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Yamaha 2013 FJR1300AS Service Manual

Summary of 2013 FJR1300AS

  • Page 1

    2013 service manual fjr1300as 1md-28197-e0

  • Page 2

    Eas20040 fjr1300as 2013 service manual ©2013 by yamaha motor co., ltd. First edition, february 2013 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Important

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

  • Page 4: How to Use This Manual

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

  • Page 5: Symbols

    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

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

  • Page 9: General Information

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

  • Page 10: Identification

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

  • Page 11: Features

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

  • Page 12: Features

    Features 1-3 et3p61042 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm², 47.0 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 13: Features

    Features 1-4 eas1md1015 outline of the ycc-s (yamaha chip controlled-shift) system and ycc-t (yamaha chip controlled-throttle) mechanism characteristics of the ycc-t yamaha developed the ycc-t system employing the most advanced electronic control technologies. Electronic control throttle systems hav...

  • Page 14: Features

    Features 1-5 mechanism characteristics of the ycc-s ycc-s offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring. Ycc-s is not an automatic transmission, although it allows the user to shift gears by foot or ha...

  • Page 15: Features

    Features 1-6 13 1,2,3 4 5 6 8 11 12 7 10 9 1. Ycc-s warning light 2. Stop mode function indicator light 3. Shift down indicator light 4. Hand shift lever switch and stop mode function switch 5. Gear position sensor 6. Neutral switch 7. Mcu (motor control unit) 8. Shift actuator 9. Ycc-s control rela...

  • Page 16: Features

    Features 1-7 shift pattern this vehicle is equipped with a constant-mesh 5-speed transmission. The gears can be shifted using either the shift pedal “1” or the hand shift switch “2”. The gear positions are shown in the illustration. Attention • do not turn the main switch to “off” while the vehicle ...

  • Page 17: Features

    Features 1-8 ycc-s and ycc-t system outline 4 10 9 3 5 6 7 8 2 1 14 11 12 13 15 1. Engine speed 2. Vehicle speed 3. Throttle grip 4. Electric throttle valve 5. Gear position sensor 6. Hand shift switch 7. Foot shift sensor 8. Stop mode function switch 9. Ecu (engine control unit) 10. Mcu (motor cont...

  • Page 18: Features

    Features 1-9 eas1mc1087 outline of the cruise control system this model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the ycc-t system, the cruise control system can be controlled elec- tronically. Based on the signals that...

  • Page 19: Features

    Features 1-10 warning ewa1mc1006 • improper use of the cruise control system may result in loss of control, which could lead to an accident. Do not activate the cruise control system in heavy traffic, poor weather conditions, or among winding, slippery, hilly, rough or gravel roads. • when traveling...

  • Page 20: Features

    Features 1-11 adjusting the set cruising speed while the cruise control system is operating, push the “res+” side of the cruise control setting switch to increase the set cruising speed or the “set–” side to decrease the set speed. Tip • pushing the setting switch once will change the speed in incre...

  • Page 21: Features

    Features 1-12 using the resume function push the “res+” side of the cruise control setting switch to reactivate the cruise control system. The traveling speed will return to the previously set cruising speed. The cruise control setting indicator light “set” will come on. If the “set–” side of the cr...

  • Page 22: Features

    Features 1-13 automatic deactivation of the cruise control system the cruise control system for this model is electronically controlled and is linked with the other control systems. The cruise control system will automatically become deactivated under the following condi- tions: • the cruise control...

  • Page 23: Features

    Features 1-14 meter displays during cruise control system operation self-diagnosis device the cruise control system will also become deactivated when an irregularity with any of the vehicle sys- tems is detected. The cruise control setting indicator light “set” will go off and the cruise control sys...

  • Page 24: Features

    Features 1-15 notice eca1mc1006 if the display indicates a fault code, the vehicle should be checked as soon as possible in order to avoid engine damage. Tip • if the cruise control system turned off because a malfunction was detected by the fi self-diagnosis, the cruise control power switch “ ” mus...

  • Page 25: Features

    Features 1-16 meter displays during cruise control system operation tip this section explains the operation of the cruise control system according to the meter displays when a malfunction is detected in the fuel injection system. The operation of the cruise control system is the same when a malfunct...

  • Page 26: Features

    Features 1-17 et3p61050 outline of the unified brake system the yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle usi...

  • Page 27: Features

    Features 1-18 brake pedal input force and braking force at each wheel metering valve this valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level. Only the rear brake caliper is operated when there is an ex...

  • Page 28: Features

    Features 1-19 et3p61019 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. However, one set of pistons in the right front brake caliper is operated together with the rear brake and this set of pi...

  • Page 29: Features

    Features 1-20 when the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • brake force: the force applied by braking to reduce the wheel speed. • wheel lock: a condition that occurs when the rota...

  • Page 30: Features

    Features 1-21 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed ...

  • Page 31: Features

    Features 1-22 warning ew3p61003 the braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of the tires. Even in vehicles equipped with abs, overturning of the vehicle c...

  • Page 32: Features

    Features 1-23 abs block diagram et3p61051 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor contains a hall ic. The wheel sensors are installed in the sensor housing...

  • Page 33: Features

    Features 1-24 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on during the abs self-diagnosis to check the electrical circuit of the light. If there are no problems detecte...

  • Page 34: Features

    Features 1-25 • hydraulic unit assembly the hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an abs motor, and abs ecu. The hydraulic unit adjusts the front and rear wheel brake fluid p...

  • Page 35: Features

    Features 1-26 3. When the abs ecu sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake mas...

  • Page 36: Features

    Features 1-27 • abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. The necessar...

  • Page 37: Features

    Features 1-28 abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when a malfunction is detected in the abs, a fault code is stored in the memory of the abs ecu for easy problem identification and trou...

  • Page 38: Features

    Features 1-29 et3p61052 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. Normal braking (abs not activated) when the abs is not activated, the inlet sol...

  • Page 39: Features

    Features 1-30 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line...

  • Page 40: Features

    Features 1-31 2. Pressurizing phase the outlet solenoid valve is closed by the “pressurization” signal transmitted from the abs ecu. At this time, the abs ecu controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, all...

  • Page 41: Features

    Features 1-32 et3p61053 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the multi-function meter center display. Instances when the abs warning light comes on 1. The abs warning light comes on...

  • Page 42: Features

    Features 1-33 2. The abs warning light comes on while the “ ” side of the start/engine stop switch is being pushed. When the engine is being started, the abs warning light comes on while the “ ” side of the start/en- gine stop switch is being pushed. (refer to “electric starting system” on page 8-7....

  • Page 43: Features

    Features 1-34 5. The abs warning light “1” flashes and a fault code “2” is indicated on the multi-function meter right display when the test coupler adapter “3” is connected to the abs test coupler “4” for troubleshooting the abs. The abs test coupler can be accessed by removing the right upper inne...

  • Page 44: Features

    Features 1-35 et3p61054 abs warning light and operation abs and ubs function warning ewa1mc1024 • when hydraulic control is performed by the abs, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake peda...

  • Page 45: Features

    Features 1-36 eas1mc1082 outline of the tcs (traction control system) the traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ecu monitors the front and rear wheel speeds using the signals from the...

  • Page 46: Features

    Features 1-37 tcs (traction control system) function the traction control system helps maintain traction when accelerating on slippery surfaces, such as un- paved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by r...

  • Page 47: Features

    Features 1-38 tip turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. Notice eca1mc1014 use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation ac...

  • Page 48: Features

    Features 1-39 eas1mc1030 multi-function meter unit warning ewa1mc1008 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. Tip the select switch “ / ” and the men...

  • Page 49: Features

    Features 1-40 fuel meter the fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “e” (empty) as the fuel level decreases. When the last segment starts flash- ing, refuel as soon as possible. When the main switch is turned to “on”, all di...

  • Page 50: Features

    Features 1-41 function display push the menu switch “menu” to switch the dis- play between the following functions. The dis- play changes each time the switch is pushed. • grip warmer adjusting function • information display selection function • windshield adjusting function • damping force adjustin...

  • Page 51: Features

    Features 1-42 • an estimated traveling range display • an elapsed time display • an ambient temperature display • a coolant temperature display • an average fuel consumption display • an instantaneous fuel consumption display the items shown in each information display can be selected. To set or sel...

  • Page 52: Features

    Features 1-43 the time that has elapsed since the key was turned to “on” is shown. The maximum time that can be shown is 99:59. This display is automatically reset when the key is turned to “off”. Tip there are also “time-2” and “time-3” elapsed time displays, but they cannot be set to the infor- ma...

  • Page 53: Features

    Features 1-44 instantaneous fuel consumption display: the instantaneous fuel consumption display modes “km/l”, “l/100km” or “mpg” (for the uk only) show the fuel consumption under the cur- rent riding conditions. • the “km/l” display shows the distance that can be traveled on 1.0 l of fuel. • the “l...

  • Page 54: Features

    Features 1-45 adjusting the temperature levels of the grip warmer settings 1. Use the select switch to highlight “grip warmer”. 2. Push the menu switch “menu”. The grip warmer setting display will be shown and “high” will flash in the display. 3. Push the menu switch “menu”. The temper- ature level ...

  • Page 55: Features

    Features 1-46 checking and resetting time-2 and time-3 1. Use the select switch to highlight “time trip”. 2. Push the menu switch “menu” to display “time-2” and “time-3”. To reset a time trip, push the “reset” button to select the item to reset. 3. While the selected item is flashing, push the “rese...

  • Page 56: Features

    Features 1-47 7. Use the select switch to highlight “ ”, and then push the menu switch “menu” to return to the setting mode menu. Selecting the display items 1. Use the select switch to highlight “display”. 2. Push the menu switch “menu”, use the se- lect switch to highlight the display to change, a...

  • Page 57: Features

    Features 1-48 2. Push the menu switch “menu”. 3. Use the select switch to select the desired brightness level, and then push the menu switch “menu” to return to the setting mode menu. Setting the clock 1. Use the select switch to highlight “clock”. 2. Push the menu switch “menu”. 3. When the hour di...

  • Page 58: Features

    Features 1-49 the self-diagnosis device also detects problems in the immobilizer system circuits. If a problem is detected in the immobilizer sys- tem circuits, the immobilizer system indicator light will flash and the information display will in- dicate a fault code when the main switch is turned t...

  • Page 59: Important Information

    Important information 1-50 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-57. 3. When disasse...

  • Page 60: Important Information

    Important information 1-51 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if...

  • Page 61: Basic Service Information

    Basic service information 1-52 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 pi...

  • Page 62: Basic Service Information

    Basic service information 1-53 eas30402 electrical system electrical parts handling notice eca16600 never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. Notice eca16751 when disconnecting the battery leads from the battery, be sure to ...

  • Page 63: Basic Service Information

    Basic service information 1-54 notice eca16620 handle electrical components with special care, and do not subject them to strong shocks. Notice 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 ...

  • Page 64: Basic Service Information

    Basic service information 1-55 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector notice eca16780 • when disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and t...

  • Page 65: Basic Service Information

    Basic service information 1-56 4. 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. 5. Check: • resistance tip th...

  • Page 66: Special Tools

    Special tools 1-57 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 67: Special Tools

    Special tools 1-58 vacuum/pressure pump gauge set 90890-06756 mityvac brake bleeding tool ys-42423 3-13 magnet base b 90890-06844 magnetic base stand yu-a8438 3-14 dial gauge & stand set 90890-01252 dial gauge set yu-03097-b 3-14 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-2...

  • Page 68: Special Tools

    Special tools 1-59 rod holder 90890-01434 damper rod holder double ended ym-01434 4-83, 4-88 damper rod holder 90890-01423 damping rod holder ym-01423 4-84, 4-85 fork seal driver 90890-01502 fork seal driver (48) ym-a0948 4-86, 4-87 fork seal driver attachment 90890-01503 4-86 rod puller 90890-01437...

  • Page 69: Special Tools

    Special tools 1-60 ring gear fix bolt (m14) 90890-01524 ym-01524 4-114 final gear backlash band 90890-01511 middle drive gear lash tool ym-01230 4-115 coupling gear/middle shaft tool 90890-01229 gear holder ym-01229 4-117, 4-120 bearing retainer wrench 90890-04050 pinion bearing retainer & remover y...

  • Page 70: Special Tools

    Special tools 1-61 pivot shaft wrench 90890-01471 frame spanner socket ym-01471 5-8, 5-9 pivot shaft wrench adapter 90890-01476 5-8, 5-9 test harness-tps(3p) 90890-03204 test harness-tps(3p) yu-03204 5-11, 5-64 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-11, 5-5...

  • Page 71: Special Tools

    Special tools 1-62 valve guide remover (ø5) 90890-04097 valve guide remover (5.0 mm) ym-04097 5-28 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-28 valve guide reamer (ø5) 90890-04099 valve guide reamer (5.0 mm) ym-04099 5-28 sheave holder 90890-01701 primary clutc...

  • Page 72: Special Tools

    Special tools 1-63 test harness- speed sensor (3p) 90890-03208 yu-03208 5-65, 8-279, 8-283 bearing retainer wrench 90890-04137 middle drive shaft bearing retainer wrench ym-04137 5-79, 5-81 damper spring compressor 90890-04090 middle drive gear damper spring com- pressor ym-33286 5-79, 5-80 bearing ...

  • Page 73: Special Tools

    Special tools 1-64 piston ring compressor 90890-05158 ym-08037 5-101 slide hammer bolt 90890-01083 slide hammer bolt 6 mm yu-01083-1 5-112 weight 90890-01084 yu-01083-3 5-112 radiator cap tester 90890-01325 mityvac cooling system tester kit yu-24460-a 6-3 tool name/tool no. Illustration reference pa...

  • Page 74: Special Tools

    Special tools 1-65 radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-13 pressure gauge 90890-...

  • Page 75: Special Tools

    Special tools 1-66 test harness- lean angle sensor (6p) 90890-03209 yu-03209 8-273 test harness s- pressure sensor (3p) 90890-03207 yu-03207 8-280 tool name/tool no. Illustration reference pages.

  • Page 76: Special Tools

    Special tools 1-67.

  • Page 77: Specifications

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

  • Page 78: General Specifications

    General specifications 2-1 eas20280 general specifications model model 1md1 (europe except (f)) 1md2 (b) (f) dimensions overall length 2230 mm (87.8 in) overall width 750 mm (29.5 in) overall height 1325/1455 mm (52.2/57.3 in) seat height 805/825 mm (31.7/32.5 in) wheelbase 1545 mm (60.8 in) ground ...

  • Page 79: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 1298.0 cm³ cylinder arrangement inline 4-cylinder bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) compression ratio 10.80 : 1 standard compression pressure (at sea level) 1600 kpa/400 ...

  • Page 80: Engine Specifications

    Engine specifications 2-3 relief valve operating pressure 480.0–560.0 kpa (4.80–5.60 kgf/cm², 69.6–81.2 psi) cooling system radiator capacity (including all routes) 2.60 l (2.75 us qt, 2.29 imp.Qt) radiator capacity 0.65 l (0.69 us qt, 0.57 imp.Qt) coolant reservoir capacity (up to the maximum level...

  • Page 81: Engine Specifications

    Engine specifications 2-4 limit 24.897 mm (0.9802 in) camshaft runout limit 0.030 mm (0.0012 in) timing chain tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.15–0.22 mm (0.0059–0.0087 in) exhaust 0.18–0.25 mm (0.0071–0.0098 in) valve dimensions valve head d...

  • Page 82: Engine Specifications

    Engine specifications 2-5 limit 0.105 mm (0.0041 in) valve stem runout 0.010 mm (0.0004 in) cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) valve spring free length (intake) 39.73 mm (1.56 in) limit 37.7...

  • Page 83: Engine Specifications

    Engine specifications 2-6 height h 5.0 mm (0.20 in) offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) limit 19.045 mm (0.7498 in) piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) limit 18.971 mm (0.7469 in) pist...

  • Page 84: Engine Specifications

    Engine specifications 2-7 crankshaft width a 61.60–63.20 mm (2.425–2.488 in) width b 325.10–326.30 mm (12.80–12.85 in) runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.160–0.262 mm (0.0063–0.0103 in) journal oil clearance 0.027–0.045 mm (0.0011–0.0018 in) bearing color code 2.Black 3.B...

  • Page 85: Engine Specifications

    Engine specifications 2-8 shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.100 mm (0.0039 in) air filter air filter element dry element fuel pump pump type electrical maximum consumption amperage 6.0 a fuel injector model/quantity 0990/4 resistanc...

  • Page 86: Engine Specifications

    Engine specifications 2-9 ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.0118–0.0236 in) ring-gear-to-thrust-washer clearance 0.20 mm (0.0079 in) final gear backlash 0.22–0.45 mm (0.0087–0.0177 in).

  • Page 87: Chassis Specifications

    Chassis specifications 2-10 eas20300 chassis specifications chassis frame type diamond caster angle 26.00° trail 109.0 mm (4.29 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 135.0 mm (5.31 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 88: Chassis Specifications

    Chassis specifications 2-11 front disc brake disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) brake disc thickness limit 4.0 mm (0.16 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 5.5 mm (0.22 in) limit 0.5 mm (0.02 in) brake pad lining thic...

  • Page 89: Chassis Specifications

    Chassis specifications 2-12 quantity 580.0 cm³ (19.61 us oz, 20.46 imp.Oz) (left side) quantity 570.0 cm³ (19.27 us oz, 20.10 imp.Oz) (right side) level 123 mm (4.8 in) rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly ...

  • Page 90: Electrical Specifications

    Electrical specifications 2-13 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 5.0°/1050 r/min engine control unit model/manufacturer tbdfh6/denso (europe except (f)) tbdfh9/denso (b) (f) ignition coil minimum ignition spa...

  • Page 91: Electrical Specifications

    Electrical specifications 2-14 engine trouble warning light led abs warning light led cruise control system indicator light led cruise control setting indicator light led immobilizer system indicator light led traction control system indicator/warning light led “stop mode” indicator light led shift ...

  • Page 92: Electrical Specifications

    Electrical specifications 2-15 grip warmer grip warmer resistance (l) 1.21–1.48 Ω grip warmer resistance (r) 1.17–1.43 Ω fuses main fuse 50.0 a cooling system fuse 30.0 a headlight fuse 25.0 a brake light fuse 1.0 a signaling system fuse 10.0 a ignition fuse 20.0 a radiator fan fuse 10.0 a × 2 auxil...

  • Page 93: Tightening Torques

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

  • Page 94: Tightening Torques

    Tightening torques 2-17 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 4 13 nm (1.3 m·kg, 9.4 ft·lb) cylinder head bolt m10 10 see tip. Cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft cap bolt m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder ...

  • Page 95: Tightening Torques

    Tightening torques 2-18 oil pan bolt m6 20 12 nm (1.2 m·kg, 8.7 ft·lb) oil pump drive chain guide bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) oil pump housing cover bolt m6 3 12 nm (1.2 m·kg, 8.7 ft·lb) oil level switch bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) throttle cable holder bolt m5 2 4 nm (0.4 m·kg, ...

  • Page 96: Tightening Torques

    Tightening torques 2-19 upper crankcase damper bolt m6 3 12 nm (1.2 m·kg, 8.7 ft·lb) damper cover bolt (clutch cover) m6 5 12 nm (1.2 m·kg, 8.7 ft·lb) stator coil assembly lead holder bolt m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) main gallery bolt m20 1 8 nm (0.8 m·kg, 5.8 ft·lb) starter clutch bolt m8 3 32...

  • Page 97: Tightening Torques

    Tightening torques 2-20 tip cylinder head bolt tighten the cylinder head bolts to 25 nm (2.5 m·kg, 18 ft·lb) in the proper tightening sequence, loosen and retighten the bolts to 25 nm (2.5 m·kg, 18 ft·lb) in the proper tightening sequence, and then tighten them further to reach the specified angle 1...

  • Page 98: Tightening Torques

    Tightening torques 2-21 tip crankcase bolt tighten the crankcase bolts to 20 nm (2.0 m·kg, 14 ft·lb) in the proper tightening sequence, loosen and retighten the bolts to 20 nm (2.0 m·kg, 14 ft·lb) in the proper tightening sequence, and then tighten them further to reach the specified angle 115–125° ...

  • Page 99: Tightening Torques

    Tightening torques 2-22 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (right front lower side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolt (right front upper side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolt (left front l...

  • Page 100: Tightening Torques

    Tightening torques 2-23 rear shock absorber assembly preload adjusting pump bolt m6 3 5 nm (0.5 m·kg, 3.6 ft·lb) rear shock absorber assembly preload adjusting pump bracket bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) rear shock absorber assembly dc motor bolt m5 3 4 nm (0.4 m·kg, 2.9 ft·lb) rear shock abso...

  • Page 101: Tightening Torques

    Tightening torques 2-24 fuel pump bolt m5 6 4 nm (0.4 m·kg, 2.9 ft·lb) front fuel tank bracket and frame bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) fuel tank and front fuel tank bracket bolt m8 2 16 nm (1.6 m·kg, 11 ft·lb) fuel tank and rear upper fuel tank bracket bolt m8 2 16 nm (1.6 m·kg, 11 ft·lb) re...

  • Page 102: Tightening Torques

    Tightening torques 2-25 front brake caliper bolt m10 4 40 nm (4.0 m·kg, 29 ft·lb) front brake hose holder bolt m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) front brake hose joint bolt m6 1 see tip. Front brake caliper bleed screw m8 3 6 nm (0.6 m·kg, 4.3 ft·lb) front brake pad bolt m10 4 17 nm (1.7 m·kg, 12 ft·l...

  • Page 103: Tightening Torques

    Tightening torques 2-26 tip lower ring nut 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 nm (1.8 m·kg, 13 ft·lb) with a torque wrench. Tip brake hose joint bracke...

  • Page 104: Tightening Torques

    Tightening torques 2-27 tip front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 nm (9.1 m·kg, 66 ft·lb). 2. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to 21 nm (2.1...

  • Page 105: 2-28

    Lubrication points and lubricant types 2-28 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobes camshaft journals balanc...

