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Yamaha 2014 MT-07 Service Manual

Summary of 2014 MT-07

  • Page 1

    2014 service manual mt07a 1xb-28197-e0

  • Page 2

    Eas20002 mt07a 2014 service manual ©2014 by yamaha motor co., ltd. First edition, october 2014 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Important

    Eas20003 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

    Eas20004 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

    Eas20005 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

    Eas10003 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 eas20007 identification eas30002 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas30003 model label the model label “1” is affixed to the frame under the passenger seat. This information will be needed...

  • Page 11: Features

    Features 1-2 eas20008 features eas30005 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sys...

  • Page 12: Features

    Features 1-3 eas30617 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 a certain level. Accordingly, when the energizing signal from the ecu energizes the fuel injector, the fuel...

  • Page 13: Features

    Features 1-4 eas30683 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The abs features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. 3. The hyd...

  • Page 14: Features

    Features 1-5 abs the operation of the yamaha abs brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. When wheel lock is detected during emergency braking, hydraulic control is performed by the h...

  • Page 15: Features

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

  • Page 16: Features

    Features 1-7 warning ewa16510 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 can...

  • Page 17: Features

    Features 1-8 abs block diagram eas30684 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel speed and transmit the rotation signal to the abs ecu. Each wheel sensor is composed of a permanent magnet and a hall ic. The sensor rotors “2” rotate with the whe...

  • Page 18: Features

    Features 1-9 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 to check the electrical circuit and the system function (abs self-diagnosis), and goes off when the vehicle i...

  • Page 19: Features

    Features 1-10 hydraulic unit assembly the hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an abs motor, and abs ecu. The hydraulic unit adjusts the front and rear wheel brake fluid pre...

  • Page 20: Features

    Features 1-11 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 21: Features

    Features 1-12 the necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly. Abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when ...

  • Page 22: Features

    Features 1-13 • the abs performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can...

  • Page 23: Features

    Features 1-14 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 24: Features

    Features 1-15 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 25: Features

    Features 1-16 eas30712 abs warning light and operation abs warning light • if the abs warning light comes on while riding, stop the vehicle, and then turn the main switch to “off”, then back to “on”. The abs operation is normal if the abs warning light comes on, then goes off. • if the rear wheel is...

  • Page 26: Features

    Features 1-17 abs function warning ewa16520 • when hydraulic control is performed by the abs, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the abs is activated, the grip between the r...

  • Page 27: Features

    Features 1-18 eas30982 multi-function meter unit warning ewa12423 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function meter unit is equipped w...

  • Page 28: Features

    Features 1-19 the clock displays when the key is turned to “on”. In addition, the clock can be displayed for 10 seconds by pushing the left set button when the main switch is in the “off”, “lock” or “ ” position. [to set the clock] 1. Turn the key to “on”. 2. Push the left set button and right set b...

  • Page 29: Features

    Features 1-20 multi-function display the multi-function display is equipped with the following: • an odometer • two tripmeters (which show the distance trav- eled since they were last set to zero) • a fuel reserve tripmeter (which shows the dis- tance traveled since the left segment of the fuel mete...

  • Page 30: Features

    Features 1-21 to switch between the instantaneous fuel con- sumption displays, push the left set button for one second when one of the displays is shown. Tip if traveling at speeds under 20 km/h (12 mi/h), “_ _._” is displayed. Average fuel consumption mode the average fuel consumption display can b...

  • Page 31: Features

    Features 1-22 self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate a fault code. If the display indicates any fault c...

  • Page 32: Important Information

    Important information 1-23 eas20009 important information eas30006 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 1-30. 3. When disasse...

  • Page 33: Important Information

    Important information 1-24 eas30010 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if a...

  • Page 34: Basic Service Information

    Basic service information 1-25 eas20010 basic service information eas30013 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 35: Basic Service Information

    Basic service information 1-26 eas30014 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 36: Basic Service Information

    Basic service information 1-27 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 37: Basic Service Information

    Basic service information 1-28 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 38: Basic Service Information

    Basic service information 1-29 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 (4). • as a quick remedy, use a contact revitalizer available at most part stores. 5. Check: • resistance tip th...

  • Page 39: Special Tools

    Special tools 1-30 eas20012 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 40: Special Tools

    Special tools 1-31 vacuum gauge 90890-03094 vacuummate yu-44456 3-9 carburetor angle driver 2 90890-03173 3-9 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-19, 4-89 oil filter wrench 90890-01426 oil filter wrench yu-38411 3-22 pressure gauge 90890-03153 pressure gauge yu-03153...

  • Page 41: Special Tools

    Special tools 1-32 fork seal driver weight 90890-01367 replacement hammer ym-a9409-7 4-83, 4-83, 4-84 fork seal driver attachment (ø41) 90890-01381 replacement 41 mm ym-a5142-2 4-83, 4-83 extension 90890-04136 5-1 compression gauge 90890-03081 engine compression tester yu-33223 5-1 rotor holding too...

  • Page 42: Special Tools

    Special tools 1-33 valve spring compressor attachment 90890-01243 valve spring compressor adapter (26 mm) ym-01253-1 5-32, 5-37 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-34 valve guide installer (ø4.5) 90890-04117 valve guide installer (4.5 mm) ym-04117 5-34 valv...

  • Page 43: Special Tools

    Special tools 1-34 piston pin puller set 90890-01304 piston pin puller yu-01304 5-77 piston ring compressor 90890-05158 piston ring compressor ym-08037 5-84 radiator cap tester 90890-01325 mityvac cooling system tester kit yu-24460-a 6-3 radiator cap tester adapter 90890-01352 pressure tester adapte...

  • Page 44: Special Tools

    Special tools 1-35 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-12 vacuum/pressure pump gauge set 90890-06756 mityvac brake bleeding tool ys-42423 7-8 fuel injector pressure adapter 90890-03210 fuel injector pressure adapter yu-03210 7-16 fuel p...

  • Page 45: Specifications

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

  • Page 46: General Specifications

    General specifications 2-1 eas20013 general specifications model model 1xb1 (bel)(che)(cze)(dnk)(fin)(gbr)(grc)(hu n)(irl)(nld)(nor)(pol)(prt)(svk)(svn)(s we)(tur)(zaf) 1xb2 (bel)(che)(cze)(dnk)(fin)(gbr)(grc)(hu n)(irl)(nld)(nor)(pol)(prt)(svk)(svn)(s we)(tur)(zaf) 1xb5 (bel)(che)(cze)(dnk)(fin)(gb...

  • Page 47: Engine Specifications

    Engine specifications 2-2 eas20014 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 689 cm³ cylinder arrangement inline 2-cylinder bore × stroke 80.0 × 68.6 mm (3.15 × 2.70 in) compression ratio 11.5 : 1 standard compression pressure (at sea level) #1 880 kpa/355 r/...

  • Page 48: Engine Specifications

    Engine specifications 2-3 relief valve operating pressure 630.0–810.0 kpa (6.30–8.10 kgf/cm², 91.4– 117.5 psi) cooling system radiator capacity (including all routes) 1.60 l (1.69 us qt, 1.41 imp.Qt) coolant reservoir capacity (up to the maximum level mark) 0.25 l (0.26 us qt, 0.22 imp.Qt) radiator ...

  • Page 49: Engine Specifications

    Engine specifications 2-4 valve dimensions valve head diameter (intake) 31.40–31.60 mm (1.2362–1.2441 in) valve head diameter (exhaust) 26.40–26.60 mm (1.0394–1.0472 in) valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in) valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 i...

