetting the ecu by turning the main switch to “off”, be sure to wait approximately 5 s...

  • Page 21: Basic Service Information

    Basic service information 1-12 eca16780 • when disconnecting a coupler, release the coupler lock, hold both sections of the coupler securely, and then disconnect the coupler. • there are many types of coupler locks; therefore, be sure to check the type of coupler lock before disconnecting the couple...

  • Page 22: Basic Service Information

    Basic service information 1-13 5. Check: • continuity (with the pocket tester) tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (3). • as a quick remedy, use a contact revitalizer available at most part stores. Pocket tester 90890-03112 ana...

  • Page 23: Special Tools

    Special tools 1-14 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers...

  • Page 24: Special Tools

    Special tools 1-15 radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 6-3 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-20, 4-60 damper rod holder 90890-01423 damping rod holder ym-01423 4-52, 4-53 oil filter wrench 90890-01426 yu-38411 3-24 rod holder 90...

  • Page 25: Special Tools

    Special tools 1-16 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-54, 4-56 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-54, 4-56 fork spring compressor 90890-01441 ym-01441 4-51, 4-56 fork seal driver 90890-01442 adjustable for...

  • Page 26: Special Tools

    Special tools 1-17 pivot shaft wrench 90890-01518 frame spanner socket ym-01518 5-9 compression gauge 90890-03081 engine compression tester yu-33223 5-1 vacuum gauge 90890-03094 vacuummate yu-44456 3-9 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-13, 8-99, 8- 100, 8-101, 8- 105, 8-106...

  • Page 27: Special Tools

    Special tools 1-18 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-43, 7-13, 8- 110, 8-112, 8- 117, 8-118 fuel pressure adapter 90890-03176 ym-03176 7-5 thickness gauge 90890-03180 feeler gauge set yu-26900-9 3-5, 5-21, 5-51 test harness- speed sensor (3p) 90890-032...

  • Page 28: Special Tools

    Special tools 1-19 valve spring compressor 90890-04019 ym-04019 5-25, 5-31 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-13 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 universal clutch holder 90890-04086 ym-910...

  • Page 29: Special Tools

    Special tools 1-20 valve guide installer (ø4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-27 valve guide reamer (ø4) 90890-04113 valve guide reamer (4.0 mm) ym-04113 5-27 extension 90890-04136 5-1 camshaft wrench 90890-04162 ym-04162 5-14, 5-17 ignition checker 90890-06754 oppama pet-4000 ...

  • Page 30: Special Tools

    Special tools 1-21.

  • Page 31: Specifications

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

  • Page 32: General Specifications

    General specifications 2-1 eas20280 general specifications model model 39p2 (usa) 39p3 (california) dimensions overall length 2140 mm (84.3 in) overall width 770 mm (30.3 in) overall height 1065 mm (41.9 in) seat height 815 mm (32.1 in) wheelbase 1460 mm (57.5 in) ground clearance 140 mm (5.51 in) m...

  • Page 33: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 779 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 68.0 × 53.6 mm (2.68 × 2.11 in) compression ratio 12.0 : 1 standard compression pressure (at sea level...

  • Page 34: Engine Specifications

    Engine specifications 2-3 radiator core width 222.6 mm (8.76 in) height 360.0 mm (14.17 in) depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 65/43 × 25/32 (1.181) impeller shaft tilt limit 0.15 mm (0.006 in) spark plug(s) manufacturer/model ngk/cr9e ...

  • Page 35: Engine Specifications

    Engine specifications 2-4 valve, valve seat, valve guide valve clearance (cold) intake 0.10–0.17 mm (0.0039–0.0067 in) exhaust 0.25–0.29 mm (0.0098–0.0114 in) valve dimensions valve head diameter a (intake) 25.90–26.10 mm (1.0197–1.0276 in) valve head diameter a (exhaust) 21.90–22.10 mm (0.8622–0.87...

  • Page 36: Engine Specifications

    Engine specifications 2-5 free length (exhaust) 38.62 mm (1.52 in) limit 36.69 mm (1.44 in) installed length (intake) 33.00 mm (1.30 in) installed length (exhaust) 33.00 mm (1.30 in) spring rate k1 (intake) 24.99 n/mm (2.55 kgf/mm, 142.69 lb/in) spring rate k2 (intake) 37.28 n/mm (3.80 kgf/mm, 212.8...

  • Page 37: Engine Specifications

    Engine specifications 2-6 end gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) limit 0.60 mm (0.0236 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 × 2.50 mm (0.03 × 0.10 in) end gap (installed) 0.35–0.50 mm (0.013...

  • Page 38: Engine Specifications

    Engine specifications 2-7 plate quantity 7 pcs clutch spring free length 52.50 mm (2.07 in) limit 49.88 mm (1.96 in) spring quantity 6 pcs transmission transmission type constant mesh 6-speed primary reduction system gear primary reduction ratio 1.512 (65/43) secondary reduction system chain seconda...

  • Page 39: Engine Specifications

    Engine specifications 2-8 air induction system reed valve bending limit 0.4 mm (0.016 in) solenoid resistance 18–22 Ω at 20 °c (68 °f) idling condition engine idling speed 1150–1250 r/min co% 4.0–5.0 % intake vacuum 30.0 kpa (225 mmhg, 8.9 inhg) water temperature 90.0–110.0 °c (194.00–230.00 °f) oil...

  • Page 40: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 25 °00’ trail 109.0 mm (4.29 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 130.0 mm (5.12 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 41: Chassis Specifications

    Chassis specifications 2-10 brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) master cylinder inside diameter 16.00 mm (0.63 in) caliper cylinder inside diameter 30.20 mm (1.19 in) 27.00 mm (1.06 in) recommended fluid dot 4 rear brake type hydraulic single disc brake operati...

  • Page 42: Chassis Specifications

    Chassis specifications 2-11 optional spring available no enclosed gas/air pressure (std) 1200 kpa (12.0 kgf/cm², 170.7 psi) spring preload adjusting positions minimum 1 standard 5 maximum 9 drive chain type/manufacturer 525v10/daido number of links 122 drive chain slack 20.0–30.0 mm (0.79–1.18 in) 1...

  • Page 43: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 5.0 °/1200 r/min engine control unit model/manufacturer tbdfd0/denso ignition coil minimum ignition spark gap 6.0 mm (0.24 in) primary coil res...

  • Page 44: Electrical Specifications

    Electrical specifications 2-13 armature coil commutator resistance 0.0100–0.2000 Ω at 20 °c (68 °f) insulation resistance above 1 m Ω at 20 °c (68 °f) brush overall length 12.0 mm (0.47 in) limit 6.50 mm (0.26 in) brush spring force 6.02–6.51 n (614–664 gf, 21.65–23.41 ozf) mica undercut (depth) 0.7...

  • Page 45: Tightening Torques

    Tightening torques 2-14 eas20320 tightening torques eas20331 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 46: Tightening Torques

    Tightening torques 2-15 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 4 13 nm (1.3 m·kgf, 9.4 ft·lbf) cylinder head nut m10 10 see tip. Cylinder head bolt m6 2 12 nm (1.2 m·kgf, 8.7 ft·lbf) cylinder head plug m18 3 42 nm (4.2 m·kgf, 30 ft·lbf) cams...

  • Page 47: Tightening Torques

    Tightening torques 2-16 exhaust pipe and muffler bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) exhaust pipe and exhaust pipe bracket bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) muffler and muffler bracket bolt m10 1 48 nm (4.8 m·kgf, 35 ft·lbf) crankcase stud bolt m10 10 8 nm (0.8 m·kgf, 5.8 ft·lbf) crankcase b...

  • Page 48: Tightening Torques

    Tightening torques 2-17 tip cylinder head nut 1. Tighten the nut to 25 nm (2.5 m·kgf, 18 ft·lbf). 2. Tighten the nut to 25 nm (2.5 m·kgf, 18 ft·lbf). 3. Tighten the nuts 1–7 and 10 to 80 ° and nuts 8 and 9 to 100°. Tip connecting rod cap bolt 1. Tighten the bolts to 20 nm (2.0 m·kgf, 14 ft·lbf) 2. T...

  • Page 49: Tightening Torques

    Tightening torques 2-18.

  • Page 50: Tightening Torques

    Tightening torques 2-19 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks upper bracket pinch bolt m8 2 26 nm (2.6 m·kgf, 19 ft·lbf) steering stem nut m28 1 115 nm (11.5 m·kgf, 83 ft·lbf) upper handlebar holder bolt m8 4 24 nm (2.4 m·kgf, 17 ft·lbf) lower handlebar ...

  • Page 51: Tightening Torques

    Tightening torques 2-20 relay arm nut (relay arm and connecting arm) m10 1 40 nm (4.0 m·kgf, 29 ft·lbf) main frame and rear frame nut m10 4 42 nm (4.2 m·kgf, 30 ft·lbf) clutch cable locknut m8 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) throttle cable locknut m6 2 4.5 nm (0.45 m·kgf, 3.3 ft·lbf) rear shock absor...

  • Page 52: Tightening Torques

    Tightening torques 2-21 tip lower ring nut 1. Tighten the ring nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 18 nm (1.8 m·kgf, 13 ft·lbf). Front wheel axle m16 1 65 nm (6.5 m·kgf, 47 ft·lbf) front w...

  • Page 53

    Lubrication points and lubricant types 2-22 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or silicone fluid bearings camshaft lobes and journals (intake and exhaust) valve stem seals (intake and exh...

  • Page 54

    Lubrication points and lubricant types 2-23 left crankcase cover (three 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 55

    Lubrication points and lubricant types 2-24 eas20380 chassis lubrication point lubricant steering bearings, seal lip and bearing lip tube guide (throttle grip) inner surface and throttle cables brake lever pivot bolt and metal-to-metal moving parts clutch lever pivot bolt, metal-to-metal moving part...

  • Page 56

    Lubrication system chart and diagrams 2-25 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 57

    Lubrication system chart and diagrams 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. Ac magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.Ac magneto axle 13.Crankshaft 14.Piston cooler 15.Timing chain tens...

  • Page 58

    Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams.

  • Page 59

    Lubrication system chart and diagrams 2-28 1. Oil delivery pipe 2. Oil level switch 3. Oil filter cartridge 4. Crankshaft.

  • Page 60

    Lubrication system chart and diagrams 2-29 2 3 4 5 6 7 8 1.

  • Page 61

    Lubrication system chart and diagrams 2-30 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump.

  • Page 62

    Lubrication system chart and diagrams 2-31.

  • Page 63

    Lubrication system chart and diagrams 2-32 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler.

  • Page 64

    Lubrication system chart and diagrams 2-33.

  • Page 65

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Oil pipe 3. Drive axle.