  • Page 106: 2-29

    Lubrication points and lubricant types 2-29 cylinder head cover mating surface three bond 1541c® cylinder head cover gasket yamaha bond no.1215 (three bond no.1215®) crankcase mating surface yamaha bond no.1215 (three bond no.1215®) crankshaft position sensor lead grommet yamaha bond no.1215 (three ...

  • Page 107: 2-30

    Lubrication points and lubricant types 2-30 eas20380 chassis lubrication point lubricant steering bearings and upper bearing cover lip lower bearing dust seal lip front wheel oil seal lip rear wheel oil seal lip rear wheel drive hub mating surface rear brake pedal pivoting point footrest assembly pi...

  • Page 108: 2-31

    Lubrication system chart and diagrams 2-31 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 15 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 14.

  • Page 109: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter cartridge 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12. Main axle 13. Oil delivery pipe 1 14. Drive ...

  • Page 110: 2-33

    Lubrication system chart and diagrams 2-33 eas20410 lubrication diagrams 5 6 7 1 2 3 4.

  • Page 111: 2-34

    Lubrication system chart and diagrams 2-34 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle.

  • Page 112: 2-35

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

  • Page 113: 2-36

    Lubrication system chart and diagrams 2-36 1. Main axle 2. Drive axle 3. Oil delivery pipe 1.

  • Page 114: 2-37

    Lubrication system chart and diagrams 2-37 6 5 4 3 2 1.

  • Page 115: 2-38

    Lubrication system chart and diagrams 2-38 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump.

  • Page 116: 2-39

    Lubrication system chart and diagrams 2-39 1 2 3 4 5 6 7 8 9.

  • Page 117: 2-40

    Lubrication system chart and diagrams 2-40 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly.

  • Page 118: 2-41

    Lubrication system chart and diagrams 2-41 4 5 3 2 1 9 8 6 7.

  • Page 119: 2-42

    Lubrication system chart and diagrams 2-42 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump.

  • Page 120: Cooling System Diagrams

    Cooling system diagrams 2-43 eas20420 cooling system diagrams 3 13 4 5 6 7 7 7 8 1 2 10 9 14 15 16 17 11 12 3.

  • Page 121: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Oil cooler outlet hose 4. Radiator 5. Coolant reservoir breather hose 6. Thermostat inlet pipe 2 7. Coolant reservoir hose 8. Radiator inlet hose 9. Thermostat inlet hose 2 10. Thermostat assembly 11. Water jacket ...

  • Page 122: Cooling System Diagrams

    Cooling system diagrams 2-45 7 1 2 3 4 5 5 8 9 6 8 9 10 11 12.

  • Page 123: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10. Water pump 11. Water jacket joint 12. Water...

  • Page 124: Cable Routing

    Cable routing 2-47 eas20430 cable routing handlebar (front view) 20 19 22 3 5 17 18 21 23 23 22 3 1 2 2 2 3 4 9 8 7 4 13 14 15 16 16 16 b a a c f 5 6 24 g 5 24 9 15 15 d e 6 5 10 10 11 12 10 11.

  • Page 125: Cable Routing

    Cable routing 2-48 1. Right front fork stepping motor 2. Right grip warmer lead 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4. Coupler rubber cover 5. Right handlebar switch lead 6. Right front fork stepping motor lead 7. Left front fork stepping motor 8. Left hand...

  • Page 126: Cable Routing

    Cable routing 2-49 radiator and battery (right side view) 1 3 4 5 6 7 8 14 14 14 14 18 22 23 24 25 j h k e f g c d d 2 n i 1 21 1 l a a b 10 9 13 12 11 15 15 m 15 16 16 17 17 15 20 19.

  • Page 127: Cable Routing

    Cable routing 2-50 1. Starter motor lead 2. Ecu (engine control unit) 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4. Right handlebar switch lead 5. Throttle cable (accelerator cable) 6. Throttle cable (decelerator cable) 7. Headlight relay (on/off) 8. Radiator fan ...

  • Page 128: Cable Routing

    Cable routing 2-51 rear brake hose (right side view) 4 5 6 7 8 9 10 11 12 1 13 14 2 3 1 a b c e 15 16 f 17 h 18 d g.

  • Page 129: Cable Routing

    Cable routing 2-52 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7. Brake pipe (hydraulic unit to pr...

  • Page 130: Cable Routing

    Cable routing 2-53 horn and radiator (left side view) a b 1 1 2 3 4 5 5 6 c 7 7 8.

  • Page 131: Cable Routing

    Cable routing 2-54 1. Radiator inlet hose 2. Left radiator fan motor 3. Radiator 4. Coolant reservoir breather hose 5. Horn 6. Left radiator fan motor coupler 7. Left radiator fan motor lead 8. Coolant reservoir hose a. After connecting the left radiator fan motor coupler, position the coupler betwe...

  • Page 132: Cable Routing

    Cable routing 2-55 front brake hose and engine (left side view) 17 18 19 a b 1 2 3 c d 4 5 5 6 f e 7 8 9 10 g h 11 12 13 14 l k m 15 n o p i j 23 24 25 22 1 t 16 17 18 20 21 q 16 19 16 r s 19.

  • Page 133: Cable Routing

    Cable routing 2-56 1. Ac magneto lead 2. Rectifier/regulator lead 3. Air filter case breather hose 4. Gear position sensor lead 5. Clutch hose 6. Fuel tank breather/overflow hose 7. Foot shift sensor lead 8. Sidestand switch 9. Sidestand switch lead 10. Oil level switch lead 11. Coolant reservoir br...

  • Page 134: Cable Routing

    Cable routing 2-57 rear fender (left side view) c 7 8 9 10 o p q r s 1 2 3 4 14 h g f 13 17 15 16 e 2 3 4 d t u v 21 22 22 28 1 2 3 4 27 18 19 20 k 21 22 23 l m 24 25 26 j n 16 i 1 2 3 4 5 6 7 7 6 6 a a 11 12 13 14 b.

  • Page 135: Cable Routing

    Cable routing 2-58 1. Wire harness 2. Shift actuator motor lead 3. Foot shift sensor lead 4. Shift actuator sensor lead 5. Tail/brake light assembly coupler 6. Tail/brake light 7. Rear turn signal light 8. Tail/brake light assembly lead 9. License plate light lead 10. Seat lock cable 11. License pla...

  • Page 136: Cable Routing

    Cable routing 2-59 throttle bodies (top view) 1 2 3 4 5 6 7 7 8 9 12 13 18 41 a b c d e f g h i j m n o p q r k l s 10 35 36 37 38 39 40 27 28 29 30 31 32 33 34 23 24 25 26 8 21 22 15 16 17 20 14 42 19 11.

  • Page 137: Cable Routing

    Cable routing 2-60 1. Ignition coil #1 coupler 2. Front wheel sensor lead 3. Left front fork stepping motor lead 4. Right front fork stepping motor lead 5. Immobilizer unit lead 6. Main switch lead 7. Throttle cable (decelerator cable) 8. Throttle cable (accelerator cable) 9. Brake hose (brake pipe/...

  • Page 138: Cable Routing

    Cable routing 2-61 rear fender (top view) 10 g 9 e f 8 e 7 d c 6 6 6 b 5 4 1 3 3 2 a 11 i 12 h.

  • Page 139: Cable Routing

    Cable routing 2-62 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. Storage compartment 4. Mcu (motor control unit) 5. Yamaha diagnostic tool coupler 6. Yamaha diagnostic tool lead 7. License plate light lead 8. Tail/brake light assembly lead 9. Seat lock cable 10. Mcu leads 11. Scu (...

  • Page 140: Cable Routing

    Cable routing 2-63 front cowling assembly and electrical components board 4 1 2 3 4 5 6 7 8 9 10 14 11 12 13 14 15 16 a b c d d d e i j f g h k l m n a 17 18 19 20 q o p 21 22 23 24 26 25 r v s u w w t.

  • Page 141: Cable Routing

    Cable routing 2-64 1. Right headlight lead 2. Right auxiliary light lead 3. Relay unit lead 4. Relay unit 5. Headlight relay (dimmer) lead 6. Left headlight lead 7. Left auxiliary light lead 8. Windshield drive unit relay (down) lead 9. Left radiator fan motor lead 10. Windshield drive unit relay (u...

  • Page 142: Cable Routing

    Cable routing 2-65 hydraulic unit assembly (top and side view) 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 a 2 1 5 4 3.

  • Page 143: Cable Routing

    Cable routing 2-66 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear br...

  • Page 144: Cable Routing

    Cable routing 2-67.

  • Page 145

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

  • Page 146

    Measuring the engine oil pressure ........................................ 3-28 checking the coolant level....................................................... 3-29 checking the cooling system .................................................... 3-29 changing the coolant..............................

  • Page 148: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 149: Periodic Maintenance

    Periodic maintenance 3-2 3 * front brake • check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √ • replace brake pads. Whenever worn to the limit 4 * rear brake • check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √ • replace brake pads. Whenever worn to the limi...

  • Page 150: Periodic Maintenance

    Periodic maintenance 3-3 eau40550 tip • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake and ycc-s clutch service • regularly check and, if necessary, correct the brake and ycc-s clutch fluid levels. • every two years replace the interna...

  • Page 151: Periodic Maintenance

    Periodic maintenance 3-4 eas21030 checking the fuel line 1. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • t-bar refer to “general chassis” on page 4-1. 2. Check: • fuel hose “1” • fuel tank breather hose “2” • fuel tank overflow hose “3”...

  • Page 152: Periodic Maintenance

    Periodic maintenance 3-5 10.Install: • t-bar refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • rider seat refer to “general chassis” on page 4-1. Eas20490 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance a...

  • Page 153: Periodic Maintenance

    Periodic maintenance 3-6 • measure the valve clearance in the following sequence. D. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft clockwise as specified in the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remov...

  • Page 154: Periodic Maintenance

    Periodic maintenance 3-7 example: if the valve pad is marked “155”, the pad thickness is 1.55 mm (0.061 in). D. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: 1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 1...

  • Page 155: Periodic Maintenance

    Periodic maintenance 3-8 3. Check: • isc (idle speed control) learning value “00” or “01” → check the intake system. “02” → clean the throttle bodies. Refer to “checking and cleaning the throttle bodies” on page 7-7. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the yamaha diagnostic ...

  • Page 156: Periodic Maintenance

    Periodic maintenance 3-9 adjusting the throttle body synchronization 1. Remove the fuel tank bolts “1” and lift up the fuel tank. Notice eca1mc1024 when lifting up the fuel tank, be careful not to pull the fuel tank breather/overflow hose. 2. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 157: Periodic Maintenance

    Periodic maintenance 3-10 • exhaust pipe assembly bolts “6” • exhaust pipe assembly and muffler bolts “7” • muffler bolts “8” 4. Install: • side cowlings refer to “general chassis” on page 4-1. Eas20600 adjusting the exhaust gas volume tip be sure to set the co density level to standard, and then ad...

  • Page 158: Periodic Maintenance

    Periodic maintenance 3-11 • to increase the selected cylinder number, press the “tcs” button. 7. After selecting the cylinder number, simulta- neously press the “tcs” button “1” and “re- set” button “2” for 2 seconds or more to execute the selection. 8. Change the co adjustment volume “3” by pressin...

  • Page 159: Periodic Maintenance

    Periodic maintenance 3-12 notice ec3p61043 never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle body synchronization, leading to...

  • Page 160: Periodic Maintenance

    Periodic maintenance 3-13 • if bleeding is difficult, it may be necessary to let the clutch fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. 1. Remove: • air filter case refer to “general chassis” on page 4-1. • rear wheel refer to “rear...

  • Page 161: Periodic Maintenance

    Periodic maintenance 3-14 c. Manually engage and disengage the clutch using the manual clutch operation bolt “3” five times, each time for less than 1 second. Tip turn the clutch operation bolt in a continuous motion, without allowing the pressure plate to stop in mid-stroke. D. Install a suitable b...

  • Page 162: Periodic Maintenance

    Periodic maintenance 3-15 c. Shift the transmission into neutral, and then rotate the rear wheel by hand. D. Shift the transmission into 1st gear, and then rotate the rear wheel by hand. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • shift operation engine stalls → check the pressure ...

  • Page 163: Periodic Maintenance

    Periodic maintenance 3-16 warning ewa13050 a soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. N...

  • Page 164: Periodic Maintenance

    Periodic maintenance 3-17 eas22780 bleeding the hydraulic brake system (abs) warning ewa14000 always bleed the brake system when the brake related parts are removed. Notice ec3p61012 • bleed the brake system in the following or- der. • 1st step: front brake calipers • 2nd step: right front brake cal...

  • Page 165: Periodic Maintenance

    Periodic maintenance 3-18 j. Check the operation of the hydraulic unit. Refer to “hydraulic unit operation tests” on page 4-71. Notice ec3p61029 make sure that the main switch is turned to “off” before checking the operation of the hydraulic unit. K. After operating the abs, repeat steps (e) to (i),...

  • Page 166: Periodic Maintenance

    Periodic maintenance 3-19 c. Tighten the locknut “1” to specification. Warning ew3p61002 a soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system wil...

  • Page 167: Periodic Maintenance

    Periodic maintenance 3-20 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories...

  • Page 168: Periodic Maintenance

    Periodic maintenance 3-21 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be g...

  • Page 169: Periodic Maintenance

    Periodic maintenance 3-22 b. Tighten the lower ring nut “4” with the steering nut wrench “5”. Tip set a torque wrench at a right angle to the steer- ing nut wrench. C. Loosen the lower ring nut completely and then tighten it to specification with the steer- ing nut wrench. Warning ewa13140 do not ov...

  • Page 170: Periodic Maintenance

    Periodic maintenance 3-23 eas1mc1042 checking the sidestand 1. Check: • sidestand operation check that the sidestand moves smoothly. Rough movement → repair or replace. Eas21720 lubricating the sidestand lubricate the pivoting point, metal-to-metal mov- ing parts, and spring contact points of the si...

  • Page 171: Periodic Maintenance

    Periodic maintenance 3-24 b. Push the menu switch “menu” “1” to switch the function display “2” to the damping force adjusting function “3”. C. Use the select switch “4” to select “hard”, “std” or “soft” “5”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • damping force setting level ...

  • Page 172: Periodic Maintenance

    Periodic maintenance 3-25 • the suspension will still operate as normal, only the preload adjusting function cannot be used. • to reset the electronically adjustable suspen- sion system warning light, wait approximately 6 minutes and then turn the key to “off” or immediately turn the key to “off” an...

  • Page 173: Periodic Maintenance

    Periodic maintenance 3-26 • if the preload is adjusted repeatedly, the pre- load setting pictogram will flash 4 times and the preload cannot be adjusted. Wait approx- imately 6 minutes for the preload adjusting function motor to cool down, and then try ad- justing the preload again. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 174: Periodic Maintenance

    Periodic maintenance 3-27 eas20780 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap “1” • engine oil drain bolt “2” (along with the gasket) 4. Drain: • engine ...

  • Page 175: Periodic Maintenance

    Periodic maintenance 3-28 b. Slightly loosen the engine oil check bolt “1”. C. Start the engine and keep it idling until engine oil starts to seep from the engine oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. D. Check the engine oil passa...

  • Page 176: Periodic Maintenance

    Periodic maintenance 3-29 8. Install: • right side cowling refer to “general chassis” on page 4-1. Eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle is upright. 2. Remove: • left side panel refer to “gener...

  • Page 177: Periodic Maintenance

    Periodic maintenance 3-30 3. Install: • exhaust pipe assembly refer to “engine removal” on page 5-3. • side cowlings refer to “general chassis” on page 4-1. Eas21130 changing the coolant 1. Remove: • side cowlings refer to “general chassis” on page 4-1. 2. Remove: • radiator cap “1” warning ewa13030...

  • Page 178: Periodic Maintenance

    Periodic maintenance 3-31 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning ewa13040 • if coolant splashes in your eyes, thorough- ly wash them with water and c...

  • Page 179: Periodic Maintenance

    Periodic maintenance 3-32 4. Install: • final gear oil filler bolt (along with the gasket ) eas21470 changing the final gear oil 1. Place a container under the final gear case. 2. Remove: • final gear oil filler bolt “1” (along with the gasket) • final gear oil drain bolt “2” (along with the gasket)...

  • Page 180: Periodic Maintenance

    Periodic maintenance 3-33 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • meter display for the rear brake light switch “on” → adjust the brake light switch or check the brake pedal operation. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the yamaha diagnostic tool. Use ...

  • Page 181: Periodic Maintenance

    Periodic maintenance 3-34 d. Tighten the locknut. E. Slide the rubber covers to its original position. Warning ewa1mc1010 after adjusting the throttle grip free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to c...

  • Page 182: Periodic Maintenance

    Periodic maintenance 3-35 tip when removing the right headlight bulb cover, it is necessary to remove the abs test coupler “3” and main fuse holder “4”. 4. Detach: • headlight bulb holder “1” 5. Remove: • headlight bulb “2” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable...

  • Page 183: Chassis

    4 chassis general chassis....................................................................................... 4-1 removing the center rear cowling.......................................... 4-2 installing the center rear cowling ........................................ 4-2 removing the rear cowlin...

  • Page 184

    Front brake ............................................................................................. 4-38 introduction ..................................................................................... 4-43 checking the front brake discs ............................................... 4-43 r...

  • Page 185

    Steering head.......................................................................................... 4-90 removing the lower bracket..................................................... 4-92 checking the steering head ....................................................... 4-92 installing the ste...

  • Page 186: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats and covers order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 1 3 grab bar 1 4 center rear cowling 1 5 left rear cowling 1 6 right rear cowling 1 7 left side cover 1 8 right side cover 1 9 rider seat height position ...

  • Page 187: General Chassis

    General chassis 4-2 eas1mc1049 removing the center rear cowling 1. Remove: • center rear cowling “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the projections on the center rear cowling from the rear fender. B. Unhook the projections on the center rear cowling from the rear cowling...

  • Page 188: General Chassis

    General chassis 4-3 b. Make sure that the grommet on the tail/brake light assembly fits into the slot in the rear cowling. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1mc1051 removing the side covers the following procedure applies to both of the side covers. 1. Remove: • side cover “1” tip...

  • Page 189: General Chassis

    General chassis 4-4 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ to install the rider seat in the low position a. Install the rider seat height position adjuster “1” so that the “l” mark “a” is aligned with the match mark “b”. B. Insert the proj...

  • Page 190: General Chassis

    General chassis 4-5 removing the side cowlings order job/parts to remove q’ty remarks tip open the accessory box lid. 1 headlight beam adjusting knob 2 2 front cowling inner panel 1 3 right upper inner panel 1 4 right lower inner panel 1 5 right side panel 1 6 right side cowling 1 7 front right turn...

  • Page 191: General Chassis

    General chassis 4-6 16 accessory box 1 17 accessory box solenoid 1 18 auxiliary dc jack 1 19 left upper inner panel 2 1 for installation, reverse the removal proce- dure. Removing the side cowlings order job/parts to remove q’ty remarks 5 3 6 7 4 8 9 11 12 10 19 15 16 1 17 2 13 18 14.

  • Page 192: General Chassis

    General chassis 4-7 eas1mc1056 adjusting the side panels the following procedure applies to both of the side panels. 1. Adjust: • side panel position tip the side panel “1” can be opened 20 mm (0.79 in) for added ventilation to suit the riding condi- tions. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 193: General Chassis

    General chassis 4-8 2. Remove: • front cowling inner panel “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the tabs “a” on the top of the front cowling inner panel from the front cowling. B. Unhook the projections “b” on the bottom of the front cowling inner panel from the upper inne...

  • Page 194: General Chassis

    General chassis 4-9 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • headlight beam adjusting knob “1” tip align the flat portion “a” of the hole in the head- light beam adjusting knob with the flat portion “b” of the headlight beam adjusting knob joint. Eas1mc1058 removing the side c...

  • Page 195: General Chassis

    General chassis 4-10 removing the front cowling assembly order job/parts to remove q’ty remarks side cowlings refer to “removing the side cowlings”. 1 windshield bracket outer cover 2 2 windshield 1 3 windshield bracket 1 4 windshield bracket inner cover 2 5 center cover assembly 1 6 upper center co...

  • Page 196: General Chassis

    General chassis 4-11 16 headlight assembly 1 for installation, reverse the removal proce- dure. Removing the front cowling assembly order job/parts to remove q’ty remarks 2 (3) (3) (3) (3) (4) 12 11 11 1 3 4 5 6 7 8 14 13 13 15 16 (5) (4) 9 9 10 7 nm (0.7 m • kg, 5.1 ft • ib) t.R . 7 nm (0.7 m • kg,...

  • Page 197: General Chassis

    General chassis 4-12 eas1mc1061 removing the windshield bracket covers the following procedure applies to both of the windshield bracket covers. 1. Remove: • windshield bracket outer cover “1” tip slide the windshield bracket outer cover upward, and then remove it. Eas1mc1064 installing the windshie...

  • Page 198: General Chassis

    General chassis 4-13 tip fit the projections on the upper center cover into the holes in the lower center cover. 2. Install: • center cover assembly “1” tip fit the projections on the lower center cover into the holes in the front cowling. Eas1mc1031 installing the front cowling assembly 1. Install:...

  • Page 199: General Chassis

    General chassis 4-14 removing the meter assembly and electrical components board order job/parts to remove q’ty remarks side cowlings refer to “removing the side cowlings”. Front cowling assembly refer to “removing the front cowling assem- bly”. 1 meter assembly coupler 1 disconnect. 2 meter assembl...

  • Page 200: General Chassis

    General chassis 4-15 removing the windshield drive unit order job/parts to remove q’ty remarks side cowlings refer to “removing the side cowlings”. Front cowling assembly refer to “removing the front cowling assem- bly”. Electrical components board refer to “removing the meter assembly and electrica...

  • Page 201: General Chassis

    General chassis 4-16 eas1mc1079 installing the windshield drive unit 1. Check: • windshield drive unit operation tip after installing the windshield drive unit to the windshield drive unit bracket, check the opera- tion of the drive unit. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install ...

  • Page 202: General Chassis

    General chassis 4-17 removing the electrical components tray 1/2 order job/parts to remove q’ty remarks right side cowling refer to “removing the side cowlings”. 1 negative battery lead 1 disconnect. 2 positive battery lead 1 disconnect. 3 battery 1 4 main fuse 1 5 abs test coupler 1 6 starter relay...