  • Page 50: Engine Specifications

    Engine specifications 2-5 piston-pin-to-piston-pin-bore clearance 0.009–0.025 mm (0.0004–0.0010 in) limit 0.075 mm (0.0030 in) piston ring top ring ring type barrel end gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) limit 0.50 mm (0.0197 in) ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) lim...

  • Page 51: Engine Specifications

    Engine specifications 2-6 transmission transmission type constant mesh 6-speed primary reduction ratio 1.925 (77/40) final drive chain secondary reduction ratio 2.688 (43/16) operation left foot operation gear ratio 1st 2.846 (37/13) 2nd 2.125 (34/16) 3rd 1.632 (31/19) 4th 1.300 (26/20) 5th 1.091 (2...

  • Page 52: Engine Specifications

    Engine specifications 2-7 intake vacuum 29.8–32.4 kpa (224–243 mmhg, 8.8–9.6 inhg) water temperature 85.0–105.0 °c (185.00–221.00 °f) oil temperature 60.0–80.0 °c (140.00–176.00 °f) throttle grip free play 3.0–5.0 mm (0.12–0.20 in).

  • Page 53: Chassis Specifications

    Chassis specifications 2-8 eas20015 chassis specifications chassis frame type diamond caster angle 24.80 ° trail 90 mm (3.5 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum wheel travel 130 mm (5.1 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel runout...

  • Page 54: Chassis Specifications

    Chassis specifications 2-9 brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) master cylinder inside diameter 15.00 mm (0.59 in) caliper cylinder inside diameter 30.23 mm (1.19 in) caliper cylinder ins...

  • Page 55: Chassis Specifications

    Chassis specifications 2-10 enclosed gas/air pressure (std) 980 kpa (9.8 kgf/cm², 139.4 psi) spring preload adjusting positions minimum 1 standard 3 maximum 9 drive chain type/manufacturer 525vaz/daido number of links 108 15-link length limit 239.3 mm (9.42 in) drive chain slack 51.0–56.0 mm (2.01–2...

  • Page 56: Electrical Specifications

    Electrical specifications 2-11 eas20016 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 10.0 °/1200 r/min engine control unit model/manufacturer tbdfh8/denso ignition coil minimum ignition spark gap 6.0 mm (0.24 in) primary coil re...

  • Page 57: Electrical Specifications

    Electrical specifications 2-12 oil pressure warning light led high beam indicator light led coolant temperature warning light led engine trouble warning light led abs warning light led immobilizer system indicator light led electric starting system system type constant mesh starter motor power outpu...

  • Page 58: Electrical Specifications

    Electrical specifications 2-13 spare fuse 2.0 a.

  • Page 59: Tightening Torques

    Tightening torques 2-14 eas20017 tightening torques eas30015 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 60: Tightening Torques

    Tightening torques 2-15 eas30016 engine tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 4 20 nm (2.0 m·kgf, 14 ft·lbf) cylinder head stud bolt (exhaust pipe) m8 4 15 nm (1.5 m·kgf, 11 ft·lbf) muffler bracket bolt m6 4 10 nm (1.0 m·kgf, 7.2 ft·lbf) muffler brack...

  • Page 61: Tightening Torques

    Tightening torques 2-16 clutch boss nut m20 1 95 nm (9.5 m·kgf, 69 ft·lbf) stake. Clutch spring bolt m6 6 8 nm (0.8 m·kgf, 5.8 ft·lbf) clutch cover bolt m6 10 12 nm (1.2 m·kgf, 8.7 ft·lbf) clutch cable holder bolt m6 2 12 nm (1.2 m·kgf, 8.7 ft·lbf) oil pump drive chain guide bolt m6 1 10 nm (1.0 m·k...

  • Page 62: Tightening Torques

    Tightening torques 2-17 tip cylinder head bolt tighten the cylinder head bolts “1”–”8” in the proper tightening sequence as follows: 1. Lubricate the cylinder head bolts “1”–“6” threads and mating surface with engine oil. 2. Tighten the cylinder head bolts “1”–“6” to 10 nm (1.0 m·kgf, 7.2 ft·lbf). 3...

  • Page 63: Tightening Torques

    Tightening torques 2-18 4. Loosen and retighten the cylinder head bolts “1”–“6” to 20 nm (2.0 m·kgf, 14 ft·lbf) in the proper tight- ening sequence, and then tighten them further to reach the specified angle 90° in the proper tight- ening sequence. 5. Tighten the cylinder head bolts “7” and “8” to 1...

  • Page 64: Tightening Torques

    Tightening torques 2-19 tip connecting rod bolt tighten the connecting rod bolts to 20 nm (2.0 m·kgf, 14 ft·lbf), and then tighten them further to reach the specified angle 175–185°. ×8 ×3 ×2 ×6 ×2 ×6 11 10 5 4 7 8 1 2 13 16 6 3 12 9 20 19 15 21 22 17 18 14 26 27 24 23 25.

  • Page 65: Tightening Torques

    Tightening torques 2-20 eas30017 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting nut (rear upper side) m10 1 55 nm (5.5 m·kgf, 40 ft·lbf) engine mounting nut (rear lower side) m10 1 55 nm (5.5 m·kgf, 40 ft·lbf) engine mounting bolt (left front side) m12 1 7...

  • Page 66: Tightening Torques

    Tightening torques 2-21 rectifier/regulator bolt m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) electrical components tray 2 nut m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) electrical components tray 2 bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) hydraulic unit assembly bolt m6 3 7 nm (0.7 m·kgf, 5.1 ft·lbf) front brake hose gu...

  • Page 67: Tightening Torques

    Tightening torques 2-22 rearview mirror m10 2 17 nm (1.7 m·kgf, 12 ft·lbf) handlebar switch screw (right) m4 2 2.0 nm (0.20 m·kgf, 1.4 ft·lbf) throttle cable housing bolt m5 2 3.8 nm (0.38 m·kgf, 2.8 ft·lbf) handlebar switch screw (left) m4 2 2.0 nm (0.20 m·kgf, 1.4 ft·lbf) grip end m16 2 10 nm (1.0...

  • Page 68: Tightening Torques

    Tightening torques 2-23 tip cap nut 1. First, tighten the cap nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the cap nut completely. 2. Retighten the cap nut to 18 nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. Connecting arm nut (frame side) m12 1 52 nm (5.2 m·...

  • Page 69: 2-24

    Lubrication points and lubricant types 2-24 eas20018 lubrication points and lubricant types eas30018 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or bearings camshaft lobes and journals (intake and exhaust) valve stem seal (installed on valve guide) valv...

  • Page 70: 2-25

    Lubrication system chart and diagrams 2-25 eas20019 lubrication system chart and diagrams eas30020 engine oil lubrication chart 1 2 7 3 4 5 6 8 9 9 10 11 12 13 14 15.

  • Page 71: 2-26

    Lubrication system chart and diagrams 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9. Oil nozzle 10. Balancer shaft assembly 11. Timing chain tensioner 12. Intake camshaft 13. Exhaust camshaft 14. Main axl...

  • Page 72: 2-27

    Lubrication system chart and diagrams 2-27 eas30021 lubrication diagrams crankcase, cylinder, and cylinder head (right side view) 1 2 3 4 5 6 7 8 9.