  • Page 66

    Lubrication system chart and diagrams 2-35.

  • Page 67

    Lubrication system chart and diagrams 2-36 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Main gallery 5. Crankshaft.

  • Page 68: Cooling System Diagrams

    Cooling system diagrams 2-37 eas20420 cooling system diagrams.

  • Page 69: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Thermostat 2. Water pump 3. Radiator 4. Radiator fan 5. Oil cooler.

  • Page 70: Cooling System Diagrams

    Cooling system diagrams 2-39.

  • Page 71: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat.

  • Page 72: Cable Routing

    Cable routing 2-41 eas20430 cable routing handlebar (front view).

  • Page 73: Cable Routing

    Cable routing 2-42 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Horn lead 5. Lower headlight stay 6. Throttle cable (return side) 7. Throttle cable (pull side) 8. Brake hose 9. Wire harness 10.Right handlebar switch lead 11.Throttle cables a. Clamp the white tape mark of main...

  • Page 74: Cable Routing

    Cable routing 2-43 handlebar (right side view).

  • Page 75: Cable Routing

    Cable routing 2-44 1. Wire harness 2. Throttle cable 3. Radiator inlet hose 4. Right radiator fan motor lead 5. Coolant reservoir hose 6. Right handlebar switch lead 7. Throttle cables 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Radiator stay 11.Clutch cable a. Connect the meter...

  • Page 76: Cable Routing

    Cable routing 2-45 engine (right side view).

  • Page 77: Cable Routing

    Cable routing 2-46 1. Cable guide 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Brake fluid reservoir hose 5. Rear brake light switch lead 6. Frame 7. Rear brake light switch stay 8. Right rider footrest bracket 9. Rear brake light switch a. For the position of the end of the fuel tank breat...

  • Page 78: Cable Routing

    Cable routing 2-47 engine (right side view) for california only.

  • Page 79: Cable Routing

    Cable routing 2-48 1. Rear brake light switch lead 2. Brake fluid reservoir hose 3. Fuel tank drain hose 4. Frame 5. Rear brake light switch stay 6. Right rider footrest bracket 7. Rear brake light switch a. Route the fuel tank drain hose further inward of the vehicle than the brake fluid reservoir....

  • Page 80: Cable Routing

    Cable routing 2-49 handlebar (left side view).

  • Page 81: Cable Routing

    Cable routing 2-50 1. Main switch lead 2. Left handlebar switch lead 3. Clutch cable 4. Clutch cable swaging metal 5. Left radiator fan motor lead 6. Water pump breather hose 7. Radiator stay 8. Horn 9. Right handlebar switch lead 10.Meter bracket 11.Brake hose 12.Throttle cables 13.Upper bracket 14...

  • Page 82: Cable Routing

    Cable routing 2-51 engine (left side view).

  • Page 83: Cable Routing

    Cable routing 2-52 1. Water pump breather hose 2. Oil level switch lead 3. Sidestand switch lead 4. O 2 sensor lead 5. Coolant reservoir tank drain hose 6. Water pump inlet pipe 7. Ac magneto lead 8. Throttle body 9. Ignition coil sub-wire harness 10.Left radiator fan motor lead 11.Clutch cable 12.W...

  • Page 84: Cable Routing

    Cable routing 2-53 rear frame (left side view).

  • Page 85: Cable Routing

    Cable routing 2-54 1. Wire harness 2. Starter motor lead 3. Battery negative lead 4. Seat lock cable 5. Ground lead 6. Ac magneto lead 7. Rectifier/regulator lead 8. Rectifier/regulator bracket 9. Fuel tank drain hose 10.Fuel tank breather hose 11.Rear brake light switch lead 12.Brake fluid reservoi...

  • Page 86: Cable Routing

    Cable routing 2-55 rear frame (left side view) for california only.

  • Page 87: Cable Routing

    Cable routing 2-56 1. Oil level switch lead 2. Sidestand switch lead 3. O 2 sensor lead 4. Waterproof coupler 5. Battery negative lead 6. Wire harness 7. Starter motor lead 8. Rectifier/regulator lead 9. Ac magneto lead 10.Fuel tank drain hose 11.Rear brake light switch lead 12.Brake fluid reservoir...

  • Page 88: Cable Routing

    Cable routing 2-57 frame (top view).

  • Page 89: Cable Routing

    Cable routing 2-58 1. Throttle cables 2. Wire harness 3. Right handlebar switch lead 4. Throttle cable (pull side) 5. Throttle cable (return side) 6. Intake air temperature sensor lead 7. Coolant reservoir hose 8. Radiator inlet hose 9. Sub-throttle position sensor lead 10.Air cut-off valve hose 11....

  • Page 90: Cable Routing

    Cable routing 2-59 frame (top view).

  • Page 91: Cable Routing

    Cable routing 2-60 1. Air filter case drain hose 2. Pickup coil lead 3. Speed sensor lead coupler 4. Engine ground lead 5. Right radiator fan motor lead 6. Neutral switch lead 7. Rear brake light switch lead 8. Fuel tank breather hose 9. Fuel tank drain hose 10.Main fuse 11.Waterproof coupler 12.Gro...

  • Page 92: Cable Routing

    Cable routing 2-61 frame (top view) for california only.

  • Page 93: Cable Routing

    Cable routing 2-62 1. Ignition coil sub-wire harness 2. Fuel injection system sub-wire harness 3. Pickup coil lead 4. Starter motor lead 5. Oil level switch lead 6. Fuel tank breather hose (fuel tank to roll- over valve) 7. Waterproof coupler 8. Ac magneto lead 9. Sidestand switch lead 10.O 2 sensor...

  • Page 94: Cable Routing

    Cable routing 2-63 frame (top view).

  • Page 95: Cable Routing

    Cable routing 2-64 1. Atmospheric pressure sensor 2. Battery positive lead 3. Radiator fan motor relay 4. Fuse box 5. Lean angle sensor 6. Right turn signal light lead 7. License plate light lead 8. Turn signal relay 9. Seat lock cable 10.Headlight relay 11.Tail/brake light coupler 12.Left turn sign...

  • Page 96: Cable Routing

    Cable routing 2-65 fuel tank (left and bottom view).

  • Page 97: Cable Routing

    Cable routing 2-66 1. Frame 2. Fuel tank cover 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel tank 6. Fuel pump 7. Clip 8. Fuel hose 9. Fuel hose connector cover a. Install the fuel tank drain hose with the white paint marks facing to the left of the vehicle. B. For the knob of the clip,...

  • Page 98: Cable Routing

    Cable routing 2-67 front brake, rear brake.

  • Page 99: Cable Routing

    Cable routing 2-68 1. Horn 2. Lower bracket 3. Front fork assembly 4. Front brake hose 5. Brake hose holder 6. Front brake master cylinder 7. Swingarm 8. Rear brake hose 9. Clamp a. Install the brake pipe to touch the projec- tion on the brake caliper (both left and right). B. Install the brake hose...

  • Page 100: Cable Routing

    Cable routing 2-69 canister (top view) for california only.

  • Page 101: Cable Routing

    Cable routing 2-70 1. Fuel pump bracket 2. Fuel tank breather hose (fuel tank to roll- over valve) 3. Fuel hose 4. Rectifier/regulator 5. Rear frame 6. Fuel tank drain hose 7. Canister purge hose 8. Frame 9. Cap 10.Waterproof coupler 11.Rectifier/regulator bracket 12.Grommet a. Install the cap to th...

  • Page 102: Cable Routing

    Cable routing 2-71 canister (left side view) for california only.

  • Page 103: Cable Routing

    Cable routing 2-72 1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Fuel tank 3. Fuel tank drain hose 4. Fuel pump bracket 5. Rear frame 6. Canister purge hose 7. Frame 8. Canister purge hose stay 9. Clamp 10.Damper 11.Rectifier/regulator bracket 12.Canister 13.Canister breather hose a....

  • Page 104: Cable Routing

    Cable routing 2-73 canister (right side view) for california only.

  • Page 105: Cable Routing

    Cable routing 2-74 1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Canister purge hose 3. Brake fluid reservoir 4. Fuel tank breather hose (rollover valve to canister) 5. Rollover valve 6. Rear frame 7. Clamp 8. Rectifier/regulator bracket a. Direct the knob of the clip to the right of...

  • Page 106: Cable Routing

    Cable routing 2-75.

  • Page 107

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

  • Page 108

    Checking the front brake light switch .............................3-28 adjusting the rear brake light switch ..............................3-28 checking and lubricating the cables ..................................3-28 adjusting the throttle cable free play ............................3-29 checking...

  • Page 110: 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 111: Periodic Maintenance

    Periodic maintenance 3-2 eas39p2302 general maintenance and lubrication chart no. Item routine initial odometer readings 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or ...

  • Page 112: 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 113: Periodic Maintenance

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

  • Page 114: Periodic Maintenance

    Periodic maintenance 3-5 7. Install: • spark plugs • ignition coils tip before installing the spark plug, clean the spark plug and gasket surface. 8. Install: • radiator upper bolt • radiator lower bolt • radiator upper cover refer to “radiator” on page 6-1. Eas20490 adjusting the valve clearance th...

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-6 tip • if the valve clearance is incorrect, record the measured reading. • measure the valve clearance in the following sequence. D. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft clockwise as specified in the fol...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-7 b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance. Example: specified valve clearance = 0.11–0.20 mm (0.004–0.008 in) measured valve clearance = 0.25 mm (0.010 in) 0.25 mm (0.010 in)–0.20 mm (0.008 in) = 0.05 mm (0.002 in) c...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-8 h. Measure the valve clearance again. I. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: • all removed parts tip for installatio...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-9 • clean the throttle bodies only if they can- not be synchronized using the air screw. Refer to “checking and cleaning the throttle bodies” on page 7-10. • if they cannot be synchronized, replace the throttle body assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • throttl...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-10 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. B. Check the vacuum pressure. If out of specification → adjust the throttle bodies synchronization. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-11 3. Install: • throttle bodies refer to “throttle bodies” on page 7-6. Eas21081 checking the exhaust system the following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • radiator lower bracket refer to “radiator” on page 6-1. 2. Check: • exhaust pipe ...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-12 2. Remove: • air filter case cover “1” refer to “general chassis” on page 4-1. 3. Check: • air filter element “1” • air filter seal damage → replace. Tip • replace the air filter element every 37000 km (24000 mi) of operation. • the air filter needs more frequent service if...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-13 tip if the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ engine side a. Loosen the locknut “1”. B. Turn the adjusting nut “2” in...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-14 • 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 signifi...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-15 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 ewa39p1302 a soft or spongy feeling in the brake pedal can indicate the presence of ...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-16 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 down the brake pedal and hold it in posi- tion. G. Loosen the bleed screw. Tip loosening the bleed screw will release the pressure an...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-17 2. Check: • brake hose holder “2” loose → tighten the holder bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • brake hose brake fluid leakage → replace the dam- aged hose. Refer to “rear brake” on page 4-31. Eas21670 checking the wheels t...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-18 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 128: Periodic Maintenance

    Periodic maintenance 3-19 keep the drive chain slack within the speci- fied limits. Tip the drive chain slack must be checked at the tightest point on the 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 ...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-20 engine oil or chain lubricant that is suitable for o-ring chains. Do not use any other lubricants on the drive chain since they may contain sol- vents that could damage the o-rings. Eas21510 checking and adjusting the steer- ing head 1. Stand the vehicle on a level surface....