  • Page 203: General Chassis

    General chassis 4-18 removing the electrical components tray 2/2 order job/parts to remove q’ty remarks 1 ecu cover 1 2 fuse box 1/fuse box 3 1/1 3 fuse box 2/fuse box 4 1/1 4 cruise control system fuse/brake light fuse 1/1 5 ecu (engine control unit) 1 6 electrical components tray 1 7 electrical co...

  • Page 204: General Chassis

    General chassis 4-19 removing the t-bar order job/parts to remove q’ty remarks rider seat refer to “removing the seats and covers”. Fuel tank refer to “fuel tank” on page 7-1. 1 t-bar 1 2 heat protector 1 for installation, reverse the removal proce- dure. 1 2 37 nm (3.7 m • kg, 27 ft • ib) t.R. 37 n...

  • Page 205: General Chassis

    General chassis 4-20 removing the air filter case order job/parts to remove q’ty remarks left side cover refer to “removing the seats and covers”. Fuel tank refer to “fuel tank” on page 7-1. Shift actuator refer to “shift actuator and shift rod” on page 5-61. T-bar refer to “removing the t-bar”. 1 c...

  • Page 206: General Chassis

    General chassis 4-21 13 air induction system hose (air filter case joint assembly to 3-way joint) 1 disconnect. 14 air filter case joint clamp screw 4 loosen. 15 air filter case assembly 1 16 air filter case breather hose 2 17 filter assembly 1 18 air filter case joint assembly 1 19 air filter case ...

  • Page 207: Front Wheel

    Front wheel 4-22 eas21880 front wheel removing the front wheel, brake discs, wheel sensor, and sensor housing order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 front fender 1 2 front wheel sensor coupler 1 di...

  • Page 208: Front Wheel

    Front wheel 4-23 12 front brake disc 2 for installation, reverse the removal proce- dure. Removing the front wheel, brake discs, wheel sensor, and sensor housing order job/parts to remove q’ty remarks t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 91 nm (9.1 m • kg, 66 ft • ib) t r . . 7 nm (0.7 m •...

  • Page 209: Front Wheel

    Front wheel 4-24 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 front wheel sensor rotor 1 3 wheel bearing 2 4 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 210: Front Wheel

    Front wheel 4-25 eas21900 removing the front wheel notice eca1mc1028 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs...

  • Page 211: Front Wheel

    Front wheel 4-26 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-19 and “checking the wheels” on page 3-19. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns...

  • Page 212: Front Wheel

    Front wheel 4-27 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the dial gauge at a right angle against the wheel sensor rotor surface. B. Measure the wheel sensor rotor deflection. Tip do not touch the surface of the rotor magnet with a sharp object. C. If the deflection is above specifi...

  • Page 213: Front Wheel

    Front wheel 4-28 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: • front wheel sensor rotor notice eca1mc1032 replace the wheel sensor rotor bolts with new ones. 3. Measure: • wheel sensor rotor deflection out of specification → correct the wheel sen- sor rotor deflection or replace th...

  • Page 214: Front Wheel

    Front wheel 4-29 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • front wheel static balance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ...

  • Page 215: Front Wheel

    Front wheel 4-30 notice ec3p61022 before tightening the wheel axle bolt, push down hard on the handlebars several times and check if the front fork rebounds smooth- ly. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the front wheel axle from the right side and tighten it with the front ...

  • Page 216: Rear Wheel

    Rear wheel 4-31 eas22030 rear wheel removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks right side cover refer to “general chassis” on page 4-1. 1 rear wheel sensor coupler 1 disconnect. 2 rear wheel sensor 1 3 rear wheel axle pinch bolt 1 loo...

  • Page 217: Rear Wheel

    Rear wheel 4-32 disassembling the rear wheel order job/parts to remove q’ty remarks 1 dust cover 1 2 rear wheel drive hub 1 3 dust seal 1 4 wheel bearing 1 5 rear wheel drive hub damper 6 6 oil seal 1 7 bearing retainer 1 left-hand threads 8 rear wheel sensor rotor 1 9 wheel bearing 1 10 spacer 1 11...

  • Page 218: Rear Wheel

    Rear wheel 4-33 eas22050 removing the rear wheel notice eca1mc1029 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs an...

  • Page 219: Rear Wheel

    Rear wheel 4-34 d. Remove the wheel sensor rotor. E. Remove the wheel bearings “1” with a gener- al bearing puller. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22090 checking the rear wheel 1. Check: • rear wheel axle • rear wheel • wheel bearings • oil seal refer to “checking the front whe...

  • Page 220: Rear Wheel

    Rear wheel 4-35 2. Install: • wheel bearings ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings in the reverse order of disassembly. Notice ec3p61021 do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only with the outer race “3”. Ti...

  • Page 221: Rear Wheel

    Rear wheel 4-36 eas22170 installing the rear wheel (rear brake disc) 1. Install: • rear brake disc tip tighten the brake disc bolts in stages and in a crisscross pattern. 2. Check: • rear brake disc refer to “checking the rear brake disc” on page 4-56. 3. Lubricate: • oil seal lips 4. Install: • rea...

  • Page 222: Rear Wheel

    Rear wheel 4-37 7. Install: • rear wheel sensor notice eca1mc1030 to route the rear wheel sensor lead, refer to “cable routing” on page 2-47. Tip when installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials. 8. Check: • rear wheel ...

  • Page 223: Front Brake

    Front brake 4-38 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 front brake caliper 1 3 brake pad bolt 2 4 brake pad spring 2 5 front brake pad 4 for installation, ...

  • Page 224: Front Brake

    Front brake 4-39 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-17. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm hold- er 1 3 brake master cylinde...

  • Page 225: Front Brake

    Front brake 4-40 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S.

  • Page 226: Front Brake

    Front brake 4-41 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-17. 1 brake hose holder 1 2 brake hose union bolt 1 3 coppe...

  • Page 227: Front Brake

    Front brake 4-42 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 bolt 2 2 brake pad spring 2 3 front brake pad 4 4 brake caliper piston 4 5 brake caliper piston dust seal 4 6 brake caliper ...

  • Page 228: Front Brake

    Front brake 4-43 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 229: Front Brake

    Front brake 4-44 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 230: Front Brake

    Front brake 4-45 3. Install: • brake pad bolts • brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-16. 5. Check: • brake lever and brake pedal operation soft or spongy ...

  • Page 231: Front Brake

    Front brake 4-46 warning ewa13560 • cover the brake caliper pistons with a rag. Be careful not to get injured when the pis- tons are expelled from the brake caliper. • never try to pry out the brake caliper pis- tons. B. Remove the brake caliper piston dust seals and brake caliper piston seals. ▲▲▲ ...

  • Page 232: Front Brake

    Front brake 4-47 2. Remove: • brake caliper 3. Install: • brake pads • brake pad springs • brake pad bolts • brake caliper • brake hose holder refer to “replacing the front brake pads” on page 4-44. 4. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the ...

  • Page 233: Front Brake

    Front brake 4-48 • copper washers “2” • brake hose (front brake master cylinder to brake pipe/lower joint assembly) “3” tip to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Eas22500 checking the front brake master cylinder 1. Check: • b...

  • Page 234: Front Brake

    Front brake 4-49 3. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ew3p61008 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performan...

  • Page 235: Rear Brake

    Rear brake 4-50 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 rear brake caliper 1 3 brake pad shim 2 4 rear brake pad 2 5 brake pad spring 2 for installation, reverse the removal proce- dure. S s.

  • Page 236: Rear Brake

    Rear brake 4-51 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-17. Right side cover refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphrag...

  • Page 237: Rear Brake

    Rear brake 4-52 12 rear brake master cylinder 1 for installation, reverse the removal proce- dure. Removing the rear brake master cylinder order job/parts to remove q’ty remarks 1 2 3 4 5 6 7 9 10 11 8 12 new new 10 new lt lt t r . . 28 nm (2.8 m • kg, 20 ft • ib) t r . . 28 nm (2.8 m • kg, 20 ft • ...

  • Page 238: Rear Brake

    Rear brake 4-53 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder push rod 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S t r . . 16 nm (1.6 m • kg...

  • Page 239: Rear Brake

    Rear brake 4-54 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-17. 1 brake hose union bolt 1 2 copper washer 2 3 brake hose (proportioning valve to rear brake caliper) 1 4 rear brake caliper bol...

  • Page 240: Rear Brake

    Rear brake 4-55 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 brake pad shim 2 3 rear brake pad 2 4 brake pad spring 2 5 rear brake caliper bracket 1 6 brake caliper piston 1 7 brake caliper piston dust seal 1 8 brake caliper piston seal 1 ...

  • Page 241: Rear Brake

    Rear brake 4-56 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 242: Rear Brake

    Rear brake 4-57 tip always install new brake pads, brake pad shims, and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw an...

  • Page 243: Rear Brake

    Rear brake 4-58 eas22600 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston dust seal “2” • brake caliper piston seal “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pis...

  • Page 244: Rear Brake

    Rear brake 4-59 • never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. Eas22670...

  • Page 245: Rear Brake

    Rear brake 4-60 4. Remove: • rear brake caliper bolts • rear brake caliper 5. Install: • brake pad springs • rear brake pads • brake pad shims • rear brake caliper bolts • rear brake caliper refer to “replacing the rear brake pads” on page 4-56. 6. Fill: • brake fluid reservoir (with the specified a...

  • Page 246: Rear Brake

    Rear brake 4-61 2. Check: • brake master cylinder kit damage/scratches/wear → replace. 3. Check: • brake fluid reservoir cracks/damage → replace. • brake fluid reservoir diaphragm cracks/damage → replace. 4. Check: • brake hose cracks/damage/wear → replace. Eas22730 assembling the rear brake master ...

  • Page 247: Rear Brake

    Rear brake 4-62 4. Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-17. 5. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-16. 6. Check: • brake pe...

  • Page 248: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-63 eas22760 abs (anti-lock brake system) et3p61060 abs components chart 4 4 6 5 6 7 8 9 10 11 12,13 14 15 1 1 2 2 3 3 5 21 20 a a 16 17 19 18 11 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake ca...

  • Page 249: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-64 removing the metering valve, proportioning valve, and brake pipes order job/parts to remove q’ty remarks right side cover/air filter case assembly refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page...

  • Page 250: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-65 12 brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 1 disconnect. 13 brake pipe (front brake master cylinder to brake pipe/lower joint assembly) 1 disconnect. 14 brake pipe/upper joint assembly 1 15 brake pipe/joint assembly stay 1 16 brak...

  • Page 251: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-66 removing the hydraulic unit assembly order job/parts to remove q’ty remarks rear cowlings/side covers/air shroud refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-17. Rear fender/metering valve/...

  • Page 252: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-67 et3p6d003 removing the hydraulic unit assembly notice eca3p6d018 unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids ...

  • Page 253: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-68 • when using a bolt, do not tighten the bolt until the bolt head touches the hydraulic unit. Other- wise, the brake pipe seating surface could be deformed. Et3p6d004 checking the hydraulic unit assembly 1. Check: • hydraulic unit assembly cracks/damage → replace the...

  • Page 254: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-69 notice eca3p6d022 if the brake pipe flare nut does not turn easi- ly, replace the hydraulic unit, brake pipes, and related parts as a set. Tip first tighten the brake pipe/joint assembly flare nuts, then the brake pipe/joint assembly bolts. 6. Install: • brake pipe ...

  • Page 255: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-70 notice eca3p6d022 if the brake pipe flare nut does not turn easi- ly, replace the hydraulic unit, brake pipes, and related parts as a set. Tip • first tighten the brake pipe flare nut, then the brake hose holder bolt. • make sure that the brake pipe is parallel to t...

  • Page 256: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-71 notice eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 14.Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-17. 15.Check the operation of the hydraul...

  • Page 257: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-72 6. Turn the main switch to “on” while operating the brake lever and the brake pedal simulta- neously. Tip • this check cannot be performed unless both the brake lever and the brake pedal are oper- ated simultaneously when the main switch is turned to “on”. • do not ...

  • Page 258: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-73 e. Retract the sidestand. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Remove: • right upper inner panel refer to “general chassis” on page 4-1. 4. Check: • battery voltage lower than 12.8 v → charge or replace the battery. Tip • if the battery voltage is lo...

  • Page 259: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-74 11.After the pulsating action has stopped in the brake lever, it is generated in the brake pedal “1” 0.5 second later and continues for approx- imately 2 seconds. Tip • the reaction-force pulsating action consists of quick pulses. • be sure to continue operating the...

  • Page 260: Handlebars

    Handlebars 4-75 eas22850 handlebars removing the left handlebar order job/parts to remove q’ty remarks 1 left handlebar 1 2 hand shift switch 1 3 left handlebar switch 1 4 left handlebar switch holder 2 5 grip end 1 6 handlebar grip 1 7 lead holder 1 8 hand shift switch lead 1 9 left handlebar switc...

  • Page 261: Handlebars

    Handlebars 4-76 removing the right handlebar order job/parts to remove q’ty remarks 1 front brake master cylinder holder 1 2 front brake master cylinder assembly 1 3 grip end 1 4 throttle cable housing 2 5 throttle cable 2 disconnect. 6 throttle grip 1 7 right handlebar 1 8 lead holder 1 9 right gri...

  • Page 262: Handlebars

    Handlebars 4-77 eas1mc1065 adjusting the handlebar position 1. Check: • handlebar position tip the handlebar position can be adjusted to one of three positions to suit the rider’s preference. 2. Adjust: • handlebar position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the plates “1”. ...

  • Page 263: Handlebars

    Handlebars 4-78 eas22890 checking the handlebars 1. Check: • left handlebar • right handlebar bends/cracks/damage → replace. Warning ewa13690 do not attempt to straighten a bent handle- bar as this may dangerously weaken it. Eas22900 installing the handlebars 1. Stand the vehicle on a level surface....

  • Page 264: Handlebars

    Handlebars 4-79 • when installing the hand shift switch, route the left grip warmer lead “2” and left handlebar switch lead “3” through the switch as shown in the illustration. • after installing the hand shift switch, check that the left grip warmer lead does not interfere with the movement of the ...

  • Page 265: Handlebars

    Handlebars 4-80 10.Install: • front brake master cylinder assembly • front brake master cylinder holder “1” tip • install the brake master cylinder holder with the “up” mark facing up. • align the projection “a” on the front brake mas- ter cylinder with hole “b” on the right handlebar. • first, tigh...

  • Page 266: Front Fork

    Front fork 4-81 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. Lower inner panels refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-22. Handlebar refer to “hand...

  • Page 267: Front Fork

    Front fork 4-82 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 (with front fork stepping motor) 1 2 o-ring 1 3 locknut 1 4 spacer 1 5 fork spring 1 6 outer tube 1 7 dust seal 1 8 oil seal clip 1 9 oi...

  • Page 268: Front Fork

    Front fork 4-83 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 269: Front Fork

    Front fork 4-84 tip stroke the damper rod “1” several times while draining the fork oil. 3. Remove: • dust seal • oil seal clip (with a flat-head screwdriver) notice eca1md1010 do not scratch the outer tube. 4. Remove: • damper rod assembly bolt • damper rod assembly notice eca1md1003 for the damper...

  • Page 270: Front Fork

    Front fork 4-85 3. Check: • damper rod assembly damage/wear → replace. Obstruction → blow out all of the oil passag- es with compressed air. Notice eca1md1005 • the front fork leg has a built-in damper rod assembly and a very sophisticated internal construction, which are particularly sensi- tive to...

  • Page 271: Front Fork

    Front fork 4-86 3. Lubricate: • inner tube outer surface 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” (onto the inner tube) notice eca1md1012 make sure the numbered side of the oil seal faces bracket side. Tip • before installing the oil seal, lubricate its lips with l...

  • Page 272: Front Fork

    Front fork 4-87 9. Install: • rod puller “1” • rod puller attachment (m10) “2” (onto the damper rod “3”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) notice eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork ...

  • Page 273: Front Fork

    Front fork 4-88 14.Install: • locknut “1” • fork spring • spacer • cap bolt (with front fork stepping motor) notice eca1md1001 do not drop the cap bolt (with front fork step- ping motor) or subject it to shocks. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the rod puller and rod pulle...

  • Page 274: Front Fork

    Front fork 4-89 warning ewa1md1001 the fork spring is compressed. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. Notice eca1md1002 when tightening the cap bolt (with front fork stepping motor),...

  • Page 275: Steering Head

    Steering head 4-90 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Handlebars refer to “handlebars” on page 4-75. Front wheel refer to “front wheel” on page 4...

  • Page 276: Steering Head

    Steering head 4-91 11 upper ring nut 1 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 upper bearing cover 1 16 upper bearing inner race 1 17 upper bearing 1 18 lower bearing 1 19 lower bearing inner race 1 20 dust seal 1 21 upper bearing outer race 1 22 lower bearing outer race 1 for i...

  • Page 277: Steering Head

    Steering head 4-92 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 278: Steering Head

    Steering head 4-93 • lock washer “4” refer to “checking and adjusting the steering head” on page 3-21. 3. Install: • upper bracket • steering stem nut tip temporarily tighten the steering stem nut. 4. Install: • front fork legs refer to “front fork” on page 4-81. Tip temporarily tighten the upper an...

  • Page 279: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-94 eas23160 rear shock absorber assembly removing the rear fender assembly order job/parts to remove q’ty remarks rear cowlings/side covers/storage compart- ment refer to “general chassis” on page 4-1. 1 brake fluid reservoir 1 2 tail/brake light assembly coupler 1 dis...

  • Page 280: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-95 14 seat lock cable assembly 1 for installation, reverse the removal proce- dure. Removing the rear fender assembly order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 6 1 2 11 14 10 8 5 7 9 3 4 13 12.

  • Page 281: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-96 removing the rear shock absorber assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-31. Mufflers/exhaust pipe assembly refer to “engine removal” on page 5-3. 1 centerstan...

  • Page 282: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-97 13 rear shock absorber assembly stepping motor protector 1 14 rear shock absorber assembly gas cylinder holder 1 15 rear shock absorber assembly 1 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order job/parts to remove ...

  • Page 283: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-98 removing the stepping motor and dc motor order job/parts to remove q’ty remarks 1 stepping motor 1 2 preload adjusting pump bracket 1 3 dc motor bracket 2 4 dc motor 1 5 sponge ring 1 6 dc motor joint 1 for installation, reverse the removal proce- dure. 4 nm (0.4 m ...

  • Page 284: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-99 eas1md1055 removing the rear fender assembly 1. Remove the rear fender bolts “1” and quick fasteners “2”. 2. Slide the rear fender assembly “1” down. 3. Remove the quick fastener “1”, and then pull the dc motor upper cover “2” up. 4. Remove the rear shock absorber a...

  • Page 285: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-100 eas23190 disposing of a rear shock absorber 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release the gas pressure, drill a 2–3 mm (0.08–0.12 in) hole through the rear shock absorber at a point 15.0 mm (0.59 in) from its end as sh...

  • Page 286: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-101 3. Check: • spacers damage/scratches → replace. Eas1md1052 replacing the stepping motor notice eca1md1020 • allow the stepping motor and rear shock absorber assembly to cool before perform- ing this procedure. • when replacing the stepping motor, re- move the rear ...

  • Page 287: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-102 tip • make sure that the oil seals do not protrude past the edges of the relay arm. • when installing the oil seals “3” to the relay arm, face the character stamp of the oil seals outside. • make sure that the oil seals “4” do not protrude past the edges of the rel...

  • Page 288: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-103 4. Place the dc motor upper cover “1” in its orig- inal position, and then install the quick fasten- er “2”. 5. Install the rear fender bolts “1” and quick fas- teners “2”. 1 2 1 1 2 2.

  • Page 289: Swingarm

    Swingarm 4-104 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks left side cover/air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-31. Rear shock absorber assembly/connecting arms refer to “rear shock absorber as- sembly” ...

  • Page 290: Swingarm

    Swingarm 4-105 12 oil seal 1 13 spacer 1 14 oil seal 1 15 circlip 1 16 bearing 1 17 spacer 1 18 bearing 1 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks lt lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • i...

  • Page 291: Swingarm

    Swingarm 4-106 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingar...

  • Page 292: Swingarm

    Swingarm 4-107 3. Tighten: • pivot shaft • pivot shaft nut • pivot shaft self-lock nut 3. Swingarm 4. Connecting arm a. Left side b. Right side t r . . Pivot shaft 23 nm (2.3 m·kg, 17 ft·lb) t r . . Pivot shaft nut 115 nm (11.5 m·kg, 85 ft·lb) t r . . Pivot shaft self-lock nut 125 nm (12.5 m·kg, 90 ...

  • Page 293: Shaft Drive

    Shaft drive 4-108 eas23550 shaft drive removing the final drive assembly order job/parts to remove q’ty remarks final gear oil drain. Refer to “changing the final gear oil” on page 3-32. Rear wheel refer to “rear wheel” on page 4-31. 1 final drive assembly 1 for installation, reverse the removal pro...

  • Page 294: Shaft Drive

    Shaft drive 4-109 removing the universal joint order job/parts to remove q’ty remarks left footrest assembly/sidestand refer to “shift actuator and shift rod” on page 5-61. Final gear oil drain. Refer to “changing the final gear oil” on page 3-32. Final drive assembly refer to “shaft drive” on page ...

  • Page 295: Shaft Drive

    Shaft drive 4-110 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 circlip 2 2 oil seal 1 3 drive shaft 1 4 spring 1 5 ring gear bearing housing 1 6 dust cover 1 7 oil seal 1 8 stopper bolt 1 left-hand threads 9 stopper bolt shim refer to “adjusting the ring-gear- to-s...

  • Page 296: Shaft Drive

    Shaft drive 4-111 * apply shaft drive gear oil (part no.: 9079e-sh002-00) 14 coupling gear nut 1 15 coupling gear 1 16 bearing retainer 1 left-hand threads 17 oil seal 1 18 final drive pinion gear 1 19 bearing 1 20 final drive pinion gear shim refer to “aligning the final drive pinion gear and ring ...