  • Page 73: 2-28

    Lubrication system chart and diagrams 2-28 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil filter cartridge 6. Oil cooler 7. Oil drain bolt 8. Oil strainer 9. Oil pump.

  • Page 74: 2-29

    Lubrication system chart and diagrams 2-29 crankcase and cylinder (left side view) 1 2 3 4 5.

  • Page 75: 2-30

    Lubrication system chart and diagrams 2-30 1. Crankshaft 2. Balancer shaft assembly 3. Connecting rod 4. Oil cooler 5. Oil filter cartridge.

  • Page 76: 2-31

    Lubrication system chart and diagrams 2-31 oil pump (bottom view) 2 3 4 5 1.

  • Page 77: 2-32

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

  • Page 78: 2-33

    Lubrication system chart and diagrams 2-33 camshaft (top view) 2 3 3 1 3.

  • Page 79: 2-34

    Lubrication system chart and diagrams 2-34 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft.

  • Page 80: 2-35

    Lubrication system chart and diagrams 2-35 crankshaft (front view) 3 4 1 2 1.

  • Page 81: 2-36

    Lubrication system chart and diagrams 2-36 1. Oil nozzle 2. Piston 3. Crankshaft 4. Main gallery.

  • Page 82: 2-37

    Lubrication system chart and diagrams 2-37 crankshaft and transmission (top view) 1 2 4 3.

  • Page 83: 2-38

    Lubrication system chart and diagrams 2-38 1. Balancer shaft assembly 2. Crankshaft 3. Main axle 4. Drive axle.

  • Page 84: Cooling System Diagrams

    Cooling system diagrams 2-39 eas20020 cooling system diagrams 1 2 3 4 5 6 7 7 8 9 10 6 3 4 5 8.

  • Page 85: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Thermostat 2. Oil cooler inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Water jacket joint inlet hose 6. Water pump outlet pipe 7. Water pump inlet pipe 8. Radiator outlet hose 9. Water jacket joint 10. Water pump.

  • Page 86: Cable Routing

    Cable routing 2-41 eas20021 cable routing handlebar (front view) 2 1 2 3 4 4 3 5 6 7 7 8 8 a b c 9 9 10 11 12 13 14 15 11 12 4 5 19 20 21 13 j h h h h m n h k l 15 16 17 g f 1 1 2 2 22 22 e 1 3 4 18 d i.

  • Page 87: Cable Routing

    Cable routing 2-42 1. Throttle cable (decelerator cable) 2. Throttle cable (accelerator cable) 3. Clutch cable 4. Handlebar switch lead (left handlebar switch) 5. Front turn signal light lead (left turn signal light) 6. Guide 7. Auxiliary light coupler 8. Wire harness 9. Headlight coupler 10. Brake ...

  • Page 88: Cable Routing

    Cable routing 2-43 clutch cable (right side view) 1 2 3 6 a 7 8 9 b c 13 12 d e 16 19 18 1 2 20 23 1 2 i h 14 15 21 22 4 5 11 10 k j 17 g f.

  • Page 89: Cable Routing

    Cable routing 2-44 1. Fuel tank breather hose 2. Fuel tank overflow hose 3. Intake solenoid coupler 4. Brake hose (hydraulic unit to left front brake caliper) 5. Brake hose (front brake master cylinder to hydraulic unit) 6. Clutch cable 7. Oil pressure switch lead 8. Oil pressure switch 9. O 2 senso...

  • Page 90: Cable Routing

    Cable routing 2-45 rectifier/regulator (left side view) 1 2 3 4 5 6 7 8 9 8 10 a b c d e f g h i 11 13 12 22 23 15 16 17 18 19 20 21 k l l n m 10 j 14.

  • Page 91: Cable Routing

    Cable routing 2-46 1. Wire harness 2. Intake air temperature sensor coupler 3. Fuel pump coupler 4. Throttle cable (decelerator cable) 5. Throttle cable (accelerator cable) 6. Throttle body assembly 7. Oil cooler inlet hose 8. Coolant reservoir hose 9. Horn lead 10. Ac magneto lead 11. Radiator inle...

  • Page 92: Cable Routing

    Cable routing 2-47 engine (left side view) 1 2 3 4 5 6 7 7 a b c d e f 16 17 18 19 20 21 m 22 23 1 1 n o 24 11 12 13 14 15 j k l 16 g 9 i 10 8 h p 7 8 24 8 19 20

  • Page 93: Cable Routing

    Cable routing 2-48 1. Starter motor lead 2. Tail/brake light assembly coupler 3. Yamaha diagnostic tool coupler 4. License plate light coupler 5. Rear turn signal light coupler (left turn signal light) 6. Rear turn signal light coupler (right turn signal light) 7. Engine ground lead 8. Sidestand swi...

  • Page 94: Cable Routing

    Cable routing 2-49 frame (top view) 1 2 3 4 1 2 4 5 5 6 9 7 8 12 14 13 15 16 17 a b c d e 21 22 23 24 25 26 27 29 29 29 f 30 31 32 33 33 34 g 35 i j 36 h 35 m 22 23 23 28 29 27 29 28 35 37 38 10 11 18 20 19 28 34 35 n 35 39 40 41 42 43 44 45 o 35 14 33 l l 29 k 46 37 43 35 23 29 p q r.

  • Page 95: Cable Routing

    Cable routing 2-50 1. Rectifier/regulator 2. Headlight relay 3. Turn signal/hazard relay 4. Radiator fan motor relay 5. Throttle cable 6. Relay unit 7. Brake hose (front brake master cylinder to hydraulic unit) 8. Brake hose (hydraulic unit to left front brake caliper) 9. Intake air temperature sens...

  • Page 96: Cable Routing

    Cable routing 2-51 rear fender (top view) a 1 2 3 1 2 3 4 4 5 5 6 6 7 8 9 10 11 12 13 13 13 13 14 13 14 13 b c d e f.

  • Page 97: Cable Routing

    Cable routing 2-52 1. Battery band 2. Wire harness 3. Positive battery lead 4. Negative battery lead 5. Fuse box 1 6. Fuse box 2 7. Lean angle sensor 8. Rear turn signal light lead (left turn signal light) 9. Rear turn signal light lead (right turn signal light) 10. License plate light lead 11. Tail...

  • Page 98: Cable Routing

    Cable routing 2-53 rear fender (left side view) b a d d d e 1 1 2 2 2 3 3 3 4 5 6 6 6 6 2 3 6 2 3 6 7 8 8 9 10 10 11 11 12 12 13 c.

  • Page 99: Cable Routing

    Cable routing 2-54 1. Seat lock cable 2. License plate light lead 3. Rear turn signal light lead (right turn signal light) 4. Tail/brake light assembly lead 5. Tail/brake light assembly 6. Rear turn signal light lead (left turn signal light) 7. Seat lock key cylinder bracket 8. Frame 9. Seat lock as...

  • Page 100: Cable Routing

    Cable routing 2-55 rear brake hose (right side view) a b c d d e e f g h i j k l 1 1 1 1 2 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 6 6.

  • Page 101: Cable Routing

    Cable routing 2-56 1. Rear wheel sensor lead 2. Rear brake fluid reservoir hose 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to rear brake caliper) 5. O 2 sensor lead 6. Rear brake light switch lead a. Route the rear wheel sensor lead to the outside of t...

  • Page 102: Cable Routing

    Cable routing 2-57 front brake hose (left and right side view) a b c d e d f g g h 1 1 2 2 2 3 2 3 4 1.