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • upper bracket refer to “handlebar” on page 4-44. Eas39p1303 lubricating the brake lever lubricate the pivoting point and metal-to-metal moving parts of the lever. Eas39p1304 lubricating the clutch lever lubricate the pivoting poi...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-22 eas21531 checking the front fork 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Check: • inner tube damage/scratches → replace. • front fork leg oil leaks between inner tube and outer ...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-23 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas39p1312 checking the connecting arm and relay arm refer to “checking the connecting arm and relay arm” on page 4-64. Eas20731 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • place the vehicle on a suitable stand...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-24 4. Drain: • engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” of...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-25 eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark “a” → add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. Eca13410 when the engine is cold, the en...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-26 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → add the recommended coolant to the proper level. Eca13470 • adding water instead of coolant lowers the antifreeze concentratio...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-27 3. Remove: • coolant reservoir tank 4. Disconnect: • coolant reservoir hose 5. Drain: • coolant (from the coolant reservoir) 6. Remove: • radiator cap bolt “1” • radiator cap “2” warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap wh...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-28 • use only distilled water. However, if dis- tilled water is not available, soft water may be used. • if coolant comes into contact with painted surfaces, immediately wash them with water. • do not mix different types of antifreeze. 13. Install: • radiator cap • radiator ca...

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-29 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 lubricating device. Eas20630 adjusting the throttle cable free play tip prior to adjusting the throttle cable fre...

  • Page 139: Periodic Maintenance

    Periodic maintenance 3-30 2. Remove: • headlight bolt “1” 3. Remove: • headlight bolts “1” • headlight unit “2” 4. Remove: • headlight coupler “1” 5. Remove: • headlight bulb cover “1” 6. Remove: • headlight bulb holder “1” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-31 12. Install: • headlight bolts 13. Install: • headlight side covers • headlight side cover bolts 14. Install: • headlight side panels • headlight side panel bolts 15. Install: • headlight top cover • headlight top cover bolts eas21810 adjusting the headlight beam 1. Adjust:...

  • Page 141: Chassis

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

  • Page 142

    Handlebar..............................................................................................4-44 removing the handlebar ...........................................................4-46 checking the handlebar............................................................4-46 installing the han...

  • Page 144: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 1 3 tool kit 1 4 battery negative lead 1 5 battery positive lead 1 6 main fuse 1 7 battery band 1 8 battery 1 9 battery seat 1 for installation, reverse t...

  • Page 145: General Chassis

    General chassis 4-2 removing the headlight and meter assembly order job/parts to remove q’ty remarks 1 headlight top cover 1 2 left headlight side panel 1 3 right headlight side panel 1 4 headlight assembly 1 5 headlight sub-wire harness coupler 1 disconnect. 6 left turn signal/position light lead c...

  • Page 146: General Chassis

    General chassis 4-3 removing the rear cover order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. 1 left side cover 1 2 right side cover 1 3 tail/brake light lead coupler 1 disconnect. 4 upper tail cover 1 5 tail/brake light bracket 1 6 tail/brake l...

  • Page 147: General Chassis

    General chassis 4-4 removing the air filter case order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air filter case cover 1 2 air filter 1 3 crankcase breather hose 1 disconnect. 4 throttle body hose 2 disconnect. 5...

  • Page 148: Front Wheel

    Front wheel 4-5 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 brake hose holder 2 2 front brake caliper 2 3 reflector bracket 2 4 reflector 2 5 wheel axle pinch bolt 1 loosen. 6 wheel axle 1 7 collar 2 8 front wheel 1 9 front brake disc 2 for ...

  • Page 149: Front Wheel

    Front wheel 4-6 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 1 3 spacer 1 4 wheel bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 150: Front Wheel

    Front wheel 4-7 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • left brake caliper • right brake caliper tip do not apply the brake lever when removing the brake calip...

  • Page 151: Front Wheel

    Front wheel 4-8 c. Remove the wheel bearings “3” with a gen- eral bearing puller. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the new wheel bearing (right side). Eca2s31011 do not contact the wh...

  • Page 152: Front Wheel

    Front wheel 4-9 c. Turn the front wheel 90 ° so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. G. The spo...

  • Page 153: Front Wheel

    Front wheel 4-10 2. Check: • front brake discs refer to “checking the front brake discs” on page 4-23. 3. Lubricate: • oil seal lips 4. Install: • collars • front wheel • wheel axle tip install the tire and wheel with the marks “1” pointing in the direction of wheel rotation. 5. Tighten: • wheel axl...

  • Page 154: Rear Wheel

    Rear wheel 4-11 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-31. 1 locknut 2 loosen. 2 adjusting bolt 2 loosen. 3 wheel axle nut 1 4 washer 1 5 wheel axle 1 6 left adjusting block 1 7 right adjusting block 1 8 r...

  • Page 155: Rear Wheel

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

  • Page 156: Rear Wheel

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

  • Page 157: Rear Wheel

    Rear wheel 4-14 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear brake caliper “1” tip...

  • Page 158: Rear Wheel

    Rear wheel 4-15 eas14b1003 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprockets as a set. 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 159: Rear Wheel

    Rear wheel 4-16 2. Check: • rear brake disc refer to “checking the rear brake disc” on page 4-37. 3. Lubricate: • oil seal lips 4. Install: • collars • brake caliper bracket • rear wheel • adjusting blocks • wheel axle • washer • wheel axle nut tip • do not install the brake caliper. • fit the brake...

  • Page 160: Rear Wheel

    Rear wheel 4-17.

  • Page 161: Front Brake

    Front brake 4-18 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 reflector bracket 1 4 reflector 1 5 brake pad clip 2 6 brake pad pin 1 7 bra...

  • Page 162: Front Brake

    Front brake 4-19 removing the front brake master cylinder order job/parts to remove q’ty remarks right rear view mirror refer to “handlebar” on page 4-44. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-15. 1 brake master cylinder reservoir cap 1 2 brake master cylinder r...

  • Page 163: Front Brake

    Front brake 4-20 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 164: Front Brake

    Front brake 4-21 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 3-15. 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose ...

  • Page 165: Front Brake

    Front brake 4-22 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal 4 7 br...

  • Page 166: Front Brake

    Front brake 4-23 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 167: Front Brake

    Front brake 4-24 d. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. ...

  • Page 168: Front Brake

    Front brake 4-25 d. Install the brake pads and brake pad spring. Tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • brake pad pin • brake pad clips • front brake caliper 6. Check: • brake fluid level below the min...

  • Page 169: Front Brake

    Front brake 4-26 warning ewa39p1401 • never try to pry out the brake caliper pis- tons. • do not loosen the bolts “4”. C. Remove the brake caliper piston dust seals and brake caliper piston seals. D. Repeat the previous steps to force out the right side pistons from the brake caliper. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 170: Front Brake

    Front brake 4-27 warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to “cable routing” on page 2-41. Eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper. 2. Remov...

  • Page 171: Front Brake

    Front brake 4-28 1. Disconnect: • brake light switch connectors (from the front brake light switch) 2. Remove: • brake hose union bolt “1” • brake hose gaskets “2” • brake hose “3” tip to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Ea...

  • Page 172: Front Brake

    Front brake 4-29 • align the end of the front brake master cylin- der holder with the punch mark “b” on the handlebar. • first, tighten the upper bolt, then the lower bolt. • there should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the front brake master cylinde...

  • Page 173: Front Brake

    Front brake 4-30 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-15..

  • Page 174: Rear Brake

    Rear brake 4-31 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad 2 5 brake pad shim 2 6 brake pad insulator 2 7 brake pad spring 1 8 bleed screw 1 for installation, reverse the removal proce- d...

  • Page 175: Rear Brake

    Rear brake 4-32 removing the rear brake master cylinder order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Right side cover refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic b...

  • Page 176: Rear Brake

    Rear brake 4-33 removing the rear brake master cylinder order job/parts to remove q’ty remarks 11 right footrest assembly 1 12 rear brake light switch 1 13 rear brake master cylinder assembly 1 for installation, reverse the removal proce- dure. 3.8 nm (0.38 m kgf, 2.8 ft ibf) t r ..

  • Page 177: Rear Brake

    Rear brake 4-34 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 brake master cylinder kit 1 3 hose joint 1 4 bushing 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 178: Rear Brake

    Rear brake 4-35 removing the rear brake caliper order job/parts to remove q’ty remarks 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 179: Rear Brake

    Rear brake 4-36 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad 2 4 brake pad shim 2 5 brake pad insulator 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston dust seal 1 9 brake caliper piston seal 1 10 blee...

  • Page 180: Rear Brake

    Rear brake 4-37 eas22561 introduction warning ewa14101 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 181: Rear Brake

    Rear brake 4-38 2. Install: • brake pad insulators • brake pad shims (onto the brake pads) • brake pad spring (into the rear brake caliper) • brake pads tip always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connec...

  • Page 182: Rear Brake

    Rear brake 4-39 6. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-15. Eas22590 removing the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. ...

  • Page 183: Rear Brake

    Rear brake 4-40 1. Check: • brake caliper piston “1” rust/scratches/wear → replace the brake caliper piston. • brake caliper cylinder “2” scratches/wear → replace the brake cal- iper assembly. • brake caliper body “3” cracks/damage → replace the brake caliper assembly. • brake fluid delivery passage...

  • Page 184: Rear Brake

    Rear brake 4-41 2. Remove: • rear brake caliper 3. Install: • brake pad insulators • brake pad shims (onto the brake pads) • brake pad spring (into the rear brake caliper) • brake pads • rear brake caliper refer to “replacing the rear brake pads” on page 4-37. 4. Fill: • brake fluid reservoir (with ...

  • Page 185: Rear Brake

    Rear brake 4-42 eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear → r...

  • Page 186: Rear Brake

    Rear brake 4-43 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...

  • Page 187: Handlebar

    Handlebar 4-44 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 rear view mirror 2 2 front brake light switch connector 2 disconnect. 3 front master cylinder holder 1 4 front brake master cylinder assembly 1 5 right handlebar switch 1 6 throttle cable housing 2 7 th...