  • Page 297: Shaft Drive

    Shaft drive 4-112 eas23560 troubleshooting tip causes a, b and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual. In...

  • Page 298: Shaft Drive

    Shaft drive 4-113 troubleshooting chart when causes (a) or (b) shown in the table at the beginning of the “troubleshooting” section ex- ist, check the following points. Yes → no ↓ no → yes ↓ yes → no ↓ 1. Place the vehicle on a suitable stand so that the front wheel is ele- vated and then spin the f...

  • Page 299: Shaft Drive

    Shaft drive 4-114 eas23570 checking the final drive oil for contamination and checking the shaft drive for leaks 1. Drain: • final gear oil (from the final gear case) refer to “changing the final gear oil” on page 3-32. 2. Check: • final gear oil large amount of metal particles → check for bearing s...

  • Page 300: Shaft Drive

    Shaft drive 4-115 b. Finger tighten the ring gear fix bolt (m14) until it stops the ring gear from moving. Tip do not overtighten the ring gear fix bolt (m14). C. Install the final gear backlash band “2” and dial gauge “3”. Tip make sure that the dial gauge plunger contacts the groove “a” in the fin...

  • Page 301: Shaft Drive

    Shaft drive 4-116 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23600 measuring the ring-gear-to- stopper-bolt clearance 1. Remove: • ring gear bearing housing (along with the ring gear) refer to “adjusting the final gear backlash” on page 4-115. 2. Measure: • ring-gear-to-stopper-bolt cleara...

  • Page 302: Shaft Drive

    Shaft drive 4-117 tip if the ring-gear-to-stopper-bolt clearance is out of specification, repeat the above procedure. Eas23620 disassembling the final drive assembly 1. Remove: • ring gear bearing housing bolts “1” • ring gear bearing housing nuts “2” tip working in a crisscross pattern, loosen each...

  • Page 303: Shaft Drive

    Shaft drive 4-118 3. Remove: • bearing “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final gear case to approximately 150 °c (302 °f). B. Remove the bearing outer races with an ap- propriately shaped punch “2”. C. Remove the inner race from the final drive pinion gear. Tip the re...

  • Page 304: Shaft Drive

    Shaft drive 4-119 b. To find final drive pinion gear shim thickness “a”, use the following formula: where: a = 87 b = a numeral on the final gear case, to be di- vided by 100 and added to “86”. Example: if the final gear case is marked “49”: therefore, the calculated final drive pinion gear shim thi...

  • Page 305: Shaft Drive

    Shaft drive 4-120 example: if the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “+ 05”, and “f” is 13.00: therefore, the calculated ring gear shim thickness is 0.41 mm. Shim sizes are supplied in the following thick- nesses. Since the ring gear...

  • Page 306: Shaft Drive

    Shaft drive 4-121 6. Adjust: • final gear backlash refer to “measuring the final gear backlash” on page 4-114 and “adjust- ing the final gear backlash” on page 4-115. 7. Measure: • ring-gear-to-thrust-washer clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the ring gear bearing ...

  • Page 307: Shaft Drive

    Shaft drive 4-122 4. Install: • circlip 5. Install: • drive shaft “1” (to the final drive pinion gear) • oil seal “2” (to the final gear case with the fork seal driver weight “3” and oil seal installing tool “4”) 6. Install: • universal joint • final drive assembly tip align the drive shaft splines ...

  • Page 308: Shaft Drive

    Shaft drive 4-123.

  • Page 309: Engine

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

  • Page 310

    Clutch ........................................................................................................ 5-44 removing the clutch ..................................................................... 5-51 checking the friction plates..................................................... 5-51 c...

  • Page 311

    Middle gear .............................................................................................. 5-75 removing the middle drive shaft assembly ......................... 5-79 disassembling the middle drive shaft assembly ............... 5-79 disassembling the middle driven shaft assembly......

  • Page 312: Engine Inspection

    Engine inspection 5-1 eas1mc1068 engine inspection eas20710 measuring the compression pressure the following procedure applies to all of the cyl- inders. Tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to ...

  • Page 313: Engine Inspection

    Engine inspection 5-2 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Install: • spark plug 10.Install: • ignition coils 11.Connect: • ignition coil couplers 12.Install: • t-bar refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • rider seat refer to “general ...

  • Page 314: Engine Removal

    Engine removal 5-3 eas23710 engine removal removing the exhaust pipe assembly and muffler order job/parts to remove q’ty remarks rider seat/side cowlings/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3...

  • Page 315: Engine Removal

    Engine removal 5-4 disconnecting the leads and hose order job/parts to remove q’ty remarks front fender refer to “front wheel” on page 4-22. Air filter case refer to “general chassis” on page 4-1. Throttle bodies refer to “throttle bodies” on page 7-4. Air cut-off valve/reed valves refer to “air ind...

  • Page 316: Engine Removal

    Engine removal 5-5 3 clutch release cylinder 1 4 dowel pin 2 5 crankcase breather hose 1 6 stator coil coupler 1 disconnect. 7 oil level switch coupler 1 disconnect. 8 crankshaft position sensor coupler 1 disconnect. 9 neutral switch coupler 1 disconnect. 10 ycc-s speed sensor coupler 1 disconnect. ...

  • Page 317: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks tip place a suitable stand under the engine. 1 brake pedal 1 2 engine bracket and engine bolt (left rear side) 2 3 engine bracket and frame bolt (left rear side) 1 4 engine bracket (left rear side) 1 5 engine bracket and f...

  • Page 318: Engine Removal

    Engine removal 5-7 16 spacer bolt 1 loosen. 17 engine mounting bolt (rear lower side) 1 18 spacer 1 19 engine mounting bolt (rear upper side) 1 20 engine 1 21 rubber damper 1 for installation, reverse the removal proce- dure. Removing the engine order job/parts to remove q’ty remarks t r . . 32 nm (...

  • Page 319: Engine Removal

    Engine removal 5-8 eas1md1028 removing the gear position sensor 1. Disconnect: • gear position sensor coupler 2. Remove: • gear position sensor tip remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. Eas1mc1066 removing the engine 1. Loosen: • spacer bolt...

  • Page 320: Engine Removal

    Engine removal 5-9 • engine mounting bolt (left front upper side) “5” • engine mounting bolt (left front lower side) “6” • spacers “7” • engine mounting bolt (right front upper side) “8” • engine mounting bolt (right front lower side) “9” • pinch bolts (front side) “10” • pinch bolts (rear lower sid...

  • Page 321: Engine Removal

    Engine removal 5-10 tip tighten the pinch bolts (rear lower side) one at a time, making sure to tighten the first bolt again after tightening the second bolt. 12.Tighten: • engine bracket and engine bolts (top) “13” (temporarily tighten) • engine bracket bolts (top) “14” (temporarily tighten) tip wh...

  • Page 322: Engine Removal

    Engine removal 5-11 tip align the punch mark “a” on the brake pedal with the punch mark “b” on the brake pedal pivot shaft. Eas1md1029 installing the gear position sensor 1. Connect: • mcu coupler • ecu coupler refer to “general chassis” on page 4-1. 2. Install: • gear position sensor “1” notice eca...

  • Page 323: Engine Removal

    Engine removal 5-12 c. Turn the main switch to “on”. D. Measure the gear position sensor voltage. E. Adjust the gear position sensor angle so that the voltage is within the specified range. F. After adjusting the gear position sensor an- gle, tighten the gear position sensor screws “4” to specificat...

  • Page 324: Camshafts

    Camshafts 5-13 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks t-bar refer to “general chassis” on page 4-1. Thermostat inlet pipe 1 refer to “thermostat” on page 6-6. Air cut-off valve/reed valves refer to “air induction system” on page 7-13. 1 ignition co...

  • Page 325: Camshafts

    Camshafts 5-14 removing the camshafts order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-37. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft cap 4 4 exhaust camshaft cap 4 ...

  • Page 326: Camshafts

    Camshafts 5-15 eas23810 removing the camshafts 1. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick-...

  • Page 327: Camshafts

    Camshafts 5-16 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: • camshaft runout out of specification → replace. 4. Me...

  • Page 328: Camshafts

    Camshafts 5-17 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 journal-to-camshaft cap clearance with the plastigauge®. D. Remove the camshaft caps and then mea- sure the width of the ...

  • Page 329: Camshafts

    Camshafts 5-18 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24010 installing the camshafts 1. Install: • exhaust camshaft sprocket • intake camshaft sprocket tip • while holding the camshaft sprockets with the rotor holding tool “1”, tighten the camshaft sprocket bolts. • make sure that the ...

  • Page 330: Camshafts

    Camshafts 5-19 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • exhaust camshaft caps • intake camshaft caps tip • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “e”, “e1”, “e2”, “e3”: exhaust “i”, “i1”, “i2”, “i3”: intake...

  • Page 331: Camshafts

    Camshafts 5-20 d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Turn: • crankshaft (several turns clockwise) 8. Check: • “t” mark make sure the “t” mark “a” on t...

  • Page 332: Camshafts

    Camshafts 5-21 11.Install: • cylinder head cover plate “1” tip be sure the “up” mark “a” is facing up. New 2 2 a 1 3 a a 1.

  • Page 333: Cylinder Head

    Cylinder head 5-22 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Camshafts refer to “camshafts” on page 5-13. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the removal proce-...

  • Page 334: Cylinder Head

    Cylinder head 5-23 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: • comb...

  • Page 335: Cylinder Head

    Cylinder head 5-24 e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Warning ew3p61014 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a...

  • Page 336: Valves and Valve Springs

    Valves and valve springs 5-25 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-22. 1 valve lifter 16 2 valve pad 16 3 valve cotter 32 4 upper spring seat 16 5 intake valve spring 8 6 exhaus...

  • Page 337: Valves and Valve Springs

    Valves and valve springs 5-26 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifte...

  • Page 338: Valves and Valve Springs

    Valves and valve springs 5-27 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼...

  • Page 339: Valves and Valve Springs

    Valves and valve springs 5-28 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replac...

  • Page 340: Valves and Valve Springs

    Valves and valve springs 5-29 b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Tip where the valve seat and valve face contacted one another, the blue layout fluid will have ...

  • Page 341: Valves and Valve Springs

    Valves and valve springs 5-30 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spri...

  • Page 342: Valves and Valve Springs

    Valves and valve springs 5-31 3. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • upper spring seat “5” (into the cylinder head) tip • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 4. I...

  • Page 343: Generator and Starter Clutch

    Generator and starter clutch 5-32 eas24480 generator and starter clutch removing the generator rotor and starter clutch order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Engine oil drain. Refer to “changing the engine oil” on page 3-27. 1 stator coil coupler 1 discon...

  • Page 344: Generator and Starter Clutch

    Generator and starter clutch 5-33 removing the stator coil assembly order job/parts to remove q’ty remarks 1 stator coil assembly lead holder 1 2 stator coil assembly 1 for installation, reverse the removal proce- dure..

  • Page 345: Generator and Starter Clutch

    Generator and starter clutch 5-34 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer tip while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff key notic...

  • Page 346: Generator and Starter Clutch

    Generator and starter clutch 5-35 b. When turning the starter clutch gear clock- wise “a”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch gear counter- clockwise “b”, it should turn freely,...

  • Page 347: Generator and Starter Clutch

    Generator and starter clutch 5-36 4. Install: • generator cover gasket • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. T r . . Generator cover bolt 12 nm (1.2 m·kg, 8.7 ft·lb) new.

  • Page 348: Pickup Rotor

    Pickup rotor 5-37 eas24520 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks side cowlings/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Generator cover refer to “generator and starter clutch” on page 5-32. 1 pickup ro...

  • Page 349: Pickup Rotor

    Pickup rotor 5-38 eas24530 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3” tip while holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. Eas24540 installing the pickup rotor 1. Install: • pickup rotor “1” • washer • p...

  • Page 350: Pickup Rotor

    Pickup rotor 5-39 4. Measure: • gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” out of specification → reinstall or replace. 5. Install: • pickup rotor cover gasket • pickup rotor cover tip tighten the pickup rotor cover bolts in stages and in a crisscross pattern. Gap (bet...

  • Page 351: Electric Starter

    Electric starter 5-40 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure..

  • Page 352: Electric Starter

    Electric starter 5-41 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 brush 2 4 brush seat (along with brushes) 1 5 washer 1 6 lock washer 1 7 oil seal 1 8 bearing 1 9 starter motor rear cover 1 10 collar 1 11 o-ring 2 12 starter moto...

  • Page 353: Electric Starter

    Electric starter 5-42 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “1” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 354: Electric Starter

    Electric starter 5-43 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” tip align the slot “a” on the brush seat with the tab “b” in the starter motor f...

  • Page 355: Clutch

    Clutch 5-44 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-27. 1 clutch cover 1 2 clutch cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 356: Clutch

    Clutch 5-45 removing the clutch order job/parts to remove q’ty remarks rear balancer refer to “balancers” on page 5-116. 1 oil guide plate 1 2 clutch spring plate retainer 1 3 clutch spring plate 1 4 clutch spring plate seat 1 5 pressure plate 1 6 short clutch push rod 1 7 ball 1 8 long clutch push ...

  • Page 357: Clutch

    Clutch 5-46 17 thrust washer 1 18 spacer 1 19 clutch housing 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks 19 18 17 16 14 15 12 11 10 9 8 7 6 5 4 3 2 1 13 (6) new new lt t r . . 90 nm (9.0 m • kg, 65 ft • ib) t r . . 10 nm (1.0 m • kg...

  • Page 358: Clutch

    Clutch 5-47 removing the clutch actuator and clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-12. Swingarm refer to “swingarm” on page 4-104. 1 rear brake hose holder 1 2 clutch actuator motor coupler 1 discon...

  • Page 359: Clutch

    Clutch 5-48 14 clutch actuator 1 for installation, reverse the removal proce- dure. Removing the clutch actuator and clutch master cylinder order job/parts to remove q’ty remarks t r . . 19 nm (1.9 m • kg, 13 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t ...

  • Page 360: Clutch

    Clutch 5-49 disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder kit 1 2 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S 1 2 new ls.

  • Page 361: Clutch

    Clutch 5-50 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-12. 1 clutch hose union bolt 1 2 copper washer 2 3 clutch hose 1 disconnect. 4 clutch release cylinder 1 5 dowel pin 2 6 plate 1 for i...

  • Page 362: Clutch

    Clutch 5-51 eas25080 removing the clutch 1. Remove: • clutch cover “1” tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • rear balancer weight refer to “balancers” on page 5-116. 3. Remove: • clu...

  • Page 363: Clutch

    Clutch 5-52 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 364: Clutch

    Clutch 5-53 2. Check: • bearing damage/wear → replace the bearing and clutch housing. Eas25160 checking the clutch boss 1. Check: • clutch boss splines damage/pitting/wear → replace the clutch boss. Tip pitting on the clutch boss splines will cause er- ratic clutch operation. Eas25170 checking the p...

  • Page 365: Clutch

    Clutch 5-54 2. Install: • spacer “1” tip install the spacer with the two screw holes facing towards the clutch boss. 3. Install: • clutch boss “1” • lock washer “2” • clutch boss nut “3” tip • install the clutch boss nut with its large inner di- ameter side facing inward as shown in the illus- trati...

  • Page 366: Clutch

    Clutch 5-55 tip tighten the clutch spring bolts in stages and in a crisscross pattern. 9. Install: • rear balancer weight refer to “balancers” on page 5-116. 10.Install: • clutch cover tip tighten the clutch cover bolts in the proper tight- ening sequence as shown. Eas1md1033 checking the clutch act...

  • Page 367: Clutch

    Clutch 5-56 b. Measure the clutch actuator sensor resis- tance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1md1031 breaking in the friction plates after replacement 1. If the friction plates are replaced, perform the following procedure to break them in. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 368: Clutch

    Clutch 5-57 eas25290 checking the clutch master cylinder 1. Check: • clutch master cylinder body cracks/damage → replace the clutch mas- ter cylinder. • clutch fluid delivery passage (clutch master cylinder body) obstruction → blow out with compressed air. 2. Check: • clutch master cylinder • clutch...

  • Page 369: Clutch

    Clutch 5-58 • when refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. Notice eca13420 clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any sp...

  • Page 370: Clutch

    Clutch 5-59 4. Adjust: • clutch engagement point “1” execute the diagnostic mode. (code no. Sh_ _66) refer to “self-diagnostic function and diagnostic code table (mcu)” on page 9-13. Tip adjust the clutch engagement point if the clutch actuator was replaced. 5. Check: • rear wheel drag torque refer ...

  • Page 371: Clutch

    Clutch 5-60 2. Fill: • clutch fluid reservoir (with the specified amount of the specified brake and clutch fluid) warning ewa1md1004 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the s...

  • Page 372: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-61 eas1md1038 shift actuator and shift rod removing the shift actuator, shift rod and foot shift sensor order job/parts to remove q’ty remarks rider seat/left side cover/air shroud/storage compartment refer to “general chassis” on page 4-1. 1 gear position sensor cover...

  • Page 373: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-62 15 washer 1 16 shift pedal 1 17 ball 1 18 spring 1 19 washer 1 for installation, reverse the removal proce- dure. Removing the shift actuator, shift rod and foot shift sensor order job/parts to remove q’ty remarks lt lt t r . . 65 nm (6.5 m • kg, 47 ft • ib) t r . ....

  • Page 374: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-63 eas1md1049 removing the shift actuator 1. Remove: • shift actuator ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pass a suitable 5 mm (0.20 in) diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod. B. Remove the ...

  • Page 375: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-64 4. Adjust: • foot shift sensor refer to “adjusting the foot shift sensor” on page 5-64. Eas1md1041 adjusting the foot shift sensor 1. Check: • foot shift sensor refer to “checking the foot shift sensor” on page 8-284. 2. Adjust: • foot shift sensor angle ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 376: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-65 et3p66042 installing the shift actuator 1. Install: • shift actuator ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the shift actuator front bolt “1” tempo- rarily. B. Tighten the shift actuator rear bolt “2”, and then tighten the front bolt “1” to spe...

  • Page 377: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-66 c. Turn the main switch to “on”. D. Measure the shift actuator sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ shift actuator sensor resistance a. Connect the digital circuit tester to the ...

  • Page 378: Shift Actuator and Shift Rod

    Shift actuator and shift rod 5-67 b. Move the shift pedal to the desired position. C. Install the shift pedal bolt, and then tighten it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a. High position b. Standard position c. Low position t r . . Shift pedal bolt 7 nm (0.7 m·kg, 5...

  • Page 379: Shift Shaft

    Shift shaft 5-68 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-44. Shift rod refer to “shift actuator and shift rod” on page 5-61. 1 oil baffle plate 1 1 2 shift arm 1 3 circlip 1 4 shift shaft 1 5 sh...

  • Page 380: Shift Shaft

    Shift shaft 5-69 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • shift lever sp...

  • Page 381: Oil Pump

    Oil pump 5-70 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-27. Throttle bodies refer to “throttle bodies” on page 7-4. Exhaust pipe assembly refer to “engine removal” on page 5-3. Sidestand r...

  • Page 382: Oil Pump

    Oil pump 5-71 10 oil pump 1 11 relief valve assembly 1 12 o 2 sensor lead bracket 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks 12.

  • Page 383: Oil Pump

    Oil pump 5-72 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump driven sprocket 1 8 oil pump housing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 384: Oil Pump

    Oil pump 5-73 eas24960 checking the oil pump 1. Check: • oil pump driven sprocket • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-ho...

  • Page 385: Oil Pump

    Oil pump 5-74 1. Check: • oil delivery pipes damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer ...

  • Page 386: Middle Gear

    Middle gear 5-75 eas25710 middle gear removing the middle gear order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Oil pan/oil pump refer to “oil pump” on page 5-70. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 387: Middle Gear

    Middle gear 5-76 15 spacer 1 16 middle driven gear 1 17 bearing retainer 1 18 bearing 1 19 middle drive pinion gear shim 20 bearing 1 for installation, reverse the removal proce- dure. Removing the middle gear order job/parts to remove q’ty remarks 160 nm (16.0 m • kg, 115 ft • lb) t.R..

  • Page 388: Middle Gear

    Middle gear 5-77 disassembling the middle drive shaft assembly order job/parts to remove q’ty remarks 1 spring retainer 2 2 spring seat 1 3 damper spring 1 4 damper driven cam 1 5 damper drive cam 1 6 middle drive shaft 1 for assembly, reverse the disassembly pro- cedure..

  • Page 389: Middle Gear

    Middle gear 5-78 disassembling the middle driven shaft assembly order job/parts to remove q’ty remarks 1 oil seal 1 2 middle driven pinion gear nut 1 3 middle driven shaft 1 4 middle driven pinion gear 1 5 bearing retainer 1 6 bearing 1 7 middle driven shaft bearing housing 1 for assembly, reverse t...

  • Page 390: Middle Gear

    Middle gear 5-79 eas25730 removing the middle drive shaft assembly 1. Remove: • middle drive pinion gear nut “1” • lock washer “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Straighten the lock washer tab. B. Loosen the middle drive pinion gear nut. Tip while holding the middle drive shaft...

  • Page 391: Middle Gear

    Middle gear 5-80 c. Remove the middle driven pinion gear nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Remove: • bearing retainer ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the middle driven shaft bearing housing onto the lower crankcase. B. Straighten the t...

  • Page 392: Middle Gear

    Middle gear 5-81 c. Tighten the bearing retainer to specification. D. Lock the threads with a drift punch. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Tighten: • middle driven pinion gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle driven pinion gear nut to s...

  • Page 393: Middle Gear

    Middle gear 5-82 • middle drive pinion gear nut “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle drive pinion gear nut to specification. Tip • lubricate the nut threads with engine oil. • install the middle drive pinion gear nut with its large inner diameter side facing in...

  • Page 394: Middle Gear

    Middle gear 5-83 eas25880 measuring the middle gear backlash 1. Measure: • middle gear backlash out of specification → refer to “adjusting the middle gear backlash” on page 5-83. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the middle drive shaft “1”. B. Install the gear lash measuremen...