  • Page 103: Cable Routing

    Cable routing 2-58 1. Brake hose (hydraulic unit to left front brake caliper) 2. Front wheel sensor lead 3. Brake hose (left front brake caliper to right front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) a. Make sure that there is no slack in the front wheel sensor l...

  • Page 104: Cable Routing

    Cable routing 2-59 hydraulic unit assembly (top and right side view) a 1 1 2 2 3 3 4 4.

  • Page 105: Cable Routing

    Cable routing 2-60 1. Brake hose (rear brake master cylinder to hydraulic unit) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Brake hose (hydraulic unit to left front brake caliper) 4. Brake hose (hydraulic unit to rear brake caliper) a. Make sure that the pipe section of the brak...

  • Page 106: Cable Routing

    Cable routing 2-61 fuel tank (left side view) a b c 1 2 3 4 b.

  • Page 107: Cable Routing

    Cable routing 2-62 1. Fuel tank 2. Fuel hose 3. Fuel tank breather hose 4. Fuel tank overflow hose a. Face the blue paint mark on the fuel tank breather hose to the right. Install the hose up to the wide portion of the pipe. B. Align the ends of the hose clamp with the paint mark on the hose. Make s...

  • Page 108: Cable Routing

    Cable routing 2-63 throttle bodies (top view) a b c d 1 2 3 4 5 6 7 8 9 10 11.

  • Page 109: Cable Routing

    Cable routing 2-64 1. Air filter case 2. Fuel hose 3. Surge tank hose 4. Surge tank 5. Intake solenoid 6. Intake solenoid vacuum hose (one-way valve to intake solenoid) 7. One-way valve 8. Intake solenoid vacuum hose (throttle body to one-way valve) 9. Cylinder head breather hose 10. Intake solenoid...

  • Page 110: Cable Routing

    Cable routing 2-65 air filter case (left and right side view) a b c d e b f g h j i k l m n o o o o p q 1 2 3 4 5 6 9 9 9 7 8 9 10 10 11 12 11 12 12 13 13 14 14 15 15 16 16 16 d.

  • Page 111: Cable Routing

    Cable routing 2-66 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Intake air pressure sensor 4. Intake air pressure sensor hose 5. Fuel hose 6. Air filter case 7. Throttle body assembly 8. Air filter case valve 9. Intake solenoid vacuum hose (intake solenoid to air fi...

  • Page 112: Cable Routing

    Cable routing 2-67 radiator (front view) a b 1 2 3 4 5 6.

  • Page 113: Cable Routing

    Cable routing 2-68 1. Radiator 2. Radiator cap 3. Coolant reservoir hose 4. Radiator inlet hose 5. Coolant reservoir 6. Radiator outlet hose a. Connect the end of the coolant reservoir hose that is identified by the white paint mark to the radiator. B. Point the ends of the hose clamp toward the fra...

  • Page 114: Cable Routing

    Cable routing 2-69 radiator (left side view) a b c d i f h g e 1 1 2 6 5 5 3 4 4 4 5 6 7 8 9 10 10 11.

  • Page 115: Cable Routing

    Cable routing 2-70 1. Coolant reservoir hose 2. Radiator inlet hose 3. Thermostat housing 4. Oil cooler inlet hose 5. Coolant reservoir breather hose 6. Coolant reservoir 7. Coolant reservoir cap 8. Radiator 9. Radiator cap 10. Ac magneto lead 11. Horn lead a. Fasten the coolant reservoir hose to th...

  • Page 116: Cable Routing

    Cable routing 2-71 radiator (right side view) a b c 3 4 2 1 5 7 8 6.

  • Page 117: Cable Routing

    Cable routing 2-72 1. Radiator inlet hose 2. Coolant reservoir hose 3. Radiator cap 4. Radiator 5. Coolant reservoir 6. Coolant reservoir breather hose 7. Radiator outlet hose 8. Oil cooler inlet hose a. Align the plastic locking tie with the white paint marks on the radiator inlet hose and coolant ...

  • Page 118: Cable Routing

    Cable routing 2-73.

  • Page 119

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

  • Page 120

    Checking and lubricating the cables .................................... 3-27 checking the throttle grip operation ................................. 3-27 checking and charging the battery ....................................... 3-28 checking the fuses ...................................................

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-1 eas20022 periodic maintenance eas30022 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 123: Periodic Maintenance

    Periodic maintenance 3-2 6 * brake hoses • check for cracks or damage. • check for correct routing and clamping. √ √ √ √ √ • replace. Every 4 years 7 * brake fluid • replace. Every 2 years 8 * wheels • check runout and for dam- age. √ √ √ √ 9 * tires • check tread depth and for damage. • replace if ...

  • Page 124: Periodic Maintenance

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

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-4 eas30619 checking the fuel line the following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • rider seat refer to “general chassis (1)” on page 4-1. • fuel tank top cover • fuel tank cover (left) • fuel tank cover (right) • fuel tank center cove...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-5 3. Check: • spark plug type incorrect → change. 4. Check: • electrode “1” damage/wear → replace the spark plug. • insulator “2” abnormal color → replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. M...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-6 5. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark “a” on the generator rotor with the slot “b” in...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-7 tip • cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • make a note of the position of each valve lifter “1” and valve pad “2” so that they can be in- stalled in the correct place. B. Calculate the difference between the sp...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-8 g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Tip • refer to “camshafts” on page 5-13. • lubricate the camshaft lobes and camshaft journals with molybdenum disulfide oil. • first, install the exhaust camshaft. • align the camshafts sprocket m...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-9 • fuel tank refer to “fuel tank” on page 7-1. 3. Disconnect: • intake solenoid vacuum hose (throttle body to one way valve) • intake air pressure sensor hose refer to “throttle bodies” on page 7-9. 4. Install: • hoses “1” (parts no.: 5jw-24311-00) • 3-way joints “2” (parts n...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-10 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Stop the engine and remove the measuring equipment. 3. Connect: • intake air pressure sensor hose • intake solenoid vacuum hose (throttle body to one way valve) refer to “throttle bodies” on page 7-9. 4. Install: • fuel t...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-11 eas31130 replacing the air filter element and cleaning the check hose tip there is an air filter check hose “1” at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter check hose and replace the air filter element. 1. Remove: •...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-12 eas30629 adjusting the clutch lever free play 1. Check: • clutch lever free play “a” out of specification → adjust. 2. Adjust: • clutch lever free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” un...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-13 warning ewa17050 • after adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial. • a soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehi...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch” on page 3-26. Eas30634 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Che...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-15 d. Place the other end of the hose into a con- tainer. E. Slowly apply the brake several times. F. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. G. Loosen the bleed screw. Tip loosening the bleed screw will release the pres- sure an...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-16 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a ha...

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-17 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 139: Periodic Maintenance

    Periodic maintenance 3-18 arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its. 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 ...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-19 eas30803 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicl...

  • Page 141: Periodic Maintenance

    Periodic maintenance 3-20 eas30647 checking the fasteners 1. Check: • fasteners damage/pitting → replace. Refer to “general chassis (1)” on page 4-1. Eas30804 lubricating the brake lever lubricate the pivoting point and metal-to-metal moving parts of the lever. Eas30649 lubricating the pedal lubrica...

  • Page 142: Periodic Maintenance

    Periodic maintenance 3-21 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Adjust the spring preload with the special wrench “1” and extension bar “2” included in the owner’s tool kit. B. Turn the adjusting ring “3” in direction “a” or “b”. C. Align the desired position on the adjusting ring wit...