  • Page 188: Handlebar

    Handlebar 4-45 removing the handlebar order job/parts to remove q’ty remarks 15 upper handlebar holder 2 16 handlebar 1 17 lower handlebar holder 2 for installation, reverse the removal proce- dure..

  • Page 189: Handlebar

    Handlebar 4-46 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” tip blow compressed air between the left handle- bar and the handlebar grip, and gradua...

  • Page 190: Handlebar

    Handlebar 4-47 3. Tighten: • lower handlebar holder nuts 4. Install: • throttle grip “1” • throttle cables • throttle cable housings “2” • grip end tip • align the projection “a” on the throttle cable housing with the hole “b” in the handlebar. • there should be 1–3 mm (0.04–0.12 in) of clearance “c...

  • Page 191: Handlebar

    Handlebar 4-48 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. B. Side the handlebar grip over the end of the left handlebar. C. Wipe off any excess rubber adhesive with a clean rag. Warning ewa13700 do not touch the handlebar grip until the...

  • Page 192: Front Fork

    Front fork 4-49 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-5. 1 front fender 1 2 band 1 left side only. 3 upper bracket pinch bolt 1 loosen. 4 cap...

  • Page 193: Front Fork

    Front fork 4-50 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 spacer 1 4 fork spring 1 5 locknut 1 6 outer tube 1 7 dust seal 1 8 oil seal clip 1 9 oil seal 1 10 washer 1 11 damper ro...

  • Page 194: Front Fork

    Front fork 4-51 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...

  • Page 195: Front Fork

    Front fork 4-52 eca39p1404 do not scratch the outer tube. 4. Remove: • damper rod assembly bolt • damper rod assembly tip while holding the damper rod with the damper rod holder “1”, loosen the damper rod assem- bly bolt. Eas23011 checking the front fork legs the following procedure applies to both ...

  • Page 196: Front Fork

    Front fork 4-53 - oil seal clip - dust seal - copper washer - o-ring • before assembling the front fork leg, make sure all of the components are clean. 1. Install: • damper rod assembly “1” eca39p1406 allow the damper rod assembly to slide slowly down the inner tube “2” until it pro- trudes from the...

  • Page 197: Front Fork

    Front fork 4-54 5. Install: • outer tube (to the inner tube) 6. Install: • washer • oil seal “1” (with the fork seal driver “2”) 7. Install: • oil seal clip “1” tip adjust the oil seal clip so that it fits into the outer tube’s groove. 8. Install: • dust seal “1” (with the fork seal driver “2”) 9. F...

  • Page 198: Front Fork

    Front fork 4-55 11. After filling the front fork leg, slowly stroke the damper rod “1” up and down (at least ten times) to distribute the fork oil. Tip be sure to stroke the damper rod slowly because the fork oil may spurt out. 12. Before measuring the fork oil level, wait ten minutes until the oil ...

  • Page 199: Front Fork

    Front fork 4-56 g. Pull up the rod puller and install the rod holder “2” between the locknut “3” and the spacer “4”. Tip use the side of the rod holder that is marked “b”. H. Remove the rod puller and rod puller attachment. I. Install the cap bolt all the way onto the damper rod assembly, and finger...

  • Page 200: Front Fork

    Front fork 4-57 warning ewa13680 make sure the brake hoses are routed prop- erly..

  • Page 201: Steering Head

    Steering head 4-58 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Meter assembly refer to “general chassis” on page 4-1. Handlebar refer to “handlebar” on pag...

  • Page 202: Steering Head

    Steering head 4-59 removing the lower bracket order job/parts to remove q’ty remarks 9 lock washer 1 10 upper ring nut 1 11 rubber washer 1 12 lower ring nut 1 13 lower bracket 1 14 bearing cover 1 15 lower bearing dust seal 1 16 upper bearing 1 17 lower bearing 1 for installation, reverse the remov...

  • Page 203: Steering Head

    Steering head 4-60 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 204: Steering Head

    Steering head 4-61 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • upper bracket • lower bracket (along with the steering stem) bends/cracks/damage → replace. Eas23140 installing the steering head 1. Lubricate: • upper bearing • lower bearing 2. Install: • lower ring nut “1” • rubber washer “2” • upper r...

  • Page 205

    Rear shock absorber assembly 4-62 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks left side cover refer to “general chassis” on page 4-1. Right side cover refer to “general chassis” on page 4-1. Brake fluid reservoir bolt refer t...

  • Page 206

    Rear shock absorber assembly 4-63 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held respo...

  • Page 207

    Rear shock absorber assembly 4-64 eas23261 checking the connecting arm and relay arm 1. Check: • connecting arm “1” • relay arms “2” damage/wear → replace. 2. Check: • bearings • oil seals damage/pitting → replace. 3. Check: • collars damage/scratches → replace. Eas23311 installing the rear shock ab...

  • Page 208

    Rear shock absorber assembly 4-65 4. Tighten: • rear shock absorber assembly upper nut • rear shock absorber assembly lower nut • frame and connecting arm nut • relay arm and swingarm nut • relay arm and connecting arm nut 3. Frame 4. Swingarm a. Left side b. Right side rear shock absorber assembly ...

  • Page 209: Swingarm

    Swingarm 4-66 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-31. Rear wheel refer to “rear wheel” on page 4-11. Relay arm refer to “rear shock absorber assembly” on page 4-62. Drive chain refer to “chain drive” on pag...

  • Page 210: Swingarm

    Swingarm 4-67 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • relay arm and swingarm bolt “1...

  • Page 211: Swingarm

    Swingarm 4-68 4. Check: • dust covers “1” • spacer “2” • oil seals “3” damage/wear → replace. • collar “4” damage/scratches → replace. • bearings “5” damage/pitting → replace. Eas23380 installing the swingarm 1. Lubricate: • spacer • dust covers • pivot shaft • oil seals • collar 2. Install: • beari...

  • Page 212: Chain Drive

    Chain drive 4-69 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to “engine removal” on page 5-3. 1 drive chain 1 for installation, reverse the removal proce- dure..

  • Page 213: Chain Drive

    Chain drive 4-70 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain tip cut the ...

  • Page 214: Chain Drive

    Chain drive 4-71 to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the o-rings. A coarse brush can also damage the o-rings. Therefore, use only kerosene to clean the drive chain. • do not soak the drive chain in ...

  • Page 215: Chain Drive

    Chain drive 4-72 b. After riveting, make sure the diameter between the edges “b” of the connecting pin “2” is 5.5–5.8 mm (0.22–0.23 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 14.1–14.3 mm (0.56–0.65 in). ▲▲▲▲...

  • Page 216: Chain Drive

    Chain drive 4-73.

  • Page 217: Engine

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

  • Page 218

    Clutch......................................................................................................5-45 removing the clutch...................................................................5-49 checking the friction plates ..................................................5-50 checking the...

  • Page 219

    Transmission.........................................................................................5-84 removing the transmission ......................................................5-89 checking the shift forks ..........................................................5-89 checking the shift dr...

  • Page 220: Engine Inspection

    Engine inspection 5-1 eas14b1052 engine inspection eas20710 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 to ...

  • Page 221: Engine Inspection

    Engine inspection 5-2 6. Install: • spark plug 7. Install: • ignition coils spark plug 13 nm (1.3 m·kgf, 9.4 ft·lbf).

  • Page 222: Engine Removal

    Engine removal 5-3 eas23711 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen. Refer to “adjusting the drive chain slack” on page 3-18. 1 locknut 2 2 shift rod 1 3 shift arm 1 4 joint 1 5 drive sprocket cover 1 6 plate 1 7 drive sprocket nut 1 8 was...

  • Page 223: Engine Removal

    Engine removal 5-4 removing the muffler and exhaust pipe order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Drive sprocket cover refer to “engine removal” on page 5-3. 1 o 2 sensor coupler 1 disconnect. 2 o 2 sensor 1...

  • Page 224: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-6. Thermostat assembly refer to “thermostat” on page 6-7. Oil cooler refer to “oil cooler” on page 6-5. Air cut...

  • Page 225: Engine Removal

    Engine removal 5-6 disconnecting the leads and hoses order job/parts to remove q’ty remarks 7 stator coil assembly lead coupler 1 disconnect. 8 crankshaft position sensor lead coupler 1 disconnect. 9 oil level switch lead coupler 1 disconnect. 10 neutral switch connector 1 disconnect. 11 speed senso...

  • Page 226: Engine Removal

    Engine removal 5-7 removing the engine order job/parts to remove q’ty remarks 1 right front engine mounting bolt 1 1 2 left front engine mounting bolt 1 3 upper engine mounting bolt/nut 1/1 4 lower engine mounting bolt/nut 1/1 5 engine mounting adjust bolt 2 loosen. 6 engine 1 for installation, reve...

  • Page 227: Engine Removal

    Engine removal 5-8 eas23720 installing the engine 1. Install: • right front engine mounting bolt 2 “1” refer to “cylinder head” on page 5- 20. 2. Tighten: • right front engine mounting bolt 2 3. Install: • engine mounting adjust bolts (temporarily tighten) 4. Install: • engine 5. Install: • lower en...

  • Page 228: Engine Removal

    Engine removal 5-9 8. Install: • lower engine mounting nut “1” • upper engine mounting nut “2” tip first tighten the lower engine mounting nut, and then tighten the upper engine mounting nut. 9. Tighten: • left front engine mounting bolt “1” • right front engine mounting bolt 1 “2” tip first tighten...

  • Page 229: Engine Removal

    Engine removal 5-10 tip align punch mark “a” of the shift arm “1” with alignment mark “b” of the crankcase. Eas39p1501 installing the drive sprocket 1. Install: • drive sprocket • washer • drive sprocket nut “1” tip • while applying the rear brake, tighten the drive sprocket nut. • stake the drive s...

  • Page 230: Camshafts

    Camshafts 5-11 eas23760 camshafts * silicone fluid removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-6. Air cut-off valve refer to “air induction system” on page 7-15. 1 cylinder id...

  • Page 231: Camshafts

    Camshafts 5-12 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “crankshaft position sen- sor” on page 5-39. Clutch cable (engine side) disconnect. Refer to “clutch” on page 5-45. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft ...

  • Page 232: Camshafts

    Camshafts 5-13 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to “crankshaft position sensor” on page 5-39. 2. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 i...

  • Page 233: Camshafts

    Camshafts 5-14 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out of specification → replace. 4. Me...

  • Page 234: Camshafts

    Camshafts 5-15 b. Position strip of plastigauge® “1” onto the camshaft journal as shown. C. Install the dowel pins and camshaft caps. Tip • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft jo...