  • Page 395: Middle Gear

    Middle gear 5-84 tip while carefully tightening the middle driven shaft bearing housing bolts in stages and in a criss- cross pattern, turn the middle driven shaft back and forth until the dial gauge reads 0.10–0.20 mm (0.0039–0.0079 in). 6. Measure: • crankcase-to-middle-driven-shaft-bearing- housi...

  • Page 396: Middle Gear

    Middle gear 5-85 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the middle gears with the appropri- ate shim(s) that has had its respective thick- ness calculated from information marked on the crankcase and middle driven pinion gear. B. To find middle drive pinion gear shim thick- ne...

  • Page 397: Middle Gear

    Middle gear 5-86 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ middle driven pinion gear shim thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50

  • Page 398: Crankcase

    Crankcase 5-87 eas25540 crankcase 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 5-22. Starter clutch refer to “generator and starter clutch” on page 5-32. Pickup rotor refer to “pickup roto...

  • Page 399: Crankcase

    Crankcase 5-88 9 ycc-s speed sensor 1 10 lower crankcase 1 11 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 f...

  • Page 400: Crankcase

    Crankcase 5-89 removing the oil baffle plate and bearings order job/parts to remove q’ty remarks connecting rod refer to “connecting rods and pis- tons” on page 5-95. Crankshaft/crankshaft journal bearings refer to “crankshaft” on page 5-103. Transmission refer to “transmission” on page 5-107. 1 oil...

  • Page 401: Crankcase

    Crankcase 5-90 13 lower crankcase 1 for installation, reverse the removal proce- dure. Removing the oil baffle plate and bearings order job/parts to remove q’ty remarks 10 ls ls 2 lt lt lt lt lt lt lt lt 4 8 3 lt 5 7 6 12 1 9 13 t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ...

  • Page 402: Crankcase

    Crankcase 5-91 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts tip • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerica...

  • Page 403: Crankcase

    Crankcase 5-92 eas25680 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) 2. Apply: • sealant (onto the crankcase mating surfaces and oil baffle plate 2) tip do not allow any sealant to come into contact with the oil gallery or crankshaft journal b...

  • Page 404: Crankcase

    Crankcase 5-93 tip • lubricate the bolts “1”–“10” thread and wash- ers with engine oil. • lubricate the bolts “11”–“31” thread part and mating surface with engine oil. • apply locking agent (loctite®) to the threads of the bolt “16”. • finger tighten the crankcase bolts. • m9 × 115 mm bolts: “1”–“10...

  • Page 405: Crankcase

    Crankcase 5-94 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Tighten: • crankcase bolts “11”–“31” tip tighten the crankcase bolts in the proper tight- ening sequence as shown. Eas1md1057 installing the oil pump drive sprocket 1. Install: • conical spring washer “1” • collar “2” • oil pump dri...

  • Page 406: Connecting Rods and Pistons

    Connecting rods and pistons 5-95 et3p61027 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-87. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston 4...

  • Page 407: Connecting Rods and Pistons

    Connecting rods and pistons 5-96 eas26030 removing the connecting rods and pistons the following procedure applies to all of the con- necting rods and pistons. 1. Remove: • connecting rod cap “1” tip identify the position of each connecting rod so that it can be reinstalled in its original place. 2....

  • Page 408: Connecting Rods and Pistons

    Connecting rods and pistons 5-97 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 measurements. B. If out of ...

  • Page 409: Connecting Rods and Pistons

    Connecting rods and pistons 5-98 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 410: Connecting Rods and Pistons

    Connecting rods and pistons 5-99 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Et3p61028 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bear...

  • Page 411: Connecting Rods and Pistons

    Connecting rods and pistons 5-100 e. Tighten the connecting rod nuts. Refer to “installing the connecting rods and pistons” on page 5-100. F. Remove the connecting rod and big end bearings. Refer to “removing the connecting rods and pistons” on page 5-96. G. Measure the compressed plastigauge® width...

  • Page 412: Connecting Rods and Pistons

    Connecting rods and pistons 5-101 tip • apply engine oil onto the piston pin. • make sure that the “y” mark “a” on the connect- ing rod is facing to the left when the punch mark “b” on the piston is pointing up. Refer to the illustration. • when installing a piston pin clips so that the clip ends ar...

  • Page 413: Connecting Rods and Pistons

    Connecting rods and pistons 5-102 8. Tighten: • connecting rod nuts “1” warning ew3p61019 replace the connecting rod bolts and nuts with new ones. Tip tighten the connecting rod nuts using the follow- ing procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the connecting rod nuts...

  • Page 414: Crankshaft

    Crankshaft 5-103 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-87. Front balancer weight refer to “balancers” on page 5-116. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-95. 1 crankshaft...

  • Page 415: Crankshaft

    Crankshaft 5-104 eas26040 removing the crankshaft journal bearings 1. Remove: • crankshaft journal upper bearings (from the upper crankcase) • crankshaft journal lower bearings (from the lower crankcase) tip identify the position of each crankshaft journal bearing so that it can be reinstalled in it...

  • Page 416: Crankshaft

    Crankshaft 5-105 e. Install the crankshaft journal lower bearings “3” into the lower crankcase and assemble the crankcase halves. Tip • align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d” in the lower crankcase. • do not move the crankshaft until the clearance m...

  • Page 417: Crankshaft

    Crankshaft 5-106 tip • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • be sure to install each crankshaft journal bear- ing in its original place..

  • Page 418: Transmission

    Transmission 5-107 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-87. Stopper lever refer to “shift shaft” on page 5-68. 1 gear position sensor bracket 1 2 oil seal 1 3 dr...

  • Page 419: Transmission

    Transmission 5-108 14 shift fork-c 1 15 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 420: Transmission

    Transmission 5-109 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 5th pinion gear 1 5 toothed spacer 1 6 toothed washer 2 7 circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 collar 1 11 mai...

  • Page 421: Transmission

    Transmission 5-110 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 middle drive gear 1 2 washer 1 3 2nd wheel gear 1 4 collar 1 5 washer 1 6 5th wheel gear 1 7 circlip 2 8 toothed washer 2 9 3rd wheel gear 1 10 toothed spacer 1 11 toothed lock washer 1 12 toothed lock ...

  • Page 422: Transmission

    Transmission 5-111 18 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 e m m m m m m 5 new new.

  • Page 423: Transmission

    Transmission 5-112 eas26250 removing the transmission 1. Remove: • main axle assembly tip remove the main axle assembly with the slide hammer bolts “1” and weight. Eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • s...

  • Page 424: Transmission

    Transmission 5-113 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replac...

  • Page 425: Transmission

    Transmission 5-114 • be sure to align the projection on the toothed lock washer that is between the alignment marks “b” with the alignment mark “c” on the re- tainer. 3. Install: • 2nd pinion gear “1” tip make sure that the side of the 2nd pinion gear with the groove “d” is facing inward as shown in...

  • Page 426: Transmission

    Transmission 5-115 4. Install: • drive axle assembly tip • the bearing pin “1” must face towards the rear of the upper crankcase. • make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • transmission rough movement → repair. Tip oil each gear, shaft, and be...

  • Page 427: Balancers

    Balancers 5-116 et3p61031 balancers removing the front balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-87. 1 front balancer lever 1 2 front balancer shaft 1 3 washer 2 4 bearing 2 5 front balancer gear 1 6 damper 4 7 front balancer weight 1 for inst...

  • Page 428: Balancers

    Balancers 5-117 removing the rear balancer order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-37. Clutch cover refer to “clutch” on page 5-44. 1 rear balancer cover 1 2 rear balancer cover gasket 1 3 rea...

  • Page 429: Balancers

    Balancers 5-118 eas26120 checking the balancers 1. Check: • front balancer gear damage/wear → replace the front balancer gear and crankshaft. • rear balancer gear damage/wear → replace the rear balancer gear and clutch housing. 2. Check: • balancer shafts cracks/damage/wear → replace the balanc- er ...

  • Page 430: Balancers

    Balancers 5-119 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • front balancer lever “1” • front balancer lever bolt “2” tip • apply locking agent (loctite®) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • front balancer shaft “...

  • Page 431: Balancers

    Balancers 5-120 2. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick- up rotor with the crankcase ma...

  • Page 432: Balancers

    Balancers 5-121 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • rear balancer lever “1” • rear balancer lever bolt “2” tip • apply locking agent (loctite®) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • rear balancer shaft “1” ...

  • Page 433: Cooling System

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

  • Page 434: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-30. Side cowlings/battery refer to “general chassis” on page 4-1. 1 coolant reservoir breather hose 1 2 coolant reservoir cap 1 3 coolant reservoir 1 4...

  • Page 435: Radiator

    Radiator 6-2 13 electrical components tray bolt 3 14 radiator 1 15 radiator cover 1 16 left radiator fan motor 1 17 right radiator fan motor 1 18 radiator bracket 1 19 thermostat assembly 1 20 air deflector 1 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to...

  • Page 436: Radiator

    Radiator 6-3 eas1mc1032 removing the radiator 1. Pull the top of electrical components tray “1” slightly outward as shown in the illustration and then remove the radiator bolt “2”. Eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the r...

  • Page 437: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-27. Coolant drain. Refer to “changing the coolant” on page 3-30. Radiator refer to “radiator” on page 6-1. Exhaust pipe assembly refer to “...

  • Page 438: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose • water pump outlet hose • water pump outlet pipe • water jacket joint inlet hose cracks/damage/wear → replace. Eas26430 installing the oil coole...

  • Page 439: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-30. Left side cowling/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 radiator cap 1 2 coola...

  • Page 440: Thermostat

    Thermostat 6-7 12 thermostat inlet pipe 1 1 for installation, reverse the removal proce- dure. Removing the thermostat assembly order job/parts to remove q’ty remarks ls new new 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 10 nm (1.0 m • kg, 7.2 ft • ib) t.R . 22 nm (2.2 m • kg, 16 ft • ib) t.R . 10 nm (1.0 ...

  • Page 441: Thermostat

    Thermostat 6-8 eas26450 checking the thermostat 1. Check: • thermostat does not open at 69.0–73.0 °c (156.20– 163.40 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermomet...

  • Page 442: Thermostat

    Thermostat 6-9 5. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3..

  • Page 443: Water Pump

    Water pump 6-10 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-30. 1 water pump breather hose 1 disconnect. 2 radiator outlet hose 1 disconnect. 3 w...

  • Page 444: Water Pump

    Water pump 6-11 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump housing cover 1 2 o-ring 1 3 circlip 1 4 impeller shaft 1 5 rubber damper holder 1 6 rubber damper 1 7 water pump seal 1 8 oil seal 1 9 bearing 2 10 water pump housing 1 for assembly, reverse the disasse...

  • Page 445: Water Pump

    Water pump 6-12 eas26510 disassembling the water pump 1. Remove: • rubber damper holder “1” • rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) tip do not scratch the impeller shaft. 2. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water ...

  • Page 446: Water Pump

    Water pump 6-13 3. Install: • rubber damper “1” • rubber damper holder “2” tip before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Notice eca14090 make sure the rubber damper and ru...

  • Page 447: Water Pump

    Water pump 6-14 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-30. 3. Check: • cooling system leaks → repair or replace any faulty part. 4. Measure: • radiator cap opening pressure below the specified pressure → replace th...

  • Page 448: Water Pump

    Water pump 6-15.

  • Page 449: Fuel System

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

  • Page 450: 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 panel 1 2 fuel sender coupler 1 disconnect. 3 fuel pump coupler 1 disconnect. 4 fuel tank breather hose 1 5 fuel tank overflow hose 1 6 fuel h...

  • Page 451: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose warning ew3p61012 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out whe...

  • Page 452: Fuel Tank

    Fuel tank 7-3 2. Install: • fuel hose (fuel pump side) • fuel hose holder notice ec3p61008 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled. Tip • install the f...

  • Page 453: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider seat/t-bar/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 throttle position sensor coupler 1 disconnect. 2 injector coupler 4 ...

  • Page 454: Throttle Bodies

    Throttle bodies 7-5 14 throttle body joint 4 for installation, reverse the removal proce- dure. Removing the throttle bodies order job/parts to remove q’ty remarks lt 9 9 9 9 9 14 9 10 1 2 2 2 3 4 5 8 6 7 11 13 12 14 4 nm (0.4 m • kg, 2.9 ft • ib) t.R . 3 nm (0.3 m • kg, 2.2 ft • ib) t.R. 3 nm (0.3 ...

  • Page 455: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 negative pressure hose 7 2 atmospheric pressure sensor 1 3 intake air pressure sensor 1 4 fuel rail 1 5 injector 4 6 throttle position sensor 1 7 accelerator position sensor 1 8 grip cancel switch 1 for installation,...

  • Page 456: Throttle Bodies

    Throttle bodies 7-7 eas1mc1069 checking the injectors (before removing) 1. Check: • injectors use the diagnostic code numbers “36”–“39”. Refer to “self-diagnostic function and diagnostic code table (ecu)” on page 9-5. Eas1mc1070 removing the injectors warning ewa1mc1015 • check the injectors in a we...

  • Page 457: Throttle Bodies

    Throttle bodies 7-8 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place the throttle bodies on a flat surface with the air filter case side facing up. B. Install the caps (895-14169-00) onto the hose fittings “a”. C. Hold the throttle valves in the open position. Warning ewa1mc1017 when clean...

  • Page 458: Throttle Bodies

    Throttle bodies 7-9 5. Adjust: • throttle bodies synchronizing out of specification → replace the throttle bodies. Refer to “synchronizing the throt- tle bodies” on page 3-8. Eas21010 checking the throttle body joints 1. Check: • throttle body joints “1” cracks/damage → replace. Eas1mc1067 replacing...

  • Page 459: Throttle Bodies

    Throttle bodies 7-10 c. Close the valve on the injector pressure adapter. D. Apply air pressure with the air compressor. E. Open the valve on the injector pressure adapter until the specified pressure is reached. Notice eca1mc1023 never exceed the specified air pressure or damage could occur. F. Clo...

  • Page 460: Throttle Bodies

    Throttle bodies 7-11 d. Start the engine. E. Measure the fuel line pressure. Faulty → replace the fuel pump. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1mc1076 adjusting the throttle position sensor warning ewa1mc1019 • handle the throttle position sensor with special care. • never subject...

  • Page 461: Throttle Bodies

    Throttle bodies 7-12 1. Check: • accelerator position sensor refer to “checking the accelerator position sensor” on page 8-278. 2. Adjust: • accelerator position sensor angle tip before adjusting the accelerator position sensor, the throttle bodies must be removed. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 462: Air Induction System

    Air induction system 7-13 eas27040 air induction system 1 2 3 5 6 7 8 1 1 2 1 1 3 6 7 8 2 2 3 5 4.

  • Page 463: Air Induction System

    Air induction system 7-14 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5. Air cut-off valve 6. Air induction system hose (3-way joi...

  • Page 464: Air Induction System

    Air induction system 7-15 removing the air cut-off valve order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air induction system solenoid coupler 1 disconnect. 2 air induction system hose (air filter case join...

  • Page 465: Air Induction System

    Air induction system 7-16 removing the reed valves order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air induction system hoses (3-way joint to reed valve cover) refer to “removing the air cut-off valve”. Therm...

  • Page 466: Air Induction System

    Air induction system 7-17 eas27060 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 467: Electrical System

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

  • Page 468

    Cruise control system ....................................................................... 8-89 circuit diagram ................................................................................ 8-89 cruise control circuit operation........................................... 8-91 basic instructions...

  • Page 469

    Abs (anti-lock brake system)......................................................... 8-129 circuit diagram .............................................................................. 8-129 abs components chart ............................................................... 8-131 abs coupler loca...

  • Page 470

    Electrical components.................................................................... 8-255 checking the switches ............................................................... 8-259 checking the bulbs and bulb sockets ................................. 8-262 checking the fuses ....................

  • Page 472: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram p on off a b br /l r r r br /w r b b b r r r b /l b /l b /l r /w r /w br /l b b r /br /w b /r b /r sb sb sb sb sb b /rl /g b /w b /w b b l /g b /w l /g l /g l b /lg y b g y /w l gy /w b /l b /r sb y /g gy o /g gy /r o gy r /b o /g...

  • Page 473: Ignition System

    Ignition system 8-2 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 34.Relay unit 43.Right handlebar switch 44.Start/engine stop switch 47.Neutral switch 106.Crankshaft position sensor 110.Lean angle sensor 115.Ecu (engine contr...

  • Page 474: Ignition System

    Ignition system 8-3 et3p61002 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the gear position ...

  • Page 475: Ignition System

    Ignition system 8-4 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar 5. Storage compartment 6. Side covers 7. Air filter case ng...

  • Page 476: Ignition System

    Ignition system 8-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the start/engine stop switch. Refer to “checking the switches” on page 8-259. • the start/engine stop switch is faulty. • replace the right handlebar switch. 9. Check the neutral switch. Refer to “checking the s...

  • Page 477: Ignition System

    Ignition system 8-6.

  • Page 478: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram p on off a press pull b br /l r r r r r /b r /b br b b b b b r r r r y r /w br /l br /l l /w g /y br br br g /y g /w r /w r /w y g b lg /b lg /b b b br g /w r /w b b l /w l /w l /w g /w g /y g /w y /b g /y y /w b...

  • Page 479: Electric Starting System

    Electric starting system 8-8 3. Main switch 4. Main fuse 5. Ycc-s motor control fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 29.Starter relay 30.Starter motor 31.Joint coupler 33.Brake light fuse 34.Relay unit 35.Starting circuit cut-off relay 40.Rear brake light switch...

  • Page 480: Electric Starting System

    Electric starting system 8-9 eas1md1001 starting circuit cut-off system operation if the start/engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “on” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open...

  • Page 481: Electric Starting System

    Electric starting system 8-10 3 17 18 19 1 2 4 5 6 7 8 8 8 10 9 a b 6 16 15 13 14 12 11 8 8 a. When the transmission is in neutral b. When the sidestand is up 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Signaling system fuse 6. Start/engine stop switch 7. Starting circuit cut-off rela...

  • Page 482: 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. Side cowlings 2. Front cowling assembly 3. Storage compartment 4. Fuel tank 5. T-bar 6. Throttle bodies ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ...

  • Page 483: Electric Starting System

    Electric starting system 8-12 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the brake light relay. Refer to “checking the re- lays” on page 8-267. Replace the brake light relay. 9. Check the brake switch relay. Refer to “checking the re- lays” on ...

  • Page 484: Electric Starting System

    Electric starting system 8-13 ng → ok ↓ 17.Check the entire starting system wiring. Refer to “circuit diagram” on page 8-7. Properly connect or replace the wire har- ness. Replace the mcu. Refer to “re- placing the mcu (motor control unit)” on page 8-174..

  • Page 485: Electric Starting System

    Electric starting system 8-14.

  • Page 486: Charging System

    Charging system 8-15 eas27200 charging system eas27210 circuit diagram a r b w ww r r b b b r r r b b a b a w ww b r (b) (gy) r r b b /g b /g b 1 2 4 26 27.

  • Page 487: Charging System

    Charging system 8-16 1. Ac magneto 2. Rectifier/regulator 4. Main fuse 26.Battery 27.Engine ground a. Wire harness b. Negative battery sub-wire harness.

  • Page 488: Charging System

    Charging system 8-17 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page ...

  • Page 489: Charging System

    Charging system 8-18.

  • Page 490: Lighting System

    Lighting system 8-19 eas27240 lighting system eas27250 circuit diagram p on off a pass br /r br /l r r r l /r l /r br /w r /g r r r /y g /l y /w r /w b b b r r r b l b bb b b l /r rr l /r l /r g y g y r /y r /w r /w br /l br /r l l /r l /r b b l /by g /l r /y gl /b yb g /l l /r l /r bb b b /l b /lb ...

  • Page 491: Lighting System

    Lighting system 8-20 3. Main switch 4. Main fuse 8. Hazard lighting fuse 11.Fuel injection system fuse 12.Backup fuse 14.Headlight fuse 16.Ignition fuse 21.Headlight relay (on/off) 26.Battery 27.Engine ground 31.Joint coupler 50.Left handlebar switch 53.Dimmer/pass switch 58.License plate light 59.T...

  • Page 492: Lighting System

    Lighting system 8-21 eas27260 troubleshooting any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tan...

  • Page 493: Lighting System

    Lighting system 8-22 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or replace the wire har- ness. Replace the ecu, meter assembly, or headlight assembly. Refer to “re- placing the ecu (engine control unit)” on page 8-264..

  • Page 494: Signaling System

    Signaling system 8-23 eas27270 signaling system eas27280 circuit diagram p on off a press pull b br /r br /l r r r r r /b r /b l /r br /w r /g r br br p b b b rr r r b y w gy br /w r /w r /w br /l br /l br /r g /y br br br g /y g /w y g b lg /b lg /b b b l yc h d g br g /w b b g /w g /y bw /bl /r w ...

  • Page 495: Signaling System

    Signaling system 8-24 3. Main switch 4. Main fuse 5. Ycc-s motor control fuse 8. Hazard lighting fuse 11.Fuel injection system fuse 12.Backup fuse 15.Abs ecu fuse 16.Ignition fuse 18.Signaling system fuse 23.Horn 26.Battery 27.Engine ground 31.Joint coupler 33.Brake light fuse 34.Relay unit 40.Rear ...

  • Page 496: Signaling System

    Signaling system 8-25 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. • the fuel meter fails to come on. • the speedometer fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Sid...

  • Page 497: Signaling System

    Signaling system 8-26 checking the signaling system the horn fails to sound. Ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the horn switch. Refer to “checking the switches” on page 8-259. • the horn switch is faulty. •...

  • Page 498: Signaling System

    Signaling system 8-27 the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the rear turn signal light bulbs and sockets. Refer to “checking the bulbs and ...

  • Page 499: Signaling System

    Signaling system 8-28 . Ng → ok ↓ the shift indicator fails to come on. Ng → ok ↓ ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter fails to come on. Ng → ok ↓ 3. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-23. Properly conn...

  • Page 500: Signaling System

    Signaling system 8-29 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ tip replace the wire harness if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white–white) (gray–gray) • between abs ecu coupler and ecu coupler. (blue/yellow–blue/yel...