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-22 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Tip before checking the engine oil level, wait a few minutes until the oil has settled. Eas30657 changing the engine oil 1. Start the engine, warm it up for sev...

  • Page 144: Periodic Maintenance

    Periodic maintenance 3-23 8. Install: • engine oil filler cap (along with the o-ring ) 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • engine (for engine oil leaks) 11.Check: • engine oil level refer to “checking the engine oil level” on page 3-21. Eas30810 m...

  • Page 145: Periodic Maintenance

    Periodic maintenance 3-24 tip lubricate the o-ring with a thin coat of lithium- soap-based grease. Eas30811 checking the coolant level 1. Stand the vehicle on a level surface. Tip • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Check: • coolant level the coolant level...

  • Page 146: Periodic Maintenance

    Periodic maintenance 3-25 place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move...

  • Page 147: Periodic Maintenance

    Periodic maintenance 3-26 warning ewa13040 • if coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • if coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • if coolant is swallowed, induce vomiting and get immediate m...

  • Page 148: Periodic Maintenance

    Periodic maintenance 3-27 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30660 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Warning ewa13270 damaged outer cable may cause the cable to corrode and interfere with its movement. Re- pl...

  • Page 149: Periodic Maintenance

    Periodic maintenance 3-28 tip if the specified throttle grip free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ handlebar side a. Slide b...

  • Page 150: Periodic Maintenance

    Periodic maintenance 3-29 4. Unhook: • headlight bulb holder “1” 5. Remove: • headlight bulb “2” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • headlight bulb secure the new headlight bul...

  • Page 151: Periodic Maintenance

    Periodic maintenance 3-30 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ tip to adjust the headlight beam (vertically), insert a crosshead screwdriver into the hole “a” in the lower bracket and turn the adjusting screw. A. Turn the adjusting screw “1” in direction “b” or “c”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 152: Periodic Maintenance

    Periodic maintenance 3-31.

  • Page 153: Chassis

    4 chassis general chassis (1) ................................................................................. 4-1 installing the rider seat............................................................... 4-2 installing the passenger seat.................................................... 4-2 gener...

  • Page 154

    Rear wheel ............................................................................................... 4-26 removing the rear wheel (disc brake) ................................... 4-30 disassembling the rear wheel .................................................. 4-30 checking the rear wheel.....

  • Page 155

    Front fork................................................................................................ 4-75 removing the front fender side covers and front fork legs.............................................................................. 4-80 disassembling the front fork legs ................

  • Page 156: General Chassis (1)

    General chassis (1) 4-1 eas20026 general chassis (1) removing the seats and battery order job/parts to remove q’ty remarks 1 passenger seat 1 2 owner’s tool kit band 1 3 owner’s tool kit 1 4 pouch 1 5 rider seat 1 6 rider seat bracket 1 7 negative battery lead 1 disconnect. 8 positive battery lead 1...

  • Page 157: General Chassis (1)

    General chassis (1) 4-2 eas31125 installing the rider seat 1. Install: • rider seat “1” tip fit the slot “a” in the rider seat onto the projection “b” on the rider seat bracket as shown, and then place the seat in the original position. Eas31126 installing the passenger seat 1. Install: • passenger ...

  • Page 158: General Chassis (2)

    General chassis (2) 4-3 eas20155 general chassis (2) removing the covers, tail/brake light assembly, and mudguard order job/parts to remove q’ty remarks rider seat/passenger seat refer to “general chassis (1)” on page 4-1. 1 center cover 1 2 upper tail cover 1 3 lower tail cover 1 4 rear side cover ...

  • Page 159: General Chassis (2)

    General chassis (2) 4-4 removing the covers, tail/brake light assembly, and mudguard order job/parts to remove q’ty remarks 9 tail/brake light assembly 1 10 lower fender cover 1 11 license plate light coupler 1 disconnect. 12 rear turn signal light coupler 2 disconnect. 13 mudguard assembly 1 (4) lt...

  • Page 160: General Chassis (2)

    General chassis (2) 4-5 eas31094 removing the center cover 1. Remove: • center cover “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the center cover screws “2”. B. Unhook the projections “a” on the center cov- er from the rear side covers. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 161: General Chassis (2)

    General chassis (2) 4-6 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas31099 installing the rear side covers the following procedure applies to both of the rear side covers. 1. Install: • rear side cover “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projection “a” on the rea...

  • Page 162: General Chassis (2)

    General chassis (2) 4-7 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections “a” on the lower fender cover into the holes “b” in the battery box. B. Install the quick fastener. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a b a 1.

  • Page 163: General Chassis (3)

    General chassis (3) 4-8 eas20156 general chassis (3) removing the headlight and meter assembly order job/parts to remove q’ty remarks 1 headlight assembly bolt 2 2 headlight assembly 1 3 front turn signal light coupler (left) 1 disconnect. 4 front turn signal light coupler (right) 1 disconnect. 5 au...

  • Page 164: General Chassis (3)

    General chassis (3) 4-9 removing the headlight and meter assembly order job/parts to remove q’ty remarks 11 meter assembly bracket 1 12 meter assembly coupler 1 disconnect. 13 meter assembly 1 1.3 nm (0.13 m • kgf, 0.94 ft • ibf) t.R. 0.8 nm (0.08 m • kgf, 0.58 ft • ibf) t.R . 0.8 nm (0.08 m • kgf, ...

  • Page 165: General Chassis (3)

    General chassis (3) 4-10 eas31128 installing the headlight assembly 1. Install: • headlight assembly “1” • headlight assembly bolts “2” tip • fit the projections “a” on the headlight bracket into the holes “b” in the headlight assembly. • when the headlight assembly bolts are tight- ened to specific...

  • Page 166: General Chassis (4)

    General chassis (4) 4-11 eas20157 general chassis (4) removing the fuel tank covers and air scoops order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. 1 fuel tank top cover 1 2 fuel tank cover (left) 1 3 fuel tank cover (right) 1 4 fuel tank center cover 1 5...

  • Page 167: General Chassis (4)

    General chassis (4) 4-12 eas31102 removing the fuel tank top cover 1. Remove: • fuel tank top cover “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank top cover bolt “2”. B. Lift the rear of the fuel tank top cover, and then pull it rearward to remove it. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 168: General Chassis (4)

    General chassis (4) 4-13 b. Fit the projections “e” on the fuel tank cover into the holes “f” in the fuel tank center cover. C. Install the fuel tank cover bolts (m5 × 12 mm) “2”, fuel tank cover bolt (m5 × 16 mm) “3”, washer, and quick fastener “4”, and then tighten the bolts to specification. ▲▲▲ ...

  • Page 169: General Chassis (5)

    General chassis (5) 4-14 eas20158 general chassis (5) removing the electrical components tray order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank center cover/fuel tank front cover refer to “general chassis (4)”...

  • Page 170: General Chassis (5)

    General chassis (5) 4-15 removing the electrical components tray order job/parts to remove q’ty remarks 4 turn signal/hazard relay 1 5 headlight relay 1 6 relay unit 1 7 fan motor relay 1 8 intake air pressure sensor coupler 1 disconnect. 9 intake air pressure sensor 1 10 joint coupler 1 11 cranksha...