  • Page 235: Camshafts

    Camshafts 5-16 eas23960 checking the timing chain ten- sioner 1. Remove: • timing chain tensioner housing “1” • timing chain tensioner rod “2” • timing chain tensioner spring “3” • timing chain tensioner spring seat “4” tip squeeze the timing chain tensioner clip “5”, and then remove the timing chai...

  • Page 236: Camshafts

    Camshafts 5-17 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas24000 installing the camshafts 1. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc, align the “t” mark “a” with the crankcase...

  • Page 237: Camshafts

    Camshafts 5-18 “el”: exhaust left side camshaft cap mark “er”: exhaust right side camshaft cap mark • make sure the arrow mark “a” on each cam- shaft points towards the right side of the engine. 5. Tighten: • camshaft cap bolts tip tighten the camshaft cap bolts in stages and in a crisscross pattern...

  • Page 238: Camshafts

    Camshafts 5-19 10. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance” on page 3-5. 11. Install: • pickup rotor cover refer to “crankshaft position sensor” on page 5-39. 12. Install: • timing chain guide (top side) • cylinder head cover gasket • cylinde...

  • Page 239: Cylinder Head

    Cylinder head 5-20 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 5-11. Exhaust camshaft refer to “camshafts” on page 5-11. 1 coolant pipe 1 2 fast idle plunger inlet ...

  • Page 240: Cylinder Head

    Cylinder head 5-21 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the cam- shafts” on page 5-13. 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 241: Cylinder Head

    Cylinder head 5-22 2. Install: • cylinder head gasket “1” • dowel pins 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 nut thread and mating surface with engine oil. 4. Tighten...

  • Page 242: Valves And Valve Springs

    Valves and valve springs 5-23 eas24270 valves and valve springs * silicone fluid removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-20. 1 intake valve lifter 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve spri...

  • Page 243: Valves And Valve Springs

    Valves and valve springs 5-24 * silicone 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 ste...

  • Page 244: Valves And Valve Springs

    Valves and valve springs 5-25 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 245: Valves And Valve Springs

    Valves and valve springs 5-26 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 246: Valves And Valve Springs

    Valves and valve springs 5-27 tip after replacing the valve guide, reface the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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...

  • Page 247: Valves And Valve Springs

    Valves and valve springs 5-28 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 248: Valves And Valve Springs

    Valves and valve springs 5-29 h. Install the valve into the cylinder head. I. Press the valve through the valve guide and onto the valve seat to make a clear impression. J. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲▲▲▲▲...

  • Page 249: Valves And Valve Springs

    Valves and valve springs 5-30 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. Eas24340 installing the valves the following procedure applies to all of the valves ...

  • Page 250: Valves And Valve Springs

    Valves and valve springs 5-31 “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- face hammer. Eca13800 hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • valve pad (with the ...

  • Page 251: Generator

    Generator 5-32 eas24480 generator removing the generator order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Left side cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Engine oil drain. Refer to “changing the engine oil” ...

  • Page 252: Generator

    Generator 5-33 removing the generator order job/parts to remove q’ty remarks 11 bearing housing 1 12 collar 1 13 bearing 1 14 starter clutch idler gear 1 15 idler gear shaft 1 16 bearing 1 for installation, reverse the removal proce- dure..

  • Page 253: Generator

    Generator 5-34 eas24490 removing the generator 1. Remove: • plug • generator rotor cover “1” tip • while pushing generator rotor, remove the generator rotor cover. • loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. • after all of the bolts are fully loosened, remove them...

  • Page 254: Generator

    Generator 5-35 4. Install: • generator rotor cover gasket • generator rotor cover “1” tip • first tighten the m8 bolts and then tighten the m6 bolts. • tighten the generator rotor cover bolts in stages and in a crisscross pattern. Generator rotor cover bolt (m8) 22 nm (2.2 m·kgf, 16 ft·lbf) generato...

  • Page 255: Starter Clutch

    Starter clutch 5-36 eas24550 starter clutch removing the starter clutch order job/parts to remove q’ty remarks 1 spacer 1 2 o-ring 1 3 washer 1 4 starter clutch drive gear 1 5 collar 1 6 washer 1 7 driven gear 1 8 damper 3 9 starter clutch assembly plate 1 10 starter clutch assembly 1 11 generator r...

  • Page 256: Starter Clutch

    Starter clutch 5-37 eas24560 removing the starter clutch 1. Remove: • spacer “1” • o-ring “2” • washer “3” 2. Remove: • starter clutch drive gear “1” • collar “2” • washer “3” 3. Remove: • driven gear “1” • dampers “2” 4. Remove: • starter clutch assembly plate “1” • starter clutch assembly “2” eas5...

  • Page 257: Starter Clutch

    Starter clutch 5-38 3. Check: • starter clutch gear’s contacting surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch drive gear “1” onto the starter clutch and hold the driven gear. B. When ...

  • Page 258: Crankshaft Position Sensor

    Crankshaft position sensor 5-39 eas24520 crankshaft position sensor removing the crankshaft position sensor order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Engine oil drain. Refer to “changing the engine oil” on pa...

  • Page 259: Crankshaft Position Sensor

    Crankshaft position sensor 5-40 eas24530 removing the crankshaft position sensor 1. Disconnect: • crankshaft position sensor lead coupler 2. Remove: • crankshaft position sensor • o-rings • pickup rotor cover “1” tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. Af...

  • Page 260: Electric Starter

    Electric starter 5-41 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-6. Right throttle body joint refer to ...

  • Page 261: Electric Starter

    Electric starter 5-42 * when replacing any of the front cover, starter motor yoke, armature assembly, and rear cover, replace the starter motor assembly. Disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 starter motor yoke 1 4 armature assembly 1 5 g...

  • Page 262: Electric Starter

    Electric starter 5-43 eas24791 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of t...

  • Page 263: Electric Starter

    Electric starter 5-44 6. Check: • gear teeth damage/wear → replace the starter motor. 7. Check: • bearing • oil seal damage/wear → replace the starter motor. Eas24800 assembling the starter motor 1. Install: • brush holder set 2. Install: • rear cover “1” • starter motor yoke “2” • front cover “3” t...

  • Page 264: Clutch

    Clutch 5-45 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-23. 1 clutch cable 1 disconnect. 2 clutch cover 1 3 clutch cover gasket 1 4 dowel pin 2 5 oil filler cap 1 for installation, reverse the removal...

  • Page 265: Clutch

    Clutch 5-46 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 2 2 pull lever 1 3 pull lever spring 1 4 pull lever shaft 1 5 oil seal 1 6 bearing 2 for installation, reverse the removal proce- dure..

  • Page 266: Clutch

    Clutch 5-47 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 1 green paint mark. 6 clutch plate 1 6 7 friction plate 2 6 purple paint mark. 8 clutch boss nut 1 9 washer 1 10 clutch boss 1 11 wire circlip ...

  • Page 267: Clutch

    Clutch 5-48 removing the clutch order job/parts to remove q’ty remarks 16 thrust plate 1 17 clutch housing 1 18 bearing 1 for installation, reverse the removal proce- dure..

  • Page 268: Clutch

    Clutch 5-49 eas30712 removing the clutch 1. Remove: • clutch cover “1” • 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 springs • pressure plat...

  • Page 269: Clutch

    Clutch 5-50 7. Remove: • clutch boss nut • washer • clutch boss assembly • thrust plate 8. Remove: • wire circlip “1” tip there is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “1” and disassemble the built-in damper unless there is se...

  • Page 270: Clutch

    Clutch 5-51 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clutch plates as a set. Eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the c...

  • Page 271: Clutch

    Clutch 5-52 eas25220 checking the pull lever shaft and pull rod 1. Check: • pull lever shaft pinion gear teeth “1” • pull rod teeth “2” damage/wear → replace the pull rod and pull lever shaft as a set. 2. Check: • pull rod bearing damage/wear → replace. Eas25240 installing the clutch 1. Install: • c...

  • Page 272: Clutch

    Clutch 5-53 • stake the clutch boss nut at a cutout “a” in the main axle. • while holding the clutch boss assembly “1” with the universal clutch holder “3”, tighten the clutch boss nut. 6. Install: • friction plate 2 • clutch plate 1 “1” tip assemble friction plate 2 to the clutch boss assembly so t...

  • Page 273: Clutch

    Clutch 5-54 9. Install: • dowel pins • clutch cover gasket • clutch cover “1” tip • apply engine oil onto the bearing. • apply locking agent (loctite®) to the threads of only the clutch cover bolt “a” shown in the illustration. • tighten the clutch cover bolts in stages and in a crisscross pattern. ...

  • Page 274: Shift Shaft

    Shift shaft 5-55 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-45. Shift arm and shift rod refer to “engine removal” on page 5-3. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 shift shaft sprin...

  • Page 275: Shift Shaft

    Shift shaft 5-56 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” • collar “3” damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace the stop- ...

  • Page 276: Oil Pump

    Oil pump 5-57 eas24921 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Drive sprocket cover refer to “engine removal” on page 5-3. Engine oil drain. Refer to “changing the engine oil” on page 3-23. O 2 sensor refer to “eng...

  • Page 277: Oil Pump

    Oil pump 5-58 removing the oil pan and oil pump 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 11 relief valve assembly 1 12 oil/water pump assembly drive chain guide 1 13 collar 1 14 oil/water pump assembly drive sprocket 1 1...

  • Page 278: Oil Pump

    Oil pump 5-59 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 pin 2 6 oil pump rotor assembly 1 7 pin 1 for assembly, reverse the disassembly pro- cedure..

  • Page 279: Oil Pump

    Oil pump 5-60 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan 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. Eas25620 checking the sprocket and ch...

  • Page 280: Oil Pump

    Oil pump 5-61 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas24971 checking the relief valve 1. Check: • relief valve body “1” • relief valve “2” • spring “3” • o-ring “4” damage/wear → replace the relief valve assembly. Eas24980 checkin...

  • Page 281: Oil Pump

    Oil pump 5-62 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” in the oil pump shaft with the groove “a” in the inner rotor “2”. 3. Install: • oil/water pump driven sprocket “1” tip 5vy mar...

  • Page 282: Oil Pump

    Oil pump 5-63 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 delivery pipe “1” 5. Install: • relief valve assembly “1” • o-ring • oil strainer “2” • o-ring • oil pipe “3” • o-rings • drain pipe “...

  • Page 283: Oil Pump

    Oil pump 5-64 tip • tighten the oil pan bolts in stages and in a crisscross pattern. • lubricate the oil level switch o-ring with lith- ium-soap-based grease..

  • Page 284: Crankcase

    Crankcase 5-65 eas25540 crankcase * yamaha bond no.1215 (three bond no.1215®) 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 5-20. Shift shaft assembly refer to “shift shaft” on page 5-55. C...