  • Page 501: Signaling System

    Signaling system 8-30

  • Page 502: Cooling System

    Cooling system 8-31 eas27300 cooling system eas27310 circuit diagram p on off a br /l r r r br /w r l g /y br /b r /w r l b y /l l b b b b r r r r b /lb /l r /w r /w y /l br /l br /b b b b /lg /wg /w b /l g /y b /w b /w r /wb r/ w b /w b /w b /w a b a r br /l r br /l r r r r /w g /y br /b b l (b) (b...

  • Page 503: Cooling System

    Cooling system 8-32 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 19.Left radiator fan motor fuse 20.Right radiator fan motor fuse 22.Radiator fan motor relay 24.Right radiator fan motor 25.Left radiator fan motor 26.Battery 27.Engine ground 28.Cooling system fuse 31.Joi...

  • Page 504: Cooling System

    Cooling system 8-33 eas27320 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, cooling system, fuel ...

  • Page 505: Cooling System

    Cooling system 8-34 ng → ok ↓ 7. Check the entire cooling system wiring. Refer to “circuit diagram” on page 8-31. Properly connect or replace the wire har- ness. Replace the ecu. Refer to “replac- ing the ecu (engine control unit)” on page 8-264..

  • Page 506: Fuel Injection System

    Fuel injection system 8-35 eas27330 fuel injection system eas27340 circuit diagram p on off a b br /l r r r br /w br /w r /g r /g r y /w g /y r /w r /w b b b r r r w gy b w w gy b /lb /l b /l b /l b /l b /l b /l b /l b b p w b l b br /w r /w r /w br /l b b r /br /w b /r b /r sb sb sb sb r /b br /w r...

  • Page 507: Fuel Injection System

    Fuel injection system 8-36 3. Main switch 4. Main fuse 11.Fuel injection system fuse 12.Backup fuse 15.Abs ecu fuse 16.Ignition fuse 21.Headlight relay (on/off) 22.Radiator fan motor relay 26.Battery 27.Engine ground 31.Joint coupler 34.Relay unit 35.Starting circuit cut-off relay 36.Fuel pump relay...

  • Page 508: Fuel Injection System

    Fuel injection system 8-37 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 en- gine under substitute ch...

  • Page 509: Fuel Injection System

    Fuel injection system 8-38 eas1md1050 troubleshooting method (ecu) tip • if there is a malfunction in the fuel injection sys- tem, the windshield adjusting function “1” will be displayed in the function display, the engine trouble warning light “2” will come on, and a fault code number “3” will be d...

  • Page 510: Fuel Injection System

    Fuel injection system 8-39 the engine operation is not normal, but the engine trouble warning light does not come on. 1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “troubleshooting details (ecu)” on page 8-43. If a malfunction is detected in the senso...

  • Page 511: Fuel Injection System

    Fuel injection system 8-40 eas1md1045 diagnostic mode (ecu) setting the diagnostic mode 1. Turn the main switch to “off”. 2. Disconnect the wire harness coupler from the fuel pump. (except for electronically adjustable sus- pension system) 3. Shift the transmission into gear and extend the sidestand...

  • Page 512: Fuel Injection System

    Fuel injection system 8-41 • to increase the selected diagnostic code number, press the “tcs” button. Press the “tcs” button for 1 second or more to automatically increase the diagnostic code numbers. 8. Check the operation of the sensor or actuator. • sensor operation the data representing the oper...

  • Page 513: Fuel Injection System

    Fuel injection system 8-42 ecu/mcu using the communication cable, you can display information that is necessary for identifying malfunctions and for maintenance to display on the computer. The displayed information includes the sensor output data and information recorded in the ecu/mcu. Functions of...

  • Page 514: Fuel Injection System

    Fuel injection system 8-43 eas1md1051 troubleshooting details (ecu) this section describes the measures per fault code number displayed on the multi-function meter right display. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. Aft...

  • Page 515: Fuel Injection System

    Fuel injection system 8-44 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between cylinder identifica- tion sensor coupler and ecu coupler. White/black–white/black blue–blue between cylinder identifica- tion sensor coupler and joint coupler. Blue–blue black/blue–black...

  • Page 516: Fuel Injection System

    Fuel injection system 8-45 1 connection of crankshaft po- sition sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the ...

  • Page 517: Fuel Injection System

    Fuel injection system 8-46 fault code no. 13 item intake air pressure sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 03 meter display displays the intake air pressure. Procedure shift the transmission into gear, extend the side...

  • Page 518: Fuel Injection System

    Fuel injection system 8-47 tip if fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. 5 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the current altitude ...

  • Page 519: Fuel Injection System

    Fuel injection system 8-48 1 condition of intake air pres- sure sensor hose. Check the intake air pressure sensor hose condition. Clogged or detached hose → repair or replace the sen- sor hose. Start the engine and let it idle for approximately 5 seconds. Fault code number is not dis- played → servi...

  • Page 520: Fuel Injection System

    Fuel injection system 8-49 13 meter display throttle position sensor signal 2 • 9–23 (fully closed position) • 94–108 (fully open position) procedure • check with throttle valves fully closed. • check with throttle valves fully open. Item probable cause of mal- function and check maintenance job con...

  • Page 521: Fuel Injection System

    Fuel injection system 8-50 6 defective throttle position sensor. Check throttle position sen- sor signal 1. Execute the diagnostic mode. (code no. 01) when the throttle valves are fully closed: a value of 12–21 is indicat- ed. When throttle valves are fully open: a value of 97–106 is indicat- ed. Ch...

  • Page 522: Fuel Injection System

    Fuel injection system 8-51 1 connection of sidestand switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 523: Fuel Injection System

    Fuel injection system 8-52 fault code no. 20 item intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “on”, the intake air pres- sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Fail-safe system able to start engine able to drive ve...

  • Page 524: Fuel Injection System

    Fuel injection system 8-53 2 defective atmospheric pres- sure sensor. Execute the diagnostic mode. (code no. 02) when engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa (757.6 mmhg, 29.8 inhg) 3000 m (9800 ft) abo...

  • Page 525: Fuel Injection System

    Fuel injection system 8-54 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 526: Fuel Injection System

    Fuel injection system 8-55 fault code no. 22 item air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 05 meter display displays the air temperature. Procedure compare the actually measured air temperature with the me...

  • Page 527: Fuel Injection System

    Fuel injection system 8-56 5 defective air temperature sensor. Execute the diagnostic mode. (code no. 05) when engine is cold: displayed temperature is close to the ambient temper- ature. The displayed temperature is not close to the ambient tem- perature. → check the air temperature sensor. Replace...

  • Page 528: Fuel Injection System

    Fuel injection system 8-57 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between atmospheric pres- sure sensor coupler and ecu coupler. Pink–pink between atmospheric pres- sure sensor coupler and joint coupler. Blue–blue black/blue–black/blue between joint coupler an...

  • Page 529: Fuel Injection System

    Fuel injection system 8-58 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 probable cause of mal- function and check maintenance job confirmation ...

  • Page 530: Fuel Injection System

    Fuel injection system 8-59 5 check fuel pressure. Refer to “checking the fuel pressure” on page 7-10. Start the engine, warm it up, and then race it, or execute the diagnostic mode. (code no. 63) fault code number is not dis- played → service is finished. Fault code number is dis- played → go to ite...

  • Page 531: Fuel Injection System

    Fuel injection system 8-60 3 defective lean angle sensor. Execute the diagnostic mode. (code no. 08) replace if defective. Refer to “checking the lean angle sensor” on page 8-273. Turn the main switch to “on”, then to “off”, and then back to “on”. Fault code number is not dis- played → service is fi...

  • Page 532: Fuel Injection System

    Fuel injection system 8-61 4 installed condition of cylin- der-#1 ignition coil. Check for looseness or pinching. Improperly installed ignition coil → reinstall or replace the ignition coil. Start the engine and let it idle for approximately 5 seconds. Fault code number is not dis- played → service ...

  • Page 533: Fuel Injection System

    Fuel injection system 8-62 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 534: Fuel Injection System

    Fuel injection system 8-63 item probable cause of mal- function and check maintenance job confirmation of service completion 1 connection of cylinder-#3 ig- nition coil coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and lock...

  • Page 535: Fuel Injection System

    Fuel injection system 8-64 fault code no. 36 item cylinder-#4 ignition coil: open or short circuit detected in the primary lead of the cylinder-#4 ignition coil. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faul...

  • Page 536: Fuel Injection System

    Fuel injection system 8-65 6 malfunction in ecu. Execute the diagnostic mode. (code no. 33) no spark → replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-264. Fault code no. 39 item injector: open or short circuit detected. Fail-safe system able to start engine (depending ...

  • Page 537: Fuel Injection System

    Fuel injection system 8-66 2 connection of injector #1, #2, #3, and/or injector #4 coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or r...

  • Page 538: Fuel Injection System

    Fuel injection system 8-67 fault code no. 41 item lean angle sensor: open or short circuit detected. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 08 meter display lean angle sensor output voltage • 0.4–1.4 (upright) • 3.7–4.4 (overturned) procedure remove the l...

  • Page 539: Fuel Injection System

    Fuel injection system 8-68 5 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-264. Fault code no. 42 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B neutral switch: open or short circuit is detected. Fail-safe sy...

  • Page 540: Fuel Injection System

    Fuel injection system 8-69 4 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. Execute t...

  • Page 541: Fuel Injection System

    Fuel injection system 8-70 fault code no. 42 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B neutral switch: open or short circuit is detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 21 meter display neutral • “on” (when...

  • Page 542: Fuel Injection System

    Fuel injection system 8-71 5 defective relay unit. Check the relay unit. Refer to “checking the relay unit (diode)” on page 8-271. Execute the diagnostic mode. (code no. 21) when the transmission is in neutral: “on” when the transmission is not in neutral: “off” correct indication → go to item 9. In...

  • Page 543: Fuel Injection System

    Fuel injection system 8-72 fault code no. 43 item fuel system voltage: incorrect voltage supplied to the fuel in- jector and fuel pump. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 09, 50 09 meter display fuel system voltage (battery voltage) approximately 12.0 pro...

  • Page 544: Fuel Injection System

    Fuel injection system 8-73 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between relay unit coupler and joint coupler. Red/blue–red/blue between joint coupler and ecu coupler. Red/blue–red/blue between relay unit coupler and fuel injection system fuse. Brown/white–br...

  • Page 545: Fuel Injection System

    Fuel injection system 8-74 fault code no. 44 item eeprom fault code number: an error is detected while reading or writing on eeprom. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. 60 meter display eeprom fault code display • 00 (no history) • 01–04: cyl...

  • Page 546: Fuel Injection System

    Fuel injection system 8-75 3 “02” is indicated in diagnostic mode (code no. 60). Eep- rom data error for adjust- ment of co concentration of cylinder #2. Change the co concentra- tion of cylinder #2, and re- write in eeprom. Refer to “adjusting the exhaust gas volume” on page 3-10. After this adjust...

  • Page 547: Fuel Injection System

    Fuel injection system 8-76 7 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-264. Fault code no. 46 item charging voltage is abnormal. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item ...

  • Page 548: Fuel Injection System

    Fuel injection system 8-77 fault code no. 59 item accelerator position sensor: open or short circuit detected. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. 14, 15 14 meter display accelerator position sensor signal 1 • 12–22 (fully closed position) • ...

  • Page 549: Fuel Injection System

    Fuel injection system 8-78 5 accelerator position sensor resistance. Measure the accelerator po- sition sensor resistance. Black/blue–blue refer to “checking the accelerator position sensor” on page 8-278. Turn the main switch to “on”. Fault code number is not dis- played → service is finished. Faul...

  • Page 550: Fuel Injection System

    Fuel injection system 8-79 1 connection of throttle servo motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har...

  • Page 551: Fuel Injection System

    Fuel injection system 8-80 meter display front wheel speed pulse 0–999 procedure check that the number increases when the front wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped. Item probable cause of mal- function and check maintenance job confirmation of...

  • Page 552: Fuel Injection System

    Fuel injection system 8-81 4 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 553: Fuel Injection System

    Fuel injection system 8-82 9 delete the fault code. Turn the main switch to “on”, and then rotate the front wheel by hand. Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (19 mph). The fault code can also be deleted by activating the di- agnostic mode ...

  • Page 554: Fuel Injection System

    Fuel injection system 8-83 1 locate the malfunction. Check the engine trouble warning light, ycc-s sys- tem warning light, and elec- tronically adjustable suspension system warning light. — • all of the lights come on → go to item 2. • only the engine trouble warning light comes on → go to “abnormal...

  • Page 555: Fuel Injection System

    Fuel injection system 8-84 4 defective meter assembly. Replace the meter assembly. Turn the main switch to “on”. Fault code number is not dis- played → service is finished. Fault code number is dis- played → go to item 5. 5 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine con...

  • Page 556: Fuel Injection System

    Fuel injection system 8-85 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. Turn the ...

  • Page 557: Fuel Injection System

    Fuel injection system 8-86 1 locate the malfunction. Check the engine trouble warning light, ycc-s sys- tem warning light, and elec- tronically adjustable suspension system warning light. — • all of the lights come on → go to “abnormal meter as- sembly communication”. • only the engine trouble warni...

  • Page 558: Fuel Injection System

    Fuel injection system 8-87 tip observe the following precautions when executing the diagnostic mode. (code no. 84) • make sure that the battery has been sufficiently charged. • place the vehicle on the centerstand. • do not operate the electronically adjustable suspension system repeatedly. • after ...

  • Page 559: Fuel Injection System

    Fuel injection system 8-88.

  • Page 560: Cruise Control System

    Cruise control system 8-89 eas1mc1010 cruise control system eas1mc1011 circuit diagram p on off a press pull g g g up do wn res set br /l r r r r r /b r /b br /w r /g r br b b b rr r r r b r /w r /w br /l br /l g /y br br g /y g /w r /w y g b y /w lg /l lg /b lg /b lg /b b b y /w g /w y /b b b g /w ...

  • Page 561: Cruise Control System

    Cruise control system 8-90 3. Main switch 4. Main fuse 5. Ycc-s motor control fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 32.Cruise control system fuse 33.Brake light fuse 40.Rear brake light switch 41.Grip ...

  • Page 562: Cruise Control System

    Cruise control system 8-91 eas1mc1012 cruise control circuit operation 23 20 22 21 19 18 17 16 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4.

  • Page 563: Cruise Control System

    Cruise control system 8-92 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10. Cruise control power switch 11. Cruise control setting switch 12. Front brake light switch 13...

  • Page 564: Cruise Control System

    Cruise control system 8-93 eas1mc1014 basic instructions for troubleshooting warning ewa1mc1001 • perform the troubleshooting [a] → [b] → [c] in order. Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted. • use sufficiently charg...

  • Page 565: Cruise Control System

    Cruise control system 8-94 eas1mc1015 basic process for troubleshooting [a] [c-2] [b-4] [b-2] [b-1] [b-3] • • • [c-1] • comes on fails to come on flashes no no push the cruise control power switch, and check the cruise control system indicator light. Fault code number is not displayed. Explain the c...

  • Page 566: Cruise Control System

    Cruise control system 8-95 warning ewa1mc1005 when maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[c-2] final check” on page 8-105.) eas1mc1016 [a] checking the c...

  • Page 567: Cruise Control System

    Cruise control system 8-96 item probable cause of mal- function and check maintenance job confirmation of service completion 1 locate the malfunction. Execute the diagnostic mode. (code 82, 83) when the front brake is ap- plied: “on” when the front brake is not applied: “off” malfunction → go to ite...

  • Page 568: Cruise Control System

    Cruise control system 8-97 6 check the fuse. (signaling system fuse, brake light fuse) abnormality → replace the fuse. (signaling system fuse, brake light fuse) turn the main switch to “on”. Operate the brake lever. Fault code number is not dis- played → service is finished. Fault code number is dis...

  • Page 569: Cruise Control System

    Cruise control system 8-98 meter display “on” (when the brakes are applied) “off” (when the brakes are not applied) procedure operate the brake pedal. Item probable cause of mal- function and check maintenance job confirmation of service completion 1 locate the malfunction. Execute the diagnostic mo...

  • Page 570: Cruise Control System

    Cruise control system 8-99 6 check the fuse. (signaling system fuse, brake light fuse) abnormality → replace the fuse. (signaling system fuse, brake light fuse) turn the main switch to “on”. Operate the brake pedal. Fault code number is not dis- played → service is finished. Fault code number is dis...

  • Page 571: Cruise Control System

    Cruise control system 8-100 fault code no. 91 item a cruise control setting switch “res+”: open or short circuit is detected. B cruise control setting switch “set–”: open or short circuit is de- tected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 80, 81 meter disp...

  • Page 572: Cruise Control System

    Cruise control system 8-101 4 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. Turn the...

  • Page 573: Cruise Control System

    Cruise control system 8-102 8 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-264. Fault code no. 91 item a cruise control setting switch “res+”: open or short circuit is de- tected. B cruise control setting switch “set–”: open or short circuit is de...

  • Page 574: Cruise Control System

    Cruise control system 8-103 3 connection of main switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. ...

  • Page 575: Cruise Control System

    Cruise control system 8-104 eas1mc1018 [b-2] diagnosis using the malfunction history codes execute the diagnostic mode (code no. 61) to check the malfunction history. • refer to “diagnostic mode (ecu)” on page 8-40. • malfunction history is displayed in the multi-function meter unit right display. [...

  • Page 576: Cruise Control System

    Cruise control system 8-105 eas1mc1020 [b-4] malfunction history is not displayed use the yamaha diagnostic tool to check whether automatic deactivation history for the cruise control system exists. 1. There is automatic deactivation history for the cruise control system. • explain the conditions fo...

  • Page 577: Cruise Control System

    Cruise control system 8-106.

  • Page 578: Fuel Pump System

    Fuel pump system 8-107 eas27550 fuel pump system eas27560 circuit diagram p on off a br /l r r r br /w br /w r b b b r r r r /w r /w br /l b b r /br /w r /b br /w r /l l /y b b b r /l l /y b /w b /w r /wb r/ w b /w b /w b /w a b a r br /l r br /l r r r /b b r /w w /l r /b r /w w /l b r /l b (dg) br ...

  • Page 579: Fuel Pump System

    Fuel pump system 8-108 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 34.Relay unit 36.Fuel pump relay 43.Right handlebar switch 44.Start/engine stop switch 97.Fuel pump 115.Ecu (engine control unit) a. Wire harness b. Negative...

  • Page 580: Fuel Pump System

    Fuel pump system 8-109 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (m...

  • Page 581: Fuel Pump System

    Fuel pump system 8-110

  • Page 582: Windshield Drive System

    Windshield drive system 8-111 eas27610 windshield drive system eas27620 circuit diagram p on off a menu f f br /l r r r r /g r br b b b r r r br /g r /w br /l br /l br /l b b w /lw /gw /rb /w br br br /g br br rr br /g br r b p /w b p /b b b /l b /l b /w b /w b /w b /w w /l w /g w /r r /g r /g r /g ...

  • Page 583: Windshield Drive System

    Windshield drive system 8-112 3. Main switch 4. Main fuse 7. Windshield drive system fuse 12.Backup fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 37.Windshield drive unit 38.Windshield drive unit relay (down) 39.Windshield drive unit relay (up) 50.Left h...

  • Page 584: Windshield Drive System

    Windshield drive system 8-113 eas27630 troubleshooting the windshield fails to move. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check that there are no rocks or o...

  • Page 585: Windshield Drive System

    Windshield drive system 8-114 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the windshield drive unit re- lay (up). Refer to “checking the re- lays” on page 8-267. Replace the windshield drive unit relay (up). 9. Check the windshield drive unit re- lay (down). Refer to “checking the re- lays” on ...

  • Page 586: Accessory Box System

    Accessory box system 8-115 et3p61009 accessory box system et3p61010 circuit diagram p on off a c c br /l r r r br b b b r r r b b b br br br br /l b b bb a b d a a c r br /l r br /l r r br b (b) b /l bb b b b b /g b /g b bb r b br 3 4 18 26 27 68 31.

  • Page 587: Accessory Box System

    Accessory box system 8-116 3. Main switch 4. Main fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 68.Accessory box solenoid a. Wire harness b. Negative battery sub-wire harness d. Accessory box sub-lead.

  • Page 588: Accessory Box System

    Accessory box system 8-117 et3p61012 troubleshooting the accessory box fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Left side cowling 3. Fuel tank 4. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and s...

  • Page 589: Accessory Box System

    Accessory box system 8-118.

  • Page 590: Immobilizer System

    Immobilizer system 8-119 eas27640 immobilizer system eas27650 circuit diagram p on off a br /l r r r br /w r /g r /g r b b b r r r y /ly /l r /w r /w br /l b b b b /l b /lb /w b /w b /w r /g r /g r /g r /w g /b l /b l /r b /w b /w l /r l /r l /bl /b l /r l /b b /w b /w r /wr /w y /l r /wb r/ w r /g ...

  • Page 591: Immobilizer System

    Immobilizer system 8-120 3. Main switch 4. Main fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 76.Meter assembly 77.Multi-function meter 79.Immobilizer system indicator light 99.Immobilizer unit 100.Yamaha diagnostic tool connector 115...

  • Page 592: Immobilizer System

    Immobilizer system 8-121 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 593: Immobilizer System

    Immobilizer system 8-122 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with...

  • Page 594: Immobilizer System

    Immobilizer system 8-123 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Tip do not start the engine with a standar...

  • Page 595: Immobilizer System

    Immobilizer system 8-124 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost st...

  • Page 596: Immobilizer System

    Immobilizer system 8-125 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, fuel injection sys- tem, and backup) refer to “checking the fus-...

  • Page 597: Immobilizer System

    Immobilizer system 8-126 eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number is indicated in the multi-function meter right display and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code...

  • Page 598: Immobilizer System

    Immobilizer system 8-127 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 55 immobilizer unit key code registra- tion malfunction. Same stand...

  • Page 599: Immobilizer System

    Immobilizer system 8-128.

  • Page 600: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 eas28790 abs (anti-lock brake system) eas27730 circuit diagram p on off a a press pull br /l r r r br /w r /g r r br b b b r r r r b y y w gy b w w gy r /l br /w r /w r /w r /w br /l br /l b /g l /w g /y br br br g /y g /w r /w r /w y g b lg /b lg /b b b l y br g /...