  • Page 171: General Chassis (5)

    General chassis (5) 4-16 removing the electrical components tray order job/parts to remove q’ty remarks 16 ecu band 1 17 ecu (engine control unit) 1 18 sub-wire harness coupler 1 19 intake solenoid 1 20 surge tank 1 21 electrical components tray 2 1 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 7 nm (0.7 m ...

  • Page 172: General Chassis (5)

    General chassis (5) 4-17 eas31108 removing the ecu (engine control unit) 1. Disconnect: • ecu coupler “1” tip while pushing the portion “a” of the ecu cou- pler, move the lock lever “b” in the direction of the arrow shown to disconnect the coupler. Eas31109 installing the ecu (engine control unit) 1...

  • Page 173: Front Wheel

    Front wheel 4-18 eas20028 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 front brake hose/lead holder 2 2 front wheel sensor lead holder 2 3 front brake caliper 2 4 front wheel sensor 1 5 wheel axle pinch bolt 1 loosen. 6 front wheel axle 1 7 collar 2 8...

  • Page 174: Front Wheel

    Front wheel 4-19 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 new new ls ls new new 1 1 2 2 3.

  • Page 175: Front Wheel

    Front wheel 4-20 eas30145 removing the front wheel notice eca20981 • keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel sensor or front wheel sensor rotor; otherwise, the sensor or rotor may be damaged, resulting in improper performan...

  • Page 176: Front Wheel

    Front wheel 4-21 • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns roughly or is loose → re- place the wheel bearings. • oil seal damage/wear → replace. Eas30155 maintenance of the front wheel sensor and sensor rotor notice eca21070 • handle...

  • Page 177: Front Wheel

    Front wheel 4-22 tip do not touch the surface of the wheel sensor ro- tor with a sharp object. C. If the deflection is above specification, re- move the sensor rotor from the wheel, rotate it by one or two bolt holes, and then install it. Notice eca18100 replace the wheel sensor rotor bolts with new...

  • Page 178: Front Wheel

    Front wheel 4-23 • adjust the front wheel static balance with the brake disc installed. 1. Remove: • balancing weight(s) 2. Find: • front wheel’s heavy spot tip place the front wheel on a suitable balancing stand. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wheel. B. When the...

  • Page 179: Front Wheel

    Front wheel 4-24 • front brake discs notice eca21010 • do not drop the wheel sensor rotor or sub- ject it to shocks. • if any solvent gets on the wheel sensor ro- tor, wipe it off immediately. • replace the brake disc bolts and wheel sensor bolts with new ones. Tip • install the wheel sensor rotor w...

  • Page 180: Front Wheel

    Front wheel 4-25 • to route the front wheel sensor lead, refer to “cable routing” on page 2-41. 7. Measure: • distance “a” (between the front wheel sensor rotor “1” and front wheel sensor “2”) out of specification → check the wheel bear- ing for looseness, and the front wheel sensor and sensor rotor...

  • Page 181: Rear Wheel

    Rear wheel 4-26 eas20029 rear wheel removing the rear wheel order job/parts to remove q’ty remarks 1 rear wheel sensor 1 2 rear brake caliper 1 3 drive chain puller locknut 2 loosen. 4 drive chain adjusting nut 2 loosen. 5 swingarm end plate (left) 1 6 swingarm end plate (right) 1 7 wheel axle nut 1...

  • Page 182: Rear Wheel

    Rear wheel 4-27 removing the rear wheel order job/parts to remove q’ty remarks 11 drive chain slack adjusting plate (right) 1 12 chain puller 2 13 rear wheel 1 14 brake caliper bracket 1 15 collar (left) 1 16 collar (right) 1 13 16 12 12 14 15 11 s 16 nm (1.6 m • kgf, 12 ft • ibf) t.R. 16 nm (1.6 m ...

  • Page 183: Rear Wheel

    Rear wheel 4-28 removing the rear brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 bracket 1 2 rear wheel sprocket assembly 1 3 rear wheel sprocket 1 4 rear wheel drive hub 1 5 rear wheel drive hub damper 6 6 collar 1 7 oil seal 1 8 bearing 1 9 rear brake disc 1 10 rear wh...

  • Page 184: Rear Wheel

    Rear wheel 4-29 disassembling the rear wheel order job/parts to remove q’ty remarks 1 oil seal 1 2 wheel bearing 2 3 spacer 1 new new 1 3 ls new 2 2.

  • Page 185: Rear Wheel

    Rear wheel 4-30 eas30156 removing the rear wheel (disc brake) notice eca21030 • keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor or rear wheel sensor rotor; otherwise, the sen- sor or rotor may be damaged, resulting in imprope...

  • Page 186: Rear Wheel

    Rear wheel 4-31 eas30161 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprock- ets as a set. 2. Replace: • rear wheel sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 187: Rear Wheel

    Rear wheel 4-32 eas30163 assembling the rear wheel notice eca21050 • do not drop the wheel sensor rotor or sub- ject it to shocks. • if any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: • wheel bearings • oil seal refer to “assembling the front wheel” on page 4-22. E...

  • Page 188: Rear Wheel

    Rear wheel 4-33 tip • install the rear wheel with the mark “a” on the rear tire pointing in the direction of wheel rota- tion. • align the projection “b” in the swingarm with the slot “c” of the brake caliper bracket. • make sure that the arrow mark “d” on each chain puller points upward. • make sur...

  • Page 189: Rear Wheel

    Rear wheel 4-34 tip to route the rear wheel sensor lead, refer to “cable routing” on page 2-41. 11.Measure: • distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) out of specification → check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor in...

  • Page 190: Front Brake

    Front brake 4-35 eas20030 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 pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 front wheel sensor lead holder 2 right side only. ...

  • Page 191: Front Brake

    Front brake 4-36 removing the front brake master cylinder order job/parts to remove q’ty remarks rearview mirror (right) refer to “handlebar” on page 4-70. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake master cylinder reservoir cap 1 2 brake master cyl...

  • Page 192: Front Brake

    Front brake 4-37 removing the front brake master cylinder order job/parts to remove q’ty remarks 8 brake hose gasket 2 9 brake hose (front brake master cylinder to hy- draulic unit) 1 10 front brake master cylinder holder 1 11 front brake master cylinder assembly 1 s 8 9 10 11 new 10 nm (1.0 m • kgf...

  • Page 193: Front Brake

    Front brake 4-38 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 2 1 new bf bf s.

  • Page 194: Front Brake

    Front brake 4-39 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 3-14. 1 front brake hose union bolt 1 2 brake hose gasket 1 l...

  • Page 195: Front Brake

    Front brake 4-40 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal 4 7 br...

  • Page 196: Front Brake

    Front brake 4-41 eas30168 introduction warning ewa14101 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 197: Front Brake

    Front brake 4-42 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 198: Front Brake

    Front brake 4-43 c. Tighten the bleed screw. D. Install the new brake pads and a new brake pad spring. Tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Install: • brake pad pin • brake pad clips • front ...

  • Page 199: Front Brake

    Front brake 4-44 eas30172 disassembling the front brake calipers the following procedure applies to both of the brake calipers. 1. Remove: • brake caliper pistons “1” • brake caliper piston dust seals “2” • brake caliper piston seals “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Secure th...

  • Page 200: Front Brake

    Front brake 4-45 eas30174 assembling the front brake calipers warning ewa13621 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust s...

  • Page 201: Front Brake

    Front brake 4-46 notice eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 5. Check: • brake fluid level below the minimum level ...