  • Page 285: Crankcase

    Crankcase 5-66 * yamaha bond no.1215 (three bond no.1215®) separating the crankcase order job/parts to remove q’ty remarks 4 crankcase breather hose 1 5 ventilation chamber cover 1 6 ventilation chamber cover gasket 1 7 left side cover 1 8 o-ring 1 9 lower crankcase 1 10 dowel pin 3 for installation...

  • Page 286: Crankcase

    Crankcase 5-67 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 decreasing numerical ...

  • Page 287: Crankcase

    Crankcase 5-68 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) eca13980 before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 6. Install: • crankcase bolts tip • lubricate the bolts “1”–“10” thread, ...

  • Page 288: Connecting Rods and Pistons

    Connecting rods and pistons 5-69 eas39p1503 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 5-65. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 ...

  • Page 289: Connecting Rods and Pistons

    Connecting rods and pistons 5-70 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 bearing so that it can be ...

  • Page 290: Connecting Rods and Pistons

    Connecting rods and pistons 5-71 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 291: Connecting Rods and Pistons

    Connecting rods and pistons 5-72 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 292: Connecting Rods and Pistons

    Connecting rods and pistons 5-73 3. Measure: • piston pin bore inside diameter “b” out of specification → replace the pis- ton. 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas39p1504 checking the connecting rods 1. Measur...

  • Page 293: Connecting Rods and Pistons

    Connecting rods and pistons 5-74 d. Assemble the connecting rod halves. Eca39p1501 tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Tip • clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil....

  • Page 294: Connecting Rods and Pistons

    Connecting rods and pistons 5-75 h. Put a mark “1” on the corner of the con- necting rod bolt “2” and the connecting rod cap “3”. I. Tighten the connecting rod bolts further to reach the specified angle 145–155 °. Warning ewa13400 if the connecting rod bolt is tightened more than the specified angle...

  • Page 295: Connecting Rods and Pistons

    Connecting rods and pistons 5-76 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 296: Connecting Rods and Pistons

    Connecting rods and pistons 5-77 e. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • oil ring expander “1” • lower oil ring...

  • Page 297: Connecting Rods and Pistons

    Connecting rods and pistons 5-78 7. Lubricate: • crankshaft pins • connecting rod big end bearing inner sur- face (with the recommended lubricant) 8. Check: • cylinder stud bolts 9. Install: • piston assemblies “1” (into the cylinder) tip while compressing the piston rings with one hand, install the...

  • Page 298: Connecting Rods and Pistons

    Connecting rods and pistons 5-79 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 299: Crankshaft

    Crankshaft 5-80 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks lower crankcase separate. Refer to “crankcase” on page 5-65. Connecting rod refer to “removing the connecting rods and pistons” on page 5-70. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crank...

  • Page 300: Crankshaft

    Crankshaft 5-81 eas25980 removing the crankshaft assembly 1. Remove: • crankshaft assembly • crankshaft journal bearings tip identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place. Eas14b1025 checking the oil nozzles the following procedure app...

  • Page 301: Crankshaft

    Crankshaft 5-82 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 “a” of the crankshaft journal lower bearings with the notches “b...

  • Page 302: Crankshaft

    Crankshaft 5-83 eas26200 installing the crankshaft 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) • crankshaft tip • align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the...

  • Page 303: Transmission

    Transmission 5-84 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 5-65. 1 drive axle assembly 1 2 oil seal 1 3 bearing 1 4 washer 1 5 shift fork guide bar retainer 2 6 ...

  • Page 304: Transmission

    Transmission 5-85 removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks 14 oil pipe 1 15 oil baffle plate 1 16 bearing 2 for installation, reverse the removal proce- dure..

  • Page 305: Transmission

    Transmission 5-86 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 tip when installing secondary pinion gear “1”, install the gear with groove “a” facing to the toothed lock washer. 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion g...

  • Page 306: Transmission

    Transmission 5-87 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 3rd wheel gear 1 8 collar 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 307: Transmission

    Transmission 5-88 disassembling the drive axle assembly order job/parts to remove q’ty remarks 20 collar 1 21 bearing 1 22 circlip 1 23 drive axle 1 for assembly, reverse the disassembly pro- cedure..

  • Page 308: Transmission

    Transmission 5-89 eas26250 removing the transmission 1. Remove: • drive axle assembly “1” • shift fork guide bar retainers “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 309: Transmission

    Transmission 5-90 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 310: Transmission

    Transmission 5-91 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmis- sion axle assemblies. 5. Check: • transmission gear movement rough movement → replace the defec- tive part(s). 6. Check: • circlips bends/damage/looseness →...

  • Page 311: Transmission

    Transmission 5-92 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 installed correctly into the transmission gears. • install shift fork “c” into the gro...

  • Page 312: Transmission

    Transmission 5-93.

  • Page 313: Cooling System

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

  • Page 314: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Drive sprocket cover refer to “engine removal” on page 5-...

  • Page 315: Radiator

    Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 8 radiator fan motor coupler 2 disconnect. 9 radiator 1 10 radiator fan motor 2 11 water pump breather hose 2 1 disconnect. 12 water pump inlet pipe 1 for installation, reverse the removal proce- dure..

  • Page 316: 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 317: Radiator

    Radiator 6-4 b. Apply 122.7 kpa (1.23 kgf/cm², 17.8 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 318: 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 3-26. Engine oil drain. Refer to “changing the engine oil” on page 3-23. 1 water jacket joint inlet hose 1 2 oil cooler inlet hose 1 3 oil cooler u...

  • Page 319: Oil Cooler

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

  • Page 320: Thermostat

    Thermostat 6-7 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Throttle body assembly refer to “throttle ...

  • Page 321: Thermostat

    Thermostat 6-8 disassembling the thermostat assembly order job/parts to remove q’ty remarks 1 thermostat housing cover 1 2 thermostat 1 3 thermostat housing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 322: Thermostat

    Thermostat 6-9 eas26450 checking the thermostat 1. Check: • thermostat does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in the water. D. Wh...

  • Page 323: Thermostat

    Thermostat 6-10 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 3-26. 2. Check: • cooling system leaks → repair or replace any faulty part. Refer to “installing the radiator” on p...

  • Page 324: Water Pump

    Water pump 6-11 eas26500 water pump disassembling the water pump order job/parts to remove q’ty remarks oil/water pump assembly refer to “oil pump” on page 5-57. Oil pump rotor refer to “oil pump” on page 5-57. 1 water pump cover 1 2 pin 2 3 impeller shaft (along with the impeller) 1 4 water pump se...

  • Page 325: Water Pump

    Water pump 6-12 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” • bearing “2” tip remove the oil seal and bearing from the out- side of the water pump housing “3”. 3. Remove...

  • Page 326: Water Pump

    Water pump 6-13 eca14080 never lubricate the water pump seal sur- face with oil or grease. Tip install the water pump seal with the special tools. 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....

  • Page 327: Fuel System

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

  • Page 328: Fuel Tank

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

  • Page 329: Fuel Tank

    Fuel tank 7-2 removing the canister (for california only) order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Left side cover refer to “general chassis” on page 4-1. Right side cover refer to “general chassis” on page 4-1. Brake fluid reservoir bolt refer to “rear brak...

  • Page 330: Fuel Tank

    Fuel tank 7-3 eas39p1713 removing the fuel tank cover 1. Remove: • fuel tank cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bolts. B. Disengage the projections from both ends of the fuel tank, slightly expanding both ends of the fuel tank cover. C. Slide the right side of the fuel tank cover...

  • Page 331: Fuel Tank

    Fuel tank 7-4 eas26690 checking the fuel pump operation 1. Check: • fuel pump operation refer to “checking the fuel pres- sure” on page 7-5. Eas39p2701 checking the rollover valve (for california only) 1. Check: • rollover valve damage/faulty → replace. Tip • check that air flows smoothly only in th...

  • Page 332: Fuel Tank

    Fuel tank 7-5 eas39p1714 installing the fuel tank cover 1. Install: • fuel tank cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert projections “a” under the fuel tank cover bracket while inserting projection “b” into the hole of the fuel tank cover bracket. B. Engage the left and right projections of th...

  • Page 333: Throttle Bodies

    Throttle bodies 7-6 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Throttle cable (handlebar side) disc...

  • Page 334: Throttle Bodies

    Throttle bodies 7-7 removing the throttle bodies order job/parts to remove q’ty remarks 11 coolant temperature sensor coupler 1 disconnect. 12 throttle bodies 1 13 throttle body joint 2 for installation, reverse the removal proce- dure..

  • Page 335: Throttle Bodies

    Throttle bodies 7-8 removing the injectors order job/parts to remove q’ty remarks 1 fuel injection system sub-wire harness 1 2 hose joint 5 3 negative pressure hose (thin) 11 4 negative pressure hose (thick) 4 5 hose joint 2 for california only 6 canister purge hose 3 for california only 7 intake ai...

  • Page 336: Throttle Bodies

    Throttle bodies 7-9 eas39p1710 removing the fuel hose (throttle body side) 1. Remove: • fuel tank refer to “removing the fuel tank” on page 7-3. 2. Remove: • fuel hose (throttle body side) eca14b1003 be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. Tip •...

  • Page 337: Throttle Bodies

    Throttle bodies 7-10 1. Check: • injector pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” to the fuel rail joint “2”, and then connect an air compressor “3” to the adapter. B. Connect the pressure gauge “4” to the injector pressure adapter “1”. C. Close the valve...

  • Page 338: Throttle Bodies

    Throttle bodies 7-11 eca39p1703 observe the following precautions; other- wise, the throttle bodies may not operate properly. • do not open the throttle valves quickly. • do not subject the throttle bodies to excessive force. • clean the throttle bodies with a cloth which petroleum-based solvent is ...

  • Page 339: Throttle Bodies

    Throttle bodies 7-12 g. Make sure that there are no carbon depos- its or other foreign materials in any of the passages “a” in each throttle body, in the space “b” between the throttle valve shaft and the throttle body or in the space “c” between the sub throttle valve shaft and the throttle body. ▲...

  • Page 340: Throttle Bodies

    Throttle bodies 7-13 c. Connect the throttle position sensor, sub- throttle position sensor and sub-throttle servo motor to the wire harness. D. Set the main switch to “off” and set the engine stop switch to “ ”. E. Simultaneously press and hold the “select” and “reset” buttons “1”, set the main swi...

  • Page 341: Throttle Bodies

    Throttle bodies 7-14 d. Set the main switch to “on” and fully close the sub-throttle valves. E. Measure the sub-throttle position sensor voltage. F. Adjust the sub-throttle position sensor angle so that the voltage is within the spec- ified range. G. After adjusting the sub-throttle position sensor ...