  • Page 601: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 3. Main switch 4. Main fuse 9. Abs motor fuse 10.Abs solenoid fuse 11.Fuel injection system fuse 12.Backup fuse 15.Abs ecu fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 29.Starter relay 31.Joint coupler 33.Brake light fuse 40.Rear brake...

  • Page 602: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 eas27740 abs components chart 6 4,5 7 11 10 12,13 14 15 1 11 2 3 6 a a 7 8 9 1. Abs test coupler 2. Abs warning light 3. Abs ecu fuse 4. Abs solenoid fuse 5. Abs motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9. Rear wheel sensor ...

  • Page 603: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132.

  • Page 604: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 eas27750 abs coupler location chart b/w l/r l/b sb w b w gy gy w w gy r/w w/l w/g w/r g/w l/r l/b g/b g/r r/g r/g r/g ch br/b br/w br/b br/w b/r l/w y/w b/y p/w p/b br/y w/y w/b b/w b/w p dg sb/w y w w b g/w l/w w/y l/b b/w gy w g/r l/r y w/l g/y sb br/w b/w b/g r ...

  • Page 605: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 1. Meter assembly coupler 2. Abs test coupler 3. Rear wheel sensor coupler 4. Abs ecu coupler 5. Front wheel sensor coupler.

  • Page 606: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler connection...

  • Page 607: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 tip the abs performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned to “on”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even sligh...

  • Page 608: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 eas27810 basic process for troubleshooting [a] [a-4] [b-1] [c-3] [a-1] [a-2] [a-3] [b-3] [b-2] • • • • • • • • • • • • • • • • • • • [c-1] [c-2] comes on fails to come on yes yes yes no no flashes yes yes cannot delete ok no no turn the main switch to “on”, and che...

  • Page 609: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138 warning ewa1mc1004 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[c-3] final check” on page 8-164.) eas27830 [a] checking the abs warning l...

  • Page 610: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 • if the t/c terminal is not short-circuited to the ground, check the internal circuit of the meter assem- bly. Turn the main switch to “off”. Disconnect the abs ecu coupler and check that the abs warning light comes on when the main switch is turned to “on”. If th...

  • Page 611: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 eas1mc1005 [b-1] a fault code number is not displayed in the multi-function meter right display 1. The abs warning light remains on. A malfunction is detected. [b-2] 2. The abs warning light flashes every 0.5 second for more than 6 seconds. A malfunction is not det...

  • Page 612: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 • if the abs warning light does not come on, the abs ecu is defective. Replace the hydraulic unit assembly. 7. The hydraulic unit assembly is defective. Eas1mc1029 [b-3] diagnosis using the fault codes connect the test coupler adapter to the abs test coupler, and t...

  • Page 613: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 abs_22 start switch signal is not received prop- erly (start switch circuit or start switch monitor circuit). • wire harness • connection of the relay unit coupler and abs ecu coupler. Abs_23 brake light signal is not received prop- erly when main switch is turned ...

  • Page 614: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-143 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the centerstand). Tip fault code num...

  • Page 615: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-144 tip with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). Fault code no. Abs_11 abs_25 symptom front wheel sensor signal is not received prop- erly. Orde...

  • Page 616: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-145 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_13 abs_26 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job 1 installed condition of wheel sensor. Check for looseness....

  • Page 617: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-146 tip vehicle possibly ridden on uneven roads. 5 hydraulic unit assembly internal mal- function. Replace the hydraulic unit assembly. Fault code no. Abs_15 symptom no continuity in the front wheel sensor circuit. Order item/components and probable cause check or main...

  • Page 618: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-147 3 defective wheel sensor. If the above items were performed and no malfunc- tions were found, connect the abs ecu coupler and front wheel sensor coupler, and then delete the fault codes. If fault code number “abs_15” could not be deleted, the front wheel sensor is ...

  • Page 619: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-148 2 wire harness continuity. • check for continuity between the gray terminal “1” and the gray terminal “3” and between the white terminal “2” and the white terminal “4”. • if there is no continuity, the wire harness is defec- tive. Replace the wire harness. • check ...

  • Page 620: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-149 2 foreign material inside sensor hous- ing. Check the interior of the sensor housing and the surface of the sensor rotor for foreign material, such as metal particles. Clean the sensor housing and sensor rotor if necessary. Refer to “maintenance of the front wheel ...

  • Page 621: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-150 2 connections • starter relay coupler • abs ecu coupler • right handlebar switch coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, replace the wire harness and connect the cou...

  • Page 622: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-151 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and brake light relay coupler. (yellow–yellow) • between rear brake light switch coupler and brake switch relay coupler. (green/white–green/white) • b...

  • Page 623: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-152 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and brake light relay coupler. (yellow–yellow) • between rear brake light switch coupler and brake switch relay coupler. (green/white–green/white) • b...

  • Page 624: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-153 fault code no. Abs_32 symptom hydraulic unit solenoid relay is short-circuited. Order item/components and probable cause check or maintenance job 1 short circuit in solenoid relay. Replace the hydraulic unit assembly. 2 hydraulic unit assembly internal mal- functio...

  • Page 625: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-154 fault code no. Abs_41 symptom front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the abs ecu to release the hydraulic pressure (when the battery voltage is normal) order item/components and probable caus...

  • Page 626: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-155 warning ewa3p6d006 the front brakes will not function properly if the connections are reversed. • brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder • brake pipe/upper joint assembly “3” and brake pipe “4” outlet: t...

  • Page 627: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-156 warning ewa3p6d007 the rear brake will not function properly if the connections are reversed. • brake pipe/middle joint assembly “1” and brake hose “2” inlet: from the rear brake master cyl- inder • brake pipe “3” outlet: to the proportioning valve • brake pipe “4”...

  • Page 628: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-157 • if the brake pipes (to the proportioning valve and the metering valve) are switched during assembly, the brakes will continue to operate as normal. However, the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be rever...

  • Page 629: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-158 fault code no. Abs_51 abs_52 symptom power voltage is too high. Order item/components and probable cause check or maintenance job 1 battery voltage replace the battery. Refer to “checking and charging the bat- tery” on page 8-264. 2 disconnected battery terminal (f...

  • Page 630: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-159 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and abs ecu fuse. (brown/white–brown/white) • between abs ecu coupler and abs solenoid fuse. (red/white–red/white) • between abs ecu coupler and joint...

  • Page 631: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-160 2 short circuit in front wheel sensor lead. • check that there is no short circuit between the white terminal “3” and the gray terminal “4”. • check that there is no short circuit between the frame ground and the white terminal “3”. • if there is a short circuit, t...

  • Page 632: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-161 2 short circuit in rear wheel sensor lead. • check that there is no short circuit between the white terminal “3” and the gray terminal “4”. • check that there is no short circuit between the frame ground and the white terminal “3”. • if there is a short circuit, th...

  • Page 633: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-162 eas1mc1007 [c-1] deleting the fault codes 1. Check: • engine stop due to sidestand operation warning ewa1mc1021 • make sure to elevate the rear wheel. • make sure that there are no persons or ob- jects in front of the vehicle. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 634: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-163 5. Check: • abs ecu voltage lower than 12.8 v → charge or replace the battery. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the abs ecu coupler. B. Measure the abs ecu voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 635: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-164 b. Shift the transmission into gear and extend the sidestand. C. Push the “ ” side of the start/engine stop switch. D. Measure the abs ecu voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. If the above-mentioned checks are within specification, replace ...

  • Page 636: Grip Warmer System

    Grip warmer system 8-165 et3p66016 grip warmer system et3p66017 circuit diagram p on off a menu br /l r r r br /w r /g r b b b r r r r /w r /w br /l b b w /lw /gw /rb /w b b /l b /l b /w b /w b /w b /w w /l w /g w /r r /g r /g r /g r /w l /b l /r l /r l /r l /bl /b l /r l /b y /ry /ry yb bb b b /w b...

  • Page 637: Grip Warmer System

    Grip warmer system 8-166 3. Main switch 4. Main fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 50.Left handlebar switch 55.Menu switch 56.Select switch 76.Meter assembly 77.Multi-function meter 83.Engine trouble warning light 115.Ecu (...

  • Page 638: Grip Warmer System

    Grip warmer system 8-167 et3p66019 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Lower center cover 3. Fuel tank 4. T-bar the grip warmers do not become warm at all. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. C...

  • Page 639: Grip Warmer System

    Grip warmer system 8-168 the grip warmers are abnormally hot while the engine is idling. Ng → ok ↓ the grip warmers do not become very warm while the vehicle is traveling. Ng → ok ↓ ng → ok ↓ the temperature levels of the grip warmer settings cannot be changed. Ng → ok ↓ ng → ok ↓ 1. Check that the ...

  • Page 640: 8-169

    Ycc-s (yamaha chip controlled-shift) system 8-169 eas1md1002 ycc-s (yamaha chip controlled-shift) system eas1md1003 circuit diagram p on off a press pull h h h h g g g up do wn br /l r r r r r /b r /b br /w r /g r br b b b rr r r y b /lb /l br /w r /w r /w br /l br /l g /y br br br g /y g /w y g b l...

  • Page 641: 8-170

    Ycc-s (yamaha chip controlled-shift) system 8-170 3. Main switch 4. Main fuse 5. Ycc-s motor control fuse 11.Fuel injection system fuse 12.Backup fuse 15.Abs ecu fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 33.Brake light fuse 34.Relay unit 35.Starting ...

  • Page 642: 8-171

    Ycc-s (yamaha chip controlled-shift) system 8-171 eas1md1058 troubleshooting • the stop mode function indicator light fails to come on. • the transmission gear display on the right multi-function meter right display fails to indicate the select- ed gear. Tip • before troubleshooting, remove the foll...

  • Page 643: 8-172

    Ycc-s (yamaha chip controlled-shift) system 8-172 checking the ycc-s system indication of stop mode function indicator light does not change (indicator light does not come on or go off). 1. Check whether “err” is displayed in the multi-function meter center display. If “err” is displayed, refer to t...

  • Page 644: 8-173

    Ycc-s (yamaha chip controlled-shift) system 8-173 ng → ok ↓ transmission gear indicated in the multi-function meter right display does not match the actual selected gear. 1. Check whether “err” is displayed in the multi-function meter center display. • if “err” is displayed, refer to the troubleshoo...

  • Page 645: 8-174

    Ycc-s (yamaha chip controlled-shift) system 8-174 ng → ok ↓ cannot shift using the hand shift switch. If mcu fault code no. Sh_ _38 is displayed together with another mcu fault code number, repair the malfunction for that fault code number first. Then, repair the malfunction for fault code no. Sh_ _...

  • Page 646: 8-175

    Ycc-s (yamaha chip controlled-shift) system 8-175 eas1md1005 mcu (motor control unit) self-diagnostic function the mcu (motor control unit) is equipped with a self-diagnostic function in order to ensure that the ycc-s system is operating normally. If this function detects a malfunction in the ycc-s ...

  • Page 647: 8-176

    Ycc-s (yamaha chip controlled-shift) system 8-176 eas1md1019 troubleshooting method tip • if there is a malfunction in the ycc-s system, the windshield adjusting function “1” will be dis- played in the function display, the ycc-s sys- tem warning light “2” will come on, and a fault code number “3” w...

  • Page 648: 8-177

    Ycc-s (yamaha chip controlled-shift) system 8-177 eas1md1026 basic instructions for the diagnostic function for information about setting the diagnostic mode, refer to “diagnostic mode (ecu)” on page 8-40. For information about using the yamaha diagnostic tool, refer to “yamaha diagnostic tool” on p...

  • Page 649: 8-178

    Ycc-s (yamaha chip controlled-shift) system 8-178 fault code no. Sh_ _12 item malfunction of power cut-off function in the mcu (motor con- trol unit). Fail-safe system unable to start unable to change the shift diagnostic code no. — meter display — procedure — item probable cause of mal- function an...

  • Page 650: 8-179

    Ycc-s (yamaha chip controlled-shift) system 8-179 1 connection of clutch actua- tor motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ...

  • Page 651: 8-180

    Ycc-s (yamaha chip controlled-shift) system 8-180 3 wire harness continuity. Short circuit → replace the wire harness. Between mcu coupler and clutch actuator motor cou- pler. Black/white–black/white red/white–red/white check the indication of the shift down indicator light when the clutch is engage...

  • Page 652: 8-181

    Ycc-s (yamaha chip controlled-shift) system 8-181 tip *1 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 5 defective clutch actuator. Replace the cl...

  • Page 653: 8-182

    Ycc-s (yamaha chip controlled-shift) system 8-182 1 connection of shift actuator motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly ...

  • Page 654: 8-183

    Ycc-s (yamaha chip controlled-shift) system 8-183 tip *2 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _64”. Sh_ _11, sh_ _12, sh_ _14, sh_ _15, sh_ _16, sh_ _18, sh_ _19, sh_ _25, sh_ _37, and sh_ _51 4 stuck shift actuator. Check whether the shift actu...

  • Page 655: 8-184

    Ycc-s (yamaha chip controlled-shift) system 8-184 meter display sh_ _63 engagement position: shift down indicator light comes on disengagement position: shift down indicator light goes off other position: shift down indicator light will flash sh_ _64 correct shifting: shift down indicator light come...

  • Page 656: 8-185

    Ycc-s (yamaha chip controlled-shift) system 8-185 3 connection of mcu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 657: 8-186

    Ycc-s (yamaha chip controlled-shift) system 8-186 4 wire harness continuity. Open or short circuit → re- place the wire harness. Between positive battery ter- minal and ycc-s motor con- trol fuse. Red–red check the operation of the clutch actuator motor and shift actuator motor. • checking the clutc...

  • Page 658: 8-187

    Ycc-s (yamaha chip controlled-shift) system 8-187 5 wire harness continuity. Open or short circuit → re- place the wire harness. Between ycc-s motor con- trol fuse and mcu coupler. Red/black–red/black check the operation of the clutch actuator motor and shift actuator motor. • checking the clutch ac...

  • Page 659: 8-188

    Ycc-s (yamaha chip controlled-shift) system 8-188 6 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and shift actuator motor coupler. Black/blue–black/blue red–red check the operation of the clutch actuator motor and shift actuator motor. • checking t...

  • Page 660: 8-189

    Ycc-s (yamaha chip controlled-shift) system 8-189 7 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and clutch actuator motor cou- pler. Black/white–black/white red/white–red/white check the operation of the clutch actuator motor and shift actuator mo...

  • Page 661: 8-190

    Ycc-s (yamaha chip controlled-shift) system 8-190 8 check the ycc-s motor con- trol fuse. Abnormality → replace the ycc-s motor control fuse. Check the operation of the clutch actuator motor and shift actuator motor. • checking the clutch actua- tor motor check the indication of the shift down indic...

  • Page 662: 8-191

    Ycc-s (yamaha chip controlled-shift) system 8-191 9 defective clutch actuator or shift actuator. Replace the clutch actuator or shift actuator. Refer to “clutch” on page 5-44 and “shift actua- tor and shift rod” on page 5-61. Check the operation of the clutch actuator motor and shift actuator motor....

  • Page 663: 8-192

    Ycc-s (yamaha chip controlled-shift) system 8-192 tip *1 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 *2 : if any of the following fault codes ar...

  • Page 664: 8-193

    Ycc-s (yamaha chip controlled-shift) system 8-193 2 connection of clutch actua- tor motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ...

  • Page 665: 8-194

    Ycc-s (yamaha chip controlled-shift) system 8-194 3 connection of mcu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 666: 8-195

    Ycc-s (yamaha chip controlled-shift) system 8-195 4 wire harness continuity. Open or short circuit → re- place the wire harness. Between positive battery ter- minal and ycc-s motor con- trol fuse. Red–red check the operation of the clutch actuator motor and shift actuator motor. • checking the clutc...

  • Page 667: 8-196

    Ycc-s (yamaha chip controlled-shift) system 8-196 5 wire harness continuity. Open or short circuit → re- place the wire harness. Between ycc-s motor con- trol fuse and mcu coupler. Red/black–red/black check the operation of the clutch actuator motor and shift actuator motor. • checking the clutch ac...

  • Page 668: 8-197

    Ycc-s (yamaha chip controlled-shift) system 8-197 6 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and shift actuator motor coupler. Black/blue–black/blue red–red check the operation of the clutch actuator motor and shift actuator motor. • checking t...

  • Page 669: 8-198

    Ycc-s (yamaha chip controlled-shift) system 8-198 7 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and clutch actuator motor cou- pler. Black/white–black/white red/white–red/white check the operation of the clutch actuator motor and shift actuator mo...

  • Page 670: 8-199

    Ycc-s (yamaha chip controlled-shift) system 8-199 8 check the ycc-s motor con- trol fuse. Abnormality → replace the ycc-s motor control fuse. Check the operation of the clutch actuator motor and shift actuator motor. • checking the clutch actua- tor motor check the indication of the shift down indic...

  • Page 671: 8-200

    Ycc-s (yamaha chip controlled-shift) system 8-200 9 defective clutch actuator or shift actuator. Replace the clutch actuator or shift actuator. Refer to “clutch” on page 5-44 and “shift actua- tor and shift rod” on page 5-61. Check the operation of the clutch actuator motor and shift actuator motor....

  • Page 672: 8-201

    Ycc-s (yamaha chip controlled-shift) system 8-201 tip *1 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 *2 : if any of the following fault codes ar...

  • Page 673: 8-202

    Ycc-s (yamaha chip controlled-shift) system 8-202 2 connection of mcu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 674: 8-203

    Ycc-s (yamaha chip controlled-shift) system 8-203 tip *1 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 4 stuck clutch actuator. Check whether the ...

  • Page 675: 8-204

    Ycc-s (yamaha chip controlled-shift) system 8-204 fault code no. Sh_ _18 item detected shift actuator position is incorrect. Fail-safe system unable to start unable to change the shift diagnostic code no. Sh_ _64 *2 meter display correct shifting: shift down indicator light comes on incorrect shifti...

  • Page 676: 8-205

    Ycc-s (yamaha chip controlled-shift) system 8-205 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and shift actuator motor coupler. Black/blue–black/blue red–red check the indication of the shift down indicator light when the transmission is shifted...

  • Page 677: 8-206

    Ycc-s (yamaha chip controlled-shift) system 8-206 tip *2 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _64”. Sh_ _11, sh_ _12, sh_ _14, sh_ _15, sh_ _16, sh_ _18, sh_ _19, sh_ _25, sh_ _37, and sh_ _51 fault code no. Sh_ _19 item shift actuator sensor: o...

  • Page 678: 8-207

    Ycc-s (yamaha chip controlled-shift) system 8-207 4 defective shift actuator sen- sor. 1. Measure the resistance of the shift actuator sensor. Refer to “checking the shift actuator sensor” on page 5-65. Specified resistance: 3.5– 6.5 k Ω out of specification → re- place the shift actuator. Turn the ...

  • Page 679: 8-208

    Ycc-s (yamaha chip controlled-shift) system 8-208 1 locate the malfunction. Check whether “err” is dis- played in the multi-function meter center display. “err” is displayed → refer to the troubleshooting when “err” is displayed in “trou- bleshooting details (ecu)”. “err” is not displayed → re- fer ...

  • Page 680: 8-209

    Ycc-s (yamaha chip controlled-shift) system 8-209 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and gear position sensor coupler. Yellow–yellow blue–blue black/blue–black/blue turn the main switch to “on”. Fault code number is not dis- played → se...

  • Page 681: 8-210

    Ycc-s (yamaha chip controlled-shift) system 8-210 1 connection of foot shift sen- sor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly o...

  • Page 682: 8-211

    Ycc-s (yamaha chip controlled-shift) system 8-211 5 installed condition of foot shift sensor. Refer to “adjusting the foot shift sensor” on page 5-64. Specified output voltage: 2.4–2.6 v out of specification → adjust the foot shift sensor again, or replace the sensor. Turn the main switch to “on”. F...

  • Page 683: 8-212

    Ycc-s (yamaha chip controlled-shift) system 8-212 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and joint coupler. Blue/green–blue/green between joint coupler and sidestand switch coupler. Blue/green–blue/green turn the main switch to “on”, and th...

  • Page 684: 8-213

    Ycc-s (yamaha chip controlled-shift) system 8-213 fault code no. Sh_ _26 item abnormal clutch movement is detected during check when main switch is turned to “on”. Fail-safe system unable to start unable to change the shift diagnostic code no. — meter display — procedure — item probable cause of mal...

  • Page 685: 8-214

    Ycc-s (yamaha chip controlled-shift) system 8-214 5 defective clutch actuator. Replace the clutch actuator. Refer to “clutch” on page 5-44. Turn the main switch to “off”. Move the shift rod by hand to shift the transmission into neutral, and then turn the main switch to “on”. Fault code number is no...

  • Page 686: 8-215

    Ycc-s (yamaha chip controlled-shift) system 8-215 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and ecu coupler. Yellow/black–yellow/black start the engine and let it run at idle. Fault code number is not dis- played → service is finished. Fault c...

  • Page 687: 8-216

    Ycc-s (yamaha chip controlled-shift) system 8-216 3 connection of mcu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 688: 8-217

    Ycc-s (yamaha chip controlled-shift) system 8-217 1 connection of right handle- bar switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure-...

  • Page 689: 8-218

    Ycc-s (yamaha chip controlled-shift) system 8-218 6 wire harness continuity. Short circuit → replace the wire harness. Between ycc-s control re- lay coupler and relay unit (starting circuit cut-off relay) coupler. Blue/red–blue/red turn the main switch to “on”, and then apply the front or rear brake...

  • Page 690: 8-219

    Ycc-s (yamaha chip controlled-shift) system 8-219 1 connection of clutch actua- tor sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure-...

  • Page 691: 8-220

    Ycc-s (yamaha chip controlled-shift) system 8-220 4 defective clutch actuator sensor. 1. Measure the resistance of the clutch actuator sen- sor. Refer to “checking the clutch actua- tor sensor” on page 5-55. Specified resistance: 1.75–3.25 k Ω out of specification → re- place the clutch actuator. Tu...