  • Page 202: Front Brake

    Front brake 4-47 eas30182 installing the front brake master cylinder 1. Install: • front brake master cylinder assembly • front brake master cylinder holder tip • install the front brake master cylinder holder with the “up” mark “a” facing up. • align the end of the front brake master cylinder holde...

  • Page 203: Front Brake

    Front brake 4-48 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 3-15. 6. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hyd...

  • Page 204: Rear Brake

    Rear brake 4-49 eas20031 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 rear brake caliper retaining bolt 1 4 rear brake caliper bolt 1 5 rear brake caliper 1 6 brake pad 2 7 brake pad shim 2 8 brake pad insulator 2 9 brak...

  • Page 205: Rear Brake

    Rear brake 4-50 removing the rear brake master cylinder order job/parts to remove q’ty remarks pivot shaft protector (right) refer to “swingarm” on page 4-95. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake fluid reservoir holder 1 2 brake fluid reservoi...

  • Page 206: Rear Brake

    Rear brake 4-51 removing the rear brake master cylinder order job/parts to remove q’ty remarks 9 brake hose (rear brake master cylinder to hy- draulic unit) 1 disconnect. 10 rear brake light switch coupler 1 disconnect. 11 footrest assembly (right) 1 12 rear brake light switch 1 13 rear brake master...

  • Page 207: Rear Brake

    Rear brake 4-52 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 brake master cylinder kit 1 3 hose joint 1 4 bushing 1 5 brake master cylinder body 1 1 2 2 3 4 5 s bf bf new new new 18 nm (1.8 m • kgf, 13 ft • ibf) t.R ..

  • Page 208: Rear Brake

    Rear brake 4-53 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 3-14. 1 rear brake hose union bolt 1 2 brake hose gasket 2 3 brake hose (hydraulic unit to rear brake caliper) 1 4 rear brake caliper...

  • Page 209: Rear Brake

    Rear brake 4-54 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 brake pad 2 4 brake pad shim 2 5 brake pad insulator 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston dust seal 1 9 brake caliper piston sea...

  • Page 210: Rear Brake

    Rear brake 4-55 eas30183 introduction warning ewa14101 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 211: Rear Brake

    Rear brake 4-56 • brake pad spring (into the rear brake caliper) • brake pads tip always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2...

  • Page 212: Rear Brake

    Rear brake 4-57 6. Check: • brake pedal operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. Eas30186 removing the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake sys...

  • Page 213: Rear Brake

    Rear brake 4-58 • brake caliper cylinder “2” scratches/wear → replace the brake caliper assembly. • brake caliper body “3” cracks/damage → replace the brake caliper assembly. • brake fluid delivery passages (brake caliper body) obstruction → blow out with compressed air. Warning ewa17070 whenever a ...

  • Page 214: Rear Brake

    Rear brake 4-59 • brake pad shims (onto the brake pads) • brake pad spring (into the rear brake caliper) • brake pads • rear brake caliper refer to “replacing the rear brake pads” on page 4-55. 4. Fill: • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ewa13090...

  • Page 215: Rear Brake

    Rear brake 4-60 3. Check: • brake fluid reservoir “1” • brake fluid reservoir diaphragm holder “2” cracks/damage → replace. • brake fluid reservoir diaphragm “3” damage/wear → replace. 4. Check: • brake hose • brake fluid reservoir hose cracks/damage → replace. Eas30195 assembling the rear brake mas...

  • Page 216: Rear Brake

    Rear brake 4-61 3. Fill: • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of b...

  • Page 217: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-62 eas20170 abs (anti-lock brake system) removing the hydraulic unit assembly order job/parts to remove q’ty remarks brake fluid drain. Refer to“bleeding the hydraulic brake system (abs)” on page 3-14. Rider seat refer to “general chassis (1)” on page 4-1. Fuel tank to...

  • Page 218: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-63 removing the hydraulic unit assembly order job/parts to remove q’ty remarks 3 brake hose gasket 8 4 brake hose (hydraulic unit to rear brake caliper) 1 disconnect. 5 brake hose (hydraulic unit to left front brake cal- iper) 1 disconnect. 6 brake hose (front brake ma...

  • Page 219: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-64 eas31036 removing the hydraulic unit assembly notice eca21090 unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids may...

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

    Abs (anti-lock brake system) 4-65 tip do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. Notice eca21110 do not remove the rubber plugs or bolts (m10 × 1.25) installed in the brake hose union bolt holes before insta...

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

    Abs (anti-lock brake system) 4-66 5. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor...

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

    Abs (anti-lock brake system) 4-67 4. Check: • battery voltage lower than 12.8 v → charge or replace the battery. Tip if the battery voltage is lower than 12.8 v, charge the battery, and then perform brake line routing confirmation. 5. Removing the protective cap “1”, and then connect the yamaha diag...

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

    Abs (anti-lock brake system) 4-68 • if the pulse is hardly felt in either the brake lever or brake pedal, check that the brake hoses and brake pipes are connected cor- rectly to the hydraulic unit assembly. 10.If the operation of the hydraulic unit is normal, delete all of the fault codes. Abs react...

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

    Abs (anti-lock brake system) 4-69 9. A reaction-force pulsating action is generated in the brake lever “1” and continues for a few seconds. Tip • the reaction-force pulsating action consists of quick pulses. • be sure to continue operating the brake lever and brake pedal even after the pulsating act...

  • Page 225: Handlebar

    Handlebar 4-70 eas20033 handlebar removing the handlebar order job/parts to remove q’ty remarks meter assembly bracket refer to “general chassis (3)” on page 4-8. 1 rearview mirror 2 2 front brake light switch connector 2 disconnect. 3 front brake master cylinder holder 1 4 front brake master cylind...

  • Page 226: Handlebar

    Handlebar 4-71 removing the handlebar order job/parts to remove q’ty remarks 9 throttle grip 1 10 clutch switch coupler 1 disconnect. 11 handlebar switch (left) 1 12 handlebar grip 1 13 clutch switch 1 14 clutch cable 1 disconnect. 15 clutch lever 1 16 clutch lever holder 1 17 upper handlebar holder...

  • Page 227: Handlebar

    Handlebar 4-72 eas30203 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • throttle cable housings “1” • grip end (right) “2” • throttle grip “3” tip while removing the throttle cab...

  • Page 228: Handlebar

    Handlebar 4-73 • fit the projection “b” on the bottom of the bolt head into the slot “c” in the bolt hole in the clutch lever holder. • while squeezing the clutch lever, fit the projec- tion “d” on the clutch switch into the slot “e” in the clutch lever holder. 4. Install: • handlebar grip “1” • gri...

  • Page 229: Handlebar

    Handlebar 4-74 • there should be 1–3 mm (0.04–0.12 in) of clearance “c” between the throttle grip and the grip end. 7. Install: • handlebar switch (right) “1” tip align the projection “a” on the right handlebar switch with the hole “b” in the handlebar. 8. Install: • throttle cable holder 1 “1” • th...

  • Page 230: Front Fork

    Front fork 4-75 eas20034 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. Meter assembly bracket refer to “general chassis (3)” on page 4-8. Handlebar refer to “handlebar” on page 4-70. Fuel tank top cover/...

  • Page 231: Front Fork

    Front fork 4-76 removing the front fork legs order job/parts to remove q’ty remarks 2 front fender side cover (right) 1 3 front fender 1 4 front fender bracket (left) 1 5 front fender bracket (right) 1 6 brake hose holder 1 7 front fork cap bolt 1 loosen. 8 upper bracket pinch bolt (left and right) ...