  • Page 342: Air Induction System

    Air induction system 7-15 eas27040 air induction system.

  • Page 343: Air Induction System

    Air induction system 7-16 1. 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 344: Air Induction System

    Air induction system 7-17 removing the air cut-off valve assembly and reed valves order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Radiator refer to “radiator”...

  • Page 345: Air Induction System

    Air induction system 7-18 eas27060 checking the air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the r...

  • Page 346: Air Induction System

    Air induction system 7-19 • reed valve assembly tip install the reed valve assembly so that the open side turns to the exhaust side of the engine. 2. Install: • reed valve cover a. Exhaust side reed valve cover bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) loctite®.

  • Page 347: Electrical System

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

  • Page 348

    Electrical components...................................................................8-93 checking the switches...............................................................8-97 checking the bulbs and bulb sockets...............................8-100 checking the fuses...............................

  • Page 350: Ignition System

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

  • Page 351: Ignition System

    Ignition system 8-2 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 16.Sidestand switch 19.Lean angle sensor 22.Cylinder identification sensor 23.Crankshaft position sensor 24.Ecu (engine control unit) 25.Ignit...

  • Page 352: Ignition System

    Ignition system 8-3 eas39p1804 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 353: 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.Neutral switch 12.Battery negative lead.

  • Page 354: 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. Fuel tank 4. Radiator ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok...

  • Page 355: Ignition System

    Ignition system 8-6 ng → ok ↓ ng → ok ↓ 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 8-97. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-97. Replace the ...

  • Page 356: Electric Starting System

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

  • Page 357: Electric Starting System

    Electric starting system 8-8 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 10.Starter relay 11.Starter motor 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 16.Sidestand switch 53.Right handlebar switch 55.Engine stop switch 56.Start switch 58.Left handleb...

  • Page 358: Electric Starting System

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

  • Page 359: 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. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Sidestand sw...

  • Page 360: 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. Fuel tank 4. Air filter case 5. Throttle bodies ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓...

  • Page 361: 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 8-97. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-97. Replace the right hand...

  • Page 362: Charging System

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

  • Page 363: Charging System

    Charging system 8-14 2. Rectifier/regulator 3. Ac magneto 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery.

  • Page 364: 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. Passenger seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fuses” on page 8-101. Replace...

  • Page 365: Charging System

    Charging system 8-16.

  • Page 366: Lighting System

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

  • Page 367: Lighting System

    Lighting system 8-18 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 24.Ecu (engine control unit) 42.Meter assembly 49.High beam indicator light 51.Meter light 58.Left handlebar switch 60.Dimmer switch 69.Headlight 70.License plate light 71.Tail/brake light 72.Headlight relay...

  • Page 368: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Headlight assembly 4. Fuel tank ng → ok ↓ ng...

  • Page 369: Lighting System

    Lighting system 8-20 ng → ok ↓ 7. 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 370: Signaling System

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

  • Page 371: Signaling System

    Signaling system 8-22 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 12.Relay unit 15.Neutral switch 18.Fuel sender 21.Speed sensor 24.Ecu (engine control unit) 39.Coolant temperature sensor 42.Meter assembly 43.Oil level warning light 44.Neutral indicator light 45.Tachomete...

  • Page 372: 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. Air filter case 5. Throttl...

  • Page 373: Signaling System

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

  • Page 374: 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 ↓ ng → ok ↓ 3. Check the turn signal relay. Refer to “checking the turn signal relay” on page 8-106. Replace the turn signal rel...

  • Page 375: Signaling System

    Signaling system 8-26 the fuel level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the fuel sender. Refer to “checking the fuel sender” on page 8-112. Repl...

  • Page 376: Cooling System

    Cooling system 8-27 eas27300 cooling system eas27310 circuit diagram.

  • Page 377: Cooling System

    Cooling system 8-28 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 24.Ecu (engine control unit) 39.Coolant temperature sensor 73.Radiator fan motor relay 74.Right radiator fan motor fuse 75.Right radiator fan motor 76.Left radiator fan motor fuse 77.Left radiator fan motor 8...

  • Page 378: Cooling System

    Cooling system 8-29 eas27320 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Air filter case 5. Throttle bodies ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and radiator fan...

  • Page 379: Cooling System

    Cooling system 8-30 ng → ok ↓ 7. Check the entire cooling system’s wiring. Refer to “circuit diagram” on page 8-27. Properly connect or repair the cooling system’s wiring. Replace the ecu..

  • Page 380: Fuel Injection System

    Fuel injection system 8-31 eas27331 fuel injection system eas27340 circuit diagram.

  • Page 381: Fuel Injection System

    Fuel injection system 8-32 1. Main switch 4. Backup fuse 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Neutral switch 16.Sidestand switch 17.Fuel pump 19.Lean angle sensor 20.Atmospheric pressure sensor 21.Speed sensor 22.C...

  • Page 382: Fuel Injection System

    Fuel injection system 8-33 eas27351 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 383: Fuel Injection System

    Fuel injection system 8-34 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 384: Fuel Injection System

    Fuel injection system 8-35 eas30580 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 faul...

  • Page 385: Fuel Injection System

    Fuel injection system 8-36 eas27411 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “on”. 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 386: Fuel Injection System

    Fuel injection system 8-37 eas27462 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 malfu...

  • Page 387: Fuel Injection System

    Fuel injection system 8-38 5 sensor installation status - check the mounting sec- tion for loose or pinched mounting. 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 388: Fuel Injection System

    Fuel injection system 8-39 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 389: Fuel Injection System

    Fuel injection system 8-40 2 connection of wire 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. Place the main switch to the on positio...

  • Page 390: Fuel Injection System

    Fuel injection system 8-41 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. 6 intake air pressure sensor malfunction check in the diagnostic mode (code no. D03). When engine is stopped: atmospheric pressure at the current altitude and wea...

  • Page 391: Fuel Injection System

    Fuel injection system 8-42 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 14 item intake air pressure sensor: hose system malfunction (clogged or detached hose). Fail-safe system able to start engine able to drive vehicle...

  • Page 392: Fuel Injection System

    Fuel injection system 8-43 fault code no. 15 item throttle position sensor: open or short circuit detected. (no normal signals are received from the throttle position sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:01 meter display throttle position sensor ...

  • Page 393: Fuel Injection System

    Fuel injection system 8-44 tip if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. 6 supply voltage of throttle position sensor lead check the supply voltage. Black/blue–yellow refer to “checking the throttle position sen- sor” on page 8-115. Pl...

  • Page 394: Fuel Injection System

    Fuel injection system 8-45 tip if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. Fault code no. 16 item throttle position sensor: stuck throttle position sensor detected. (signal from throttle position sensor will not change.) fail-safe system...

  • Page 395: Fuel Injection System

    Fuel injection system 8-46 fault code no. 19 item sidestand switch: a break or disconnection of the blue/yellow lead of the ecu is detected. (no normal signals are received from the sidestand switch.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:20 meter disp...

  • Page 396: Fuel Injection System

    Fuel injection system 8-47 5 sidestand switch malfunction diagnostic mode (code no. D20). The transmission is in gear 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 t...

  • Page 397: Fuel Injection System

    Fuel injection system 8-48 fault code no. 20 item intake air pressure sensor or atmospheric pressure sensor: when the main switch is set to “on”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Fail-safe system able to start engine able to drive vehicle...

  • Page 398: Fuel Injection System

    Fuel injection system 8-49 3 ecu malfunction replace the ecu. Fault code no. 21 item coolant temperature sensor: open or short circuit detected. (no nor- mal signals are received from the coolant temperature sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:0...

  • Page 399: Fuel Injection System

    Fuel injection system 8-50 3 connection of fuel injection system 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. Place the main s...

  • Page 400: Fuel Injection System

    Fuel injection system 8-51 fault code no. 22 item intake air temperature sensor: open or short circuit detected. (no normal signals are received from the intake air temperature sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:05 meter display displays the in...

  • Page 401: Fuel Injection System

    Fuel injection system 8-52 5 intake air temperature sensor malfunction check in the diagnostic mode (code no. D05). Sensor inspection procedure refer to “checking the intake air temperature sensor” on page 8-118. During cold starting: a tem- perature close to the ambient temperature is indicated. Af...

  • Page 402: Fuel Injection System

    Fuel injection system 8-53 2 connection of wire 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. Place the main switch to the on position, and ...

  • Page 403: Fuel Injection System

    Fuel injection system 8-54 5 atmospheric pressure sensor malfunction check in the diagnostic mode (code no. D02). 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: appr...

  • Page 404: Fuel Injection System

    Fuel injection system 8-55 fault code no. 24 item o 2 sensor: no normal signals are received from the o 2 sensor. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check or maintenance job sensor inspectio...

  • Page 405: Fuel Injection System

    Fuel injection system 8-56 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 d63. No fault code indicated. ...

  • Page 406: Fuel Injection System

    Fuel injection system 8-57 3 lean angle sensor malfunc- tion diagnostic mode (code no. D08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-109. 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. Pl...

  • Page 407: Fuel Injection System

    Fuel injection system 8-58 2 connection of wire 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 408: Fuel Injection System

    Fuel injection system 8-59 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 108. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...

  • Page 409: Fuel Injection System

    Fuel injection system 8-60 2 connection of wire 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 410: Fuel Injection System

    Fuel injection system 8-61 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 108. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...

  • Page 411: Fuel Injection System

    Fuel injection system 8-62 2 connection of wire 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 412: Fuel Injection System

    Fuel injection system 8-63 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 108. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...

  • Page 413: Fuel Injection System

    Fuel injection system 8-64 2 connection of wire 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 414: Fuel Injection System

    Fuel injection system 8-65 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 108. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...

  • Page 415: Fuel Injection System

    Fuel injection system 8-66 fault code no. 39 item injector: open circuit detected. (no normal signals are received from the injector.) fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faulty cylinders) diagnostic co...

  • Page 416: Fuel Injection System

    Fuel injection system 8-67 4 connection of wire 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 417: Fuel Injection System

    Fuel injection system 8-68 6 continuity of wire harness open or short circuit → con- nect it securely, or repair/ replace the wire harness. Fuel injector #1 red/blue–red/blue red/black–red/black fuel injector #2 red/blue–red/blue green/black–green/black fuel injector #3 red/blue–red/blue blue/black–...

  • Page 418: Fuel Injection System

    Fuel injection system 8-69 fault code no. 41 item lean angle sensor: open or short circuit detected. (no normal sig- nals are received from the lean angle sensor.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:08 meter display lean angle sensor output voltage ...

  • Page 419: Fuel Injection System

    Fuel injection system 8-70 4 lean angle sensor malfunc- tion diagnostic mode (code no. D08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-109. Rotate the main switch to the off position first, and then rotate it to the on position again. Then, check the fault code ...