  • Page 692: 8-221

    Ycc-s (yamaha chip controlled-shift) system 8-221 2 connection of clutch actua- tor motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ...

  • Page 693: 8-222

    Ycc-s (yamaha chip controlled-shift) system 8-222 1 connection of hand shift le- ver switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure...

  • Page 694: 8-223

    Ycc-s (yamaha chip controlled-shift) system 8-223 fault code no. Sh_ _41 item coolant temperature sensor: open or short circuit detected. Fail-safe system able to start able to change the shift diagnostic code no. — meter display — procedure — item probable cause of mal- function and check maintenan...

  • Page 695: 8-224

    Ycc-s (yamaha chip controlled-shift) system 8-224 3 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 696: 8-225

    Ycc-s (yamaha chip controlled-shift) system 8-225 1 locate the malfunction. Abs fault code number is displayed → refer to “[b-3] diagnosis using the fault codes” on page 8-141. Other fault code number is displayed → go to item 2. — 2 connection of abs ecu coupler. Check the locking condition of the ...

  • Page 697: 8-226

    Ycc-s (yamaha chip controlled-shift) system 8-226 tip *1 : if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 item probable cause of mal- function and ch...

  • Page 698: 8-227

    Ycc-s (yamaha chip controlled-shift) system 8-227 item probable cause of mal- function and check maintenance job confirmation of service completion 1 installed condition of gear position sensor. Refer to “adjusting the gear position sen- sor” on page 5-11. Sensor output voltage when neutral indicato...

  • Page 699: 8-228

    Ycc-s (yamaha chip controlled-shift) system 8-228 tip *1:if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _63”. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 *2:if any of the following fault codes are de...

  • Page 700: 8-229

    Ycc-s (yamaha chip controlled-shift) system 8-229 1 locate the malfunction. If fuel injection system fault code no. 12 is displayed → perform the checks and maintenance jobs for fault code no. 12. Refer to “fuel injection system” on page 8-35. — if fault code no. Sh_ _31 is displayed (malfunction in...

  • Page 701: 8-230

    Ycc-s (yamaha chip controlled-shift) system 8-230 6 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and ecu coupler. Yellow/black–yellow/black malfunction is repaired → service is finished. Malfunction could not be found → go to item 7. 7 defective ge...

  • Page 702: 8-231

    Ycc-s (yamaha chip controlled-shift) system 8-231 diagnostic code no. — meter display — procedure — item probable cause of mal- function and check maintenance job confirmation of service completion 1 refer to the information for cruise control system fault code no. 90. Refer to “[b-1] diagnosis usin...

  • Page 703: 8-232

    Ycc-s (yamaha chip controlled-shift) system 8-232 3 connection of throttle servo motor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly ...

  • Page 704: 8-233

    Ycc-s (yamaha chip controlled-shift) system 8-233 fault code no. Sh_ _49 item engine speed is too high when vehicle is started. Fail-safe system able to start able to change the shift diagnostic code no. Sh_ _65 *3 meter display sh_ _65 no reading error: the shift down indicator light comes on for 0...

  • Page 705: 8-234

    Ycc-s (yamaha chip controlled-shift) system 8-234 tip *3:if any of the following fault codes are detected, do not execute the diagnostic mode “sh_ _65”. Sh_ _11, sh_ _12, sh_ _13, sh_ _14, sh_ _15, sh_ _16, sh_ _17, sh_ _18, sh_ _19, sh_ _21, sh_ _25, sh_ _26, sh_ _32, sh_ _36, sh_ _37, sh_ _44, sh_...

  • Page 706: 8-235

    Ycc-s (yamaha chip controlled-shift) system 8-235 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between mcu coupler and shift actuator sensor coupler. Green/yellow–green/yellow between mcu coupler and joint coupler. Blue–blue black/blue–black/blue between joint coupl...

  • Page 707: 8-236

    Ycc-s (yamaha chip controlled-shift) system 8-236 1 connection of mcu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 708: 8-237

    Electronically adjustable suspension system 8-237 eas1md1008 electronically adjustable suspension system eas1md1009 circuit diagram p on off a d d d d e e e e br /l r r r r br /l br /w r /g r b b b rr r r r /w r /w br /l b b b b /l b /lb /w b /w b /w r /g r /g r /g r /w l /b l /r l /r l /r l /r l /b...

  • Page 709: 8-238

    Electronically adjustable suspension system 8-238 3. Main switch 4. Main fuse 6. Scu fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 71.Scu (suspension control unit) 72.Left front fork stepping motor 73.Right front fork stepping motor 7...

  • Page 710: 8-239

    Electronically adjustable suspension system 8-239 eas1md1053 maintenance of the scu (suspension control unit) checking the scu (suspension control unit) 1. Check: • terminals “1” of the scu cracks/damages → replace the scu. • terminals “2” of the scu couplers connection defective, contaminated, come...

  • Page 711: 8-240

    Electronically adjustable suspension system 8-240 eas1md1024 troubleshooting method (scu) tip • if there is a malfunction in the electronically ad- justable suspension system, the damping force adjusting function “1” will be displayed in the function display, the electronically adjust- able suspensi...

  • Page 712: 8-241

    Electronically adjustable suspension system 8-241 eas1md1010 basic instructions for diagnostic function for information about setting the diagnostic mode, refer to “diagnostic mode (ecu)” on page 8-40. Eas1md1025 troubleshooting details (scu) this section describes the measures per fault code number...

  • Page 713: 8-242

    Electronically adjustable suspension system 8-242 2 locate the faulty data (pre- load adjustment) in the scu. Turn the main switch to “off”. Execute the diagnostic mode. (code no. 84) turn the main switch to “on”. Fault code number is not dis- played → service is finished. Fault code number is dis- ...

  • Page 714: 8-243

    Electronically adjustable suspension system 8-243 tip if a fault code number other than fault code no. 50 is displayed, repair the malfunction for that fault code number first. Meter display when completed successfully “00” is displayed in the multi-function meter right display and the electronicall...

  • Page 715: 8-244

    Electronically adjustable suspension system 8-244 2 wire harness continuity. Open or short circuit → re- place the wire harness. Between ecu coupler and joint coupler. Blue/black–blue/black blue/red–blue/red between the joint coupler and meter assembly coupler. Blue/black–blue/black blue/red–blue/re...

  • Page 716: 8-245

    Electronically adjustable suspension system 8-245 1 connection of stepping mo- tor coupler. Check the locking condition of the coupler. • left front fork stepping mo- tor • right front fork stepping motor • rear shock absorber as- sembly stepping motor disconnect the coupler and check the pins (bent...

  • Page 717: 8-246

    Electronically adjustable suspension system 8-246 4 wire harness and/or front fork stepping motor sub-lead continuity. Open circuit → replace. • between scu coupler and left front fork stepping mo- tor. Gray/black–gray/black white/black–white/black yellow/black–yellow/black green/black–green/black •...

  • Page 718: 8-247

    Electronically adjustable suspension system 8-247 4 wire harness and/or front fork stepping motor sub-lead continuity. • scu internal circuit (be- tween left front fork step- ping motor “1” and power battery”5”) gray/black–brown/blue white/black–brown/blue yellow/black–brown/blue green/black–brown/b...

  • Page 719: 8-248

    Electronically adjustable suspension system 8-248 5 malfunction in stepping mo- tor. Stepping motor operation confirmation steps: a. Connect the pocket tester ( Ω × 10) to the stepping motor. • positive tester probe “1” • negative tester probe “2” a. Stepping motor cou- pler b. Connection wiring dia...

  • Page 720: 8-249

    Electronically adjustable suspension system 8-249 fault code no. 94 item preload adjusting motor (rear shock absorber assembly dc motor) is locked, rotary encoder signal is not received, encod- er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code no. 8...

  • Page 721: 8-250

    Electronically adjustable suspension system 8-250 3 connection of scu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wi...

  • Page 722: 8-251

    Electronically adjustable suspension system 8-251 4 wire harness continuity. Short circuit → replace the wire harness. • scu internal circuit (be- tween rear shock absorber assembly dc motor “1” and power ground “2”) green/red–black light green/red–black red–black white–black gray–black • scu intern...

  • Page 723: 8-252

    Electronically adjustable suspension system 8-252 5 incorrect wiring of wire har- ness. Check the rotary encoder signal lead for incorrect wir- ing. Incorrect wiring → replace the wire harness. A. Scu coupler b. Rear shock absorber as- sembly dc motor coupler turn the main switch to “off” and back t...

  • Page 724: 8-253

    Electronically adjustable suspension system 8-253 8 malfunction in scu. Replace the scu. Execute the diagnostic mode (code no. 84). Service is fin- ished. 9 defective rear shock absorb- er assembly. Replace the rear shock ab- sorber assembly. Execute the diagnostic mode (code no. 84). Service is fin...

  • Page 725: 8-254

    Electronically adjustable suspension system 8-254 1 wire harness continuity. Refer to “rear shock ab- sorber assembly” on page 4-94. Short circuit → replace the wire harness. • scu internal circuit (be- tween rear shock absorber assembly dc motor “1” and signal ground “2”) green/red–black/blue light...

  • Page 726: Electrical Components

    Electrical components 8-255 eas27970 electrical components 26 25 3 2 1 4 5 6 10 11 9 8 7 12 13 14 15 16 17 20 19 18 24 23 22 21.

  • Page 727: Electrical Components

    Electrical components 8-256 1. Windshield drive unit 2. Battery 3. Starter relay 4. Cooling system fuse 5. Front brake light switch 6. Fuse box 3 7. Fuse box 1 8. Fuse box 2 9. Fuse box 4 10. Cruise control system fuse 11. Brake light fuse 12. Right radiator fan motor 13. Left radiator fan motor 14....

  • Page 728: Electrical Components

    Electrical components 8-257 7 1 3 2 21 24 23 22 9 10 8 14 13 15 16 17 18 19 20 6 4 5 12 11.

  • Page 729: Electrical Components

    Electrical components 8-258 1. Coolant temperature sensor 2. Accelerator position sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Atmospheric pressure sensor 6. Ycc-s control relay 7. Brake light relay 8. Mcu (motor control unit) 9. Scu (suspension control unit) 10. Brake switch ...

  • Page 730: Electrical Components

    Electrical components 8-259 eas27980 checking the switches 4 r br/l br/r br/l br/r r 5 6 15 w/b l/r w/y 13 p b 9 11 12 10 1 br/g l/r 2 3 8 g/w g/y y/w y/b g/w g/y y/b y/w pull br b y g press br g b y b b b/w w/g mode r/b w/l b r/w b/w br/g w/g l/r r/b b r/w w/l 14 w/l b/w menu w/g b/w w/r l/b r/y y ...

  • Page 731: Electrical Components

    Electrical components 8-260 1. Start/engine stop switch 2. Hazard switch 3. Mode switch 4. Front brake light switch 5. Main switch 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Horn switch 10. Dimmer/pass switch 11. Cruise control power switch 12. Cruise control setting switch ...

  • Page 732: Electrical Components

    Electrical components 8-261 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes...

  • Page 733: Electrical Components

    Electrical components 8-262 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or b...

  • Page 734: Electrical Components

    Electrical components 8-263 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 735: Electrical Components

    Electrical components 8-264 warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possib...

  • Page 736: Electrical Components

    Electrical components 8-265 3. Remove: • battery 4. Check: • battery charge ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals. Tip • the charge state of an vrla (valve regulated lead acid) battery can be checked by measur- ing its open-circuit vo...

  • Page 737: Electrical Components

    Electrical components 8-266 • if the battery becomes hot to the touch at any time during the charging process, dis- connect the battery charger and let the bat- tery cool before reconnecting it. Hot batteries can explode! • as shown in the following illustration, the open-circuit voltage of an vrla ...

  • Page 738: Electrical Components

    Electrical components 8-267 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) notice eca13630 first, connect the positive battery lead “1”, and then the negative battery lead “2”. 8. Check: • battery terminals dirt → clean ...

  • Page 739: Electrical Components

    Electrical components 8-268 relay unit (fuel pump relay) headlight relay (on/off) headlight relay (dimmer) first step: second step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive battery ...

  • Page 740: Electrical Components

    Electrical components 8-269 brake switch relay brake light relay first step: second step: radiator fan motor relay windshield drive unit relay (down) first step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3”...

  • Page 741: Electrical Components

    Electrical components 8-270 second step: windshield drive unit relay (up) first step: second step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe 5. Negative tester probe result no continuity (between “3” and “4”) continuity (between “3” a...

  • Page 742: Electrical Components

    Electrical components 8-271 ycc-s control relay first step: second step: eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Tip the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 743: Electrical Components

    Electrical components 8-272 c. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28100 checking the ignition coils the following procedure applies to all of the igni- tion coils. 1. Check: • primary co...

  • Page 744: Electrical Components

    Electrical components 8-273 c. Turn the main switch to “on”. D. Measure the ignition spark gap “a”. E. Crank the engine by pushing the “ ” side of the start/engine stop switch and gradually in- crease the spark gap until a misfire occurs. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28120 ch...

  • Page 745: Electrical Components

    Electrical components 8-274 c. Turn the main switch to “on”. D. Turn the lean angle sensor to 65°. E. Measure the lean angle sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61016 checking the starter motor operation 1. Check: • starter motor operation does not operate ...

  • Page 746: Electrical Components

    Electrical components 8-275 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the battery terminals as shown. B. Start the engine and let it run at approximate- ly 5000 r/min. C. Measure the charging voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 747: Electrical Components

    Electrical components 8-276 b. Move the fuel sender float to minimum “3” and maximum “4” level position. C. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas29040 checking the fuel meter/fuel level warning light this model is equipped with a self-diagnosis de-...

  • Page 748: Electrical Components

    Electrical components 8-277 eas28250 checking the radiator fan motors the following procedure applies to both of the radiator fan motors. 1. Check: • radiator fan motor faulty/rough movement → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the radiator fan motor coupler fro...

  • Page 749: Electrical Components

    Electrical components 8-278 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the throttle position sensor terminals as shown. B. Measure the throttle position sensor maxi- mum resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • throt...

  • Page 750: Electrical Components

    Electrical components 8-279 notice eca1mc1004 do not use a 12 v battery to operate the throt- tle servo motor. Tip do not use old batteries to operate the throttle servo motor. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28370 checking the air induction system solenoid 1. Check: • air induc...

  • Page 751: Electrical Components

    Electrical components 8-280 c. Turn the main switch to “on”. D. Rotate the crankshaft. E. Measure the voltage of white/black and black/blue. Turn the crankshaft twice and check that the output voltage rises to approx- imately 4.8 v once. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1mc1028 c...

  • Page 752: Electrical Components

    Electrical components 8-281 c. Turn the main switch to “on”. D. Measure the atmospheric pressure sensor output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1mc1025 checking the air temperature sensor 1. Remove: • air temperature sensor (from the windshield drive unit) warning ewa1mc...

  • Page 753: Electrical Components

    Electrical components 8-282 eas1mc1078 checking the windshield drive unit 1. Check: • windshield drive unit operation faulty/rough movement → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the windshield drive unit sub-lead from the wire harness. B. Connect the battery (dc ...

  • Page 754: Electrical Components

    Electrical components 8-283 c. Measure the grip warmer resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas1md1012 checking the ycc-s speed sensor 1. Check: • ycc-s speed sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect t...

  • Page 755: Electrical Components

    Electrical components 8-284 b. Measure the gear position sensor maximum resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • gear position sensor refer to “installing the gear posi- tion sensor” on page 5-11. Eas1md1014 checking the foot shift sensor 1. Remove: • foot shift se...

  • Page 756: Electrical Components

    Electrical components 8-285.

  • Page 757: Troubleshooting

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

  • Page 758: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ad...

  • Page 759: Troubleshooting

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

  • Page 760: Troubleshooting

    Troubleshooting 9-3 • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump 4. Thermostat • thermostat stays closed 5. Oi...

  • Page 761: Troubleshooting

    Troubleshooting 9-4 • faulty rear suspension control stepping motor • faulty rear shock absorber assembly dc mo- tor tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent o...

  • Page 762: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-5 eas1md1016 self-diagnostic function and diagnostic code table (ecu) tip • if there is a malfunction in the fuel injection system, the windshield adjusting function “1” will be dis- played in the function display, the engine trouble warning...

  • Page 763: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-6 34 cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil. 8-61 35 cylinder-#3 ignition coil: open or short circuit detected in the primary lead of the cylinder-#3 ignition coil. 8-62...

  • Page 764: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-7 communication error with the meter diagnostic code: sensor operation table fault code no. Item reference pages 89 (yamaha diagnostic tool) multi-function meter: signals cannot be transmit- ted between the ecu and the multi-function meter. ...

  • Page 765: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-8 07 rear wheel vehicle speed pulses rear wheel speed pulse 0–999 check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. 08 lean angle sensor lean angle...

  • Page 766: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-9 21 neutral switch shift the transmission. • transmission is in neu- tral on • transmission is not in neutral off 60 eeprom fault code dis- play • no history 00 • no malfunctions detect- ed (if the self-diagnosis fault code 44 is indicat- e...

  • Page 767: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-10 62 malfunction history code erasure • no history 00 — • history exists • displays the total num- ber of malfunctions, in- cluding the current malfunction, that have occurred since the histo- ry was last erased. (for example, if there have...

  • Page 768: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-11 diagnostic code: actuator operation table 82 cruise control cancel cir- cuit operate the clutch lever, brake lever, brake pedal, and throttle grip. • clutch lever is squeezed on • clutch lever is released off • brake lever is squeezed on ...

  • Page 769: (Ecu)

    Self-diagnostic function and diagnostic code table (ecu) 9-12 36 injector #1 actuates the injector #1 five times at one-second intervals. Illuminates the engine trouble warning light. Check that injector #1 is actuated five times by lis- tening for the operating sound. 37 injector #2 actuates the in...

  • Page 770: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-13 eas1md1017 self-diagnostic function and diagnostic code table (mcu) tip • if there is a malfunction in the ycc-s (yamaha chip controlled-shift) system, the windshield adjust- ing function “1” will be displayed in the function display, the...

  • Page 771: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-14 * this fault code number can be checked only using the yamaha diagnostic tool. Sh_ _31 engine speed signal is abnormal. 8-214 sh_ _32 vehicle speed signal is abnormal. 8-215 sh_ _35 start switch signal is abnormal. 8-216 sh_ _36 clutch ac...

  • Page 772: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-15 diagnostic code table diagnos- tic code no. Item meter display procedure sh_ _61 malfunction history code display • no history 00 — • history exists fault codes sh_ _11–sh_ _52 • (if more than one code number is detected, the dis- play al...

  • Page 773: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-16 sh_ _63 clutch actuator oper- ation tip if any of the following fault codes are de- tected, do not exe- cute the diagnostic mode. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ _16, sh_ _17, sh_ _25, sh_ _26, sh_ _36, sh_ _37, and sh_ _44 actuat...

  • Page 774: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-17 sh_ _65 gear position setting tip if any of the following fault codes are de- tected, do not exe- cute the diagnostic mode. Sh_ _11, sh_ _12, sh_ _13, sh_ _14, sh_ _15, sh_ _16, sh_ _17, sh_ _18, sh_ _19, sh_ _21, sh_ _25, sh_ _26, sh_ _3...

  • Page 775: (McU)

    Self-diagnostic function and diagnostic code table (mcu) 9-18 sh_ _65 gear position setting tip if any of the following fault codes are de- tected, do not exe- cute the diagnostic mode. Sh_ _11, sh_ _12, sh_ _13, sh_ _14, sh_ _15, sh_ _16, sh_ _17, sh_ _18, sh_ _19, sh_ _21, sh_ _25, sh_ _26, sh_ _3...

  • Page 776: (Scu)

    Self-diagnostic function and diagnostic code table (scu) 9-19 eas1md1020 self-diagnostic function and diagnostic code table (scu) tip • if there is a malfunction in the electronically adjustable suspension system, the damping force adjust- ing function “1” will be displayed in the function display, ...

  • Page 777: (Scu)

    Self-diagnostic function and diagnostic code table (scu) 9-20 diagnostic code table diagnostic code no. Item meter display procedure 09 monitor voltage displays the monitor volt- age. Approximately 12.0 compare the actually measured battery voltage with the meter display val- ue. (if the actually me...

  • Page 778: (Scu)

    Self-diagnostic function and diagnostic code table (scu) 9-21 tip observe the following precautions when executing the diagnostic mode. (code no. 84) • make sure that the battery has been sufficiently charged. • place the vehicle on the centerstand. • after operating the electronically adjustable su...

  • Page 779: (Scu)

    Self-diagnostic function and diagnostic code table (scu) 9-22.

  • Page 780: Wiring Diagram

    Eas28740 wiring diagram fjr1300as 2013 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Ycc-s motor control fuse 6. Scu fuse 7. Windshield drive system fuse 8. Hazard lighting fuse 9. Abs motor fuse 10. Abs solenoid fuse 11. Fuel injection system fuse 12. Backup fuse 13. Electric ...

  • Page 781

    Eas28750 color code b black br brown ch chocolate dg dark green g green gy gray l blue lg light green o orange p pink r red sb sky blue w white y yellow b/g black/green b/l black/blue b/r black/red b/w black/white b/y black/yellow br/b brown/black br/g brown/green br/l brown/blue br/r brown/red br/w...

  • Page 785

    Fjr1300as 2013 wiring diagram fjr1300as 2013 schÉma de cblage fjr1300as 2013 schaltplan fjr1300as 2013 schema elettrico fjr1300as 2013 diagrama elÉctrico p on off a a press menu pass res set pull mode c c f b f h h h h g g g d d d d e e e e up down r b w w w br/r br/l r r r r r br/l r/b r/b l/r l/r ...

  • Page 786

    Fjr1300as 2013 wiring diagram fjr1300as 2013 schÉma de cblage fjr1300as 2013 schaltplan fjr1300as 2013 schema elettrico fjr1300as 2013 diagrama elÉctrico p on off a a press menu pass pull mode c c f b f h h h h g g g d d d d e e e e a b c d a b a a c e f a d a e g h a f a g i a h (b) (gy) (gy) (b) (...