  • Page 420: Fuel Injection System

    Fuel injection system 8-71 fault code no. 42 item a. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral circuit of the neu- tral switch. C. Open or short circuit is detected in the clutch circuit of the clutch switch. A fail-safe sys- tem able t...

  • Page 421: Fuel Injection System

    Fuel injection system 8-72 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 422: Fuel Injection System

    Fuel injection system 8-73 b. Neutral switch sensor system malfunction item/components and probable cause check or maintenance job sensor inspection proce- dure 1 connection of neutral switch coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, ...

  • Page 423: Fuel Injection System

    Fuel injection system 8-74 c. Clutch switch system malfunction 6 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 5-90. Malfunction → replace the shift drum. Start the engin...

  • Page 424: Fuel Injection System

    Fuel injection system 8-75 5 continuity of leads between clutch switch and relay unit coupler open or short circuit → replace the wire harness. Yellow/black–yellow/black start the engine. Ride the vehicle at a low speed (approx. 20–30 km/h). Then, check the fault code indication. No fault code indic...

  • Page 425: Fuel Injection System

    Fuel injection system 8-76 2 connection of wire 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. Place the main switch to the on positi...

  • Page 426: Fuel Injection System

    Fuel injection system 8-77 5 fuel pump relay malfunction check in the diagnostic mode (code no. D09). Fuel-related voltage: 3 v or less → replace the relay unit. Place the main switch to the on position for approxi- mately 5 seconds. Then, check the fault code indication. No fault code indicated. → ...

  • Page 427: Fuel Injection System

    Fuel injection system 8-78 fault code no. 46 item incorrect voltage is supplied to the ecu. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check or maintenance job sensor inspection proce- dure 1 chargi...

  • Page 428: Fuel Injection System

    Fuel injection system 8-79 tip if fault codes 47 and 48 are indicated simultaneously, take the actions specified for fault code 47 first. 4 continuity of wire harness open or short circuit → replace the wire harness black/blue–black/blue green/yellow–green/yellow blue–blue place the main switch to t...

  • Page 429: Fuel Injection System

    Fuel injection system 8-80 fault code no. 48 item sub-throttle servo motor: stuck sub-throttle servo motor detected. Signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) fail-safe system able to start engine able to drive vehicle diagnostic code no. ...

  • Page 430: Fuel Injection System

    Fuel injection system 8-81 tip if fault codes 47 and 48 are indicated simultaneously, take the actions specified for fault code 47 first. 5 continuity of wire harness open or short circuit → replace the wire harness yellow/red–yellow/red yellow/white–yellow/white gray/black–gray/black gray/white–gra...

  • Page 431: Fuel Injection System

    Fuel injection system 8-82 fault code no. 70 item engine idling stop: engine has been left idling. (the ecu automati- cally stops the engine after 20 minutes if it is left idling.) fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/comp...

  • Page 432: Fuel Injection System

    Fuel injection system 8-83 4 abnormal meter unit opera- tion replace the meter unit. 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. 5 ecu malfunction replace the ecu fault code no. Er-2...

  • Page 433: Fuel Injection System

    Fuel injection system 8-84 4 abnormal meter unit opera- tion replace the meter unit. 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. 5 ecu malfunction replace the ecu. Fault code no. Er-...

  • Page 434: Fuel Injection System

    Fuel injection system 8-85 4 abnormal meter unit opera- tion replace the meter unit. 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. 5 ecu malfunction replace the ecu. Fault code no. Er-...

  • Page 435: Fuel Injection System

    Fuel injection system 8-86 4 abnormal meter unit opera- tion replace the meter unit. 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. 5 ecu malfunction replace the ecu. Fault code no. Er-...

  • Page 436: Fuel Injection System

    Fuel injection system 8-87 eas30660 diagnostic code table tip the following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (these items are not listed in “troubleshooting details”.) diag- nostic code no. Item meter display/actuation pro...

  • Page 437: Fuel Injection System

    Fuel injection system 8-88 set the main switch to “off” to cancel the diagnostic mode. Tip information about each diagnostic code no. Is organized in this manual as follows: • if a diagnostic code no. Has a corresponding fault code no., the information is shown in trou- bleshooting details. (refer t...

  • Page 438: Fuel Pump System

    Fuel pump system 8-89 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 439: Fuel Pump System

    Fuel pump system 8-90 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 17.Fuel pump 24.Ecu (engine control unit) 53.Right handlebar switch 55.Engine stop switch 80.Ignition fuse.

  • Page 440: Fuel Pump System

    Fuel pump system 8-91 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignitio...

  • Page 441: Fuel Pump System

    Fuel pump system 8-92 ng → ok ↓ 7. Check the entire fuel pump sys- tem’s wiring. Refer to “circuit diagram” on page 8-89. Properly connect or repair the fuel pump system’s wiring. Replace the ecu..

  • Page 442: Electrical Components

    Electrical components 8-93 eas27973 electrical components.

  • Page 443: Electrical Components

    Electrical components 8-94 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Ignition coil 5. Main fuse 6. Battery 7. Fuse box 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear brake light switch 12.O 2 sensor 13.Speed sensor 14.Sidestand switch 15.Oil level ...

  • Page 444: Electrical Components

    Electrical components 8-95.

  • Page 445: Electrical Components

    Electrical components 8-96 1. Intake air temperature sensor 2. Ecu (engine control unit) 3. Intake air pressure sensor 4. Fuel pump 5. Atmospheric pressure sensor 6. Relay unit 7. Lean angle sensor 8. Turn signal relay 9. Headlight relay 10.Radiator fan motor relay 11.Coolant temperature sensor 12.C...

  • Page 446: Electrical Components

    Electrical components 8-97 eas27981 checking the switches.

  • Page 447: Electrical Components

    Electrical components 8-98 1. Clutch switch 2. Dimmer switch 3. Turn signal switch 4. Horn switch 5. Main switch 6. Oil level switch 7. Sidestand switch 8. Front brake light switch 9. Engine stop switch 10.Start switch 11.Neutral switch 12.Rear brake light switch.

  • Page 448: Electrical Components

    Electrical components 8-99 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 th...

  • Page 449: Electrical Components

    Electrical components 8-100 eas27990 checking the bulbs and bulb sock- ets 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 or both. Improperly connected → properly connect. ...

  • Page 450: Electrical Components

    Electrical components 8-101 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in t...

  • Page 451: Electrical Components

    Electrical components 8-102 4. Install: • rider seat refer to “general chassis” on page 4-1. Eas28031 checking and charging the battery warning ewa13290 batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always fo...

  • Page 452: Electrical Components

    Electrical components 8-103 • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warnin...

  • Page 453: Electrical Components

    Electrical components 8-104 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat- tery and st...

  • Page 454: Electrical Components

    Electrical components 8-105 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery terminals 10. Install: • rider seat refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the po...

  • Page 455: Electrical Components

    Electrical components 8-106 relay unit (fuel pump relay) headlight relay radiator fan motor relay eas39p1801 checking the turn signal relay 1. Check: • turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal relay coupler is faulty and must b...

  • Page 456: Electrical Components

    Electrical components 8-107 b. Turn the main switch to “on”. C. Measure the turn signal relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • turn signal relay output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the turn s...

  • Page 457: Electrical Components

    Electrical components 8-108 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 458: Electrical Components

    Electrical components 8-109 3. Check: • ignition spark gap out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the ignition checker “1” as shown. B. Set the main switch to “on” and engine stop switch to “ ”. C. Measure the ignition spark gap “a”. D. Crank the engine by pushing ...

  • Page 459: Electrical Components

    Electrical components 8-110 c. Set the main switch to “on”. D. Turn the lean angle sensor to 65 °. 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 460: Electrical Components

    Electrical components 8-111 b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 8-110. ▼▼▼▼▼...

  • Page 461: Electrical Components

    Electrical components 8-112 eas28180 checking the horn 1. Check: • horn resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn terminals. B. Connect the digital circuit tester to the horn terminals. C. Measure the horn resistance. ▲▲▲▲▲▲▲...

  • Page 462: Electrical Components

    Electrical components 8-113 3. Remove: • fuel pump (from the fuel tank) 4. Check: • fuel sender resistance out of specification → replace the fuel pump assembly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 10) to the fuel sender terminals as shown. B. Measure the fuel sender re...

  • Page 463: Electrical Components

    Electrical components 8-114 e. Measure the voltage. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28250 checking the radiator fan motors 1. Check: • radiator fan motor faulty/rough movement → repla...

  • Page 464: Electrical Components

    Electrical components 8-115 3. Install: • coolant temperature sensor eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1 k) to the thrott...

  • Page 465: Electrical Components

    Electrical components 8-116 c. Connect the pocket tester ( Ω × 1 k) to the sub-throttle position sensor as shown. D. While slowly turning the sub-throttle posi- tion sensor shaft, check that the sub-throt- tle position sensor resistance is within the specified range. The resistance does not change o...

  • Page 466: Electrical Components

    Electrical components 8-117 b. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor 5s7 (3p). C. Set the main switch to “on”. D. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28390 checking the cylinder identifica- tion sensor 1. ...

  • Page 467: Electrical Components

    Electrical components 8-118 eca16730 pay attention to the installing direction of the test harness s-pressure sensor 5s7 (3p) coupler. B. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor 5s7 (3p). C. Set the main switch to “on”. D. Measure the intake air pressure sensor...

  • Page 468: Electrical Components

    Electrical components 8-119.

  • Page 469: Troubleshooting

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

  • Page 470: 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 471: Troubleshooting

    Troubleshooting 9-2 fuel system 1. Throttle body (-ies) • damaged or loose throttle body joint • improperly synchronized throttle bodies • improperly adjusted engine idling speed (idle adjusting screw) • improper throttle cable free play • flooded throttle body • faulty air induction system electric...

  • Page 472: Troubleshooting

    Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity (high) • deteriorated oil eas30480 overheating engine 1. Clogged coolant passages • cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil qua...

  • Page 473: Troubleshooting

    Troubleshooting 9-4 3. Front fork leg(s) • incorrect oil level • unevenly tensioned fork spring (both front fork legs) • broken fork spring • bent or damaged inner tube • bent or damaged outer tube 4. Swingarm • worn bearing or bushing • bent or damaged swingarm 5. Rear shock absorber assembly(-ies)...

  • Page 474

    Eas28740 wiring diagram fz8na(c) 2011 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 9. Fuel injection system fuse 10. Starter relay 11. Starter motor 12. Relay unit 13. Starting circuit cut-off relay 14. Fuel pump relay 15...

  • Page 477

    Wiring diagram fz8na(c).

  • Page 478

    Wiring diagram fz8na(c).