  • Page 232: Front Fork

    Front fork 4-77 removing the front fork legs order job/parts to remove q’ty remarks 14 o-ring 1 15 lower bracket pinch bolt 2 loosen. 16 front fork leg 1 14 15 15 16 new lt lt lt lt lt lt 21 nm (2.1 m • kgf, 15 ft • ibf) t.R. 23 nm (2.3 m • kgf, 17 ft • ibf) t.R . 26 nm (2.6 m • kgf, 19 ft • ibf) t....

  • Page 233: Front Fork

    Front fork 4-78 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 protector 1 2 front fork cap bolt 1 3 o-ring 1 4 spacer 1 5 spring seat 1 6 fork spring 1 7 dust seal 1 8 oil seal clip 1 9 front fork damper rod...

  • Page 234: Front Fork

    Front fork 4-79 disassembling the front fork legs order job/parts to remove q’ty remarks 11 damper rod 1 12 damper rod ring 1 13 rebound spring 1 14 inner tube 1 15 oil seal 1 16 washer 1 17 outer tube bushing 1 18 inner tube bushing 1 19 oil flow stopper spring 1 20 oil flow stopper 1 21 outer tube...

  • Page 235: Front Fork

    Front fork 4-80 eas31110 removing the front fender side covers and front fork legs the following procedure applies to both of the front fender side covers and front fork legs. 1. Remove: • front fender side cover “1” • front fender “2” • front fender brackets ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 236: Front Fork

    Front fork 4-81 3. Remove: • front fork damper rod bolt “1” • copper washer tip while holding the damper rod with the damper rod holder “2” and t-handle “3”, loosen the front fork damper rod bolt. 4. Remove: • inner tube ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the front fork leg ho...

  • Page 237: Front Fork

    Front fork 4-82 warning ewa13660 • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling and a loss of stability. Tip • when assembling the front fork leg, be sure to replace the following parts: –inner tube bushing –outer tube bushing –oil sea...

  • Page 238: Front Fork

    Front fork 4-83 5. Tighten: • front fork damper rod bolt “1” tip while holding the damper rod assembly with the damper rod holder “2” and t-handle “3”, tighten the front fork damper rod bolt. 6. Install: • outer tube bushing “1” • washer “2” (with the fork seal driver attachment “3” and fork seal dr...

  • Page 239: Front Fork

    Front fork 4-84 9. Install: • dust seal “1” (with the fork seal driver weight “2”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) 11.Measure: • front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork...

  • Page 240: Front Fork

    Front fork 4-85 tip make sure that the o-ring contacts the top of the lower bracket “3”. 2. Install: • front fork cover “1” • upper bracket “2” tip • before installing the upper bracket, remove any grease from the outer surface “a” of the cap nut. • make sure the inner tube end is flush with the top...

  • Page 241: Front Fork

    Front fork 4-86 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ d b a c 1.

  • Page 242: Steering Head

    Steering head 4-87 eas20035 steering head removing the lower bracket * loosen the cap nut completely, and then tighten it to specification. Order job/parts to remove q’ty remarks headlight assembly refer to “general chassis (3)” on page 4-8. Handlebar front fork legs refer to “front fork” on page 4-...

  • Page 243: Steering Head

    Steering head 4-88 removing the lower bracket * loosen the cap nut completely, and then tighten it to specification. Order job/parts to remove q’ty remarks 6 lower bracket 1 7 lower bracket cap 1 8 bearing cover 1 9 lower bearing dust seal 1 10 upper bearing 1 11 lower bearing 1 11 9 6 7 10 8 ls ls ...

  • Page 244: Steering Head

    Steering head 4-89 eas30213 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: • cap nut “1” • lower bracket warning ewa13730 securely support the lower bracket so that there is n...

  • Page 245: Steering Head

    Steering head 4-90 tip face the holes “a” in the lower bracket cap rear- ward. 3. Install: • lower bracket • cap nut “1” refer to “checking and adjusting the steering head” on page 3-19. Tip before installing the cap nut, remove any grease from the contact surfaces “a” between the cap nut and the be...

  • Page 246: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-91 eas20036 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks 1 drive chain guard 1 2 rear shock absorber assembly nut/bolt (front side) 1/1 3 spacer 1 4 rear shock absorber assembly nut/bolt (rear side) 1/1 5...

  • Page 247: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-92 removing the rear shock absorber assembly order job/parts to remove q’ty remarks 9 bearing 1 10 relay arm nut/bolt 1/1 11 spacer 1 12 oil seal 2 13 bearing 1 14 connecting arm nut/bolt (relay arm side) 1/1 15 relay arm 1 16 spacer 1 17 oil seal 2 18 bearing 1 7 nm (...

  • Page 248: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-93 eas30826 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 249: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-94 tip when installing the oil seals to the relay arm, face the character stamps of the oil seals out- side. 3. Install: • relay arm “1” • relay arm rubber cover “2” (to the relay arm) tip make sure that the portion “a” of the relay arm rubber cover is positioned on to...

  • Page 250: Swingarm

    Swingarm 4-95 eas20037 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper/rear brake hose guide/rear brake hose holder refer to “rear brake” on page 4-49. Rear wheel refer to “rear wheel” on page 4-26. Relay arm refer to “rear shock absorber as- sembly” on page ...

  • Page 251: Swingarm

    Swingarm 4-96 removing the swingarm order job/parts to remove q’ty remarks 5 footrest assembly (left) 1 6 pivot shaft nut 1 7 washer 1 8 pivot shaft 1 9 swingarm 1 10 footrest bracket (left) 1 11 drive chain guide 1 12 dust cover 2 13 oil seal 2 14 spacer 2 15 oil seal 2 16 bearing 3 6 7 8 5 12 13 1...

  • Page 252: Swingarm

    Swingarm 4-97 removing the swingarm order job/parts to remove q’ty remarks 17 connecting arm nut/bolt (frame side) 1/1 18 connecting arm 1 19 spacer 1 20 oil seal 2 21 bearing 2 17 17 19 18 20 20 21 lt lt lt lt ls ls ls ls ls new new new new new 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 7 nm (0.7 m • k...

  • Page 253: Swingarm

    Swingarm 4-98 eas30226 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm...

  • Page 254: Swingarm

    Swingarm 4-99 3. Check: • collar damage/scratches → replace. Eas31114 installing the connecting arm 1. Lubricate: • spacers • bearings 2. Install: • bearings “1” • oil seals “2” (to the connecting arm “3”) tip when installing the oil seals to the connecting arm, face the character stamp of the oil s...

  • Page 255: Swingarm

    Swingarm 4-100 3. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-17. A. Left side b. Right side drive chain slack 51.0–56.0 mm (2.01–2.20 in) a b 1 1 new 2 new 2 new 2 new 2 b c a b d.

  • Page 256: Chain Drive

    Chain drive 4-101 eas20038 chain drive removing the drive chain order job/parts to remove q’ty remarks drive chain guard refer to “rear shock absorber as- sembly” on page 4-91. Pivot shaft protectors/sidestand refer to “swingarm” on page 4-95. 1 shift rod locknut (shift arm side) 1 2 shift rod lockn...

  • Page 257: Chain Drive

    Chain drive 4-102 removing the drive chain order job/parts to remove q’ty remarks 8 pivot shaft nut 1 loosen. 9 drive chain 1 10 drive sprocket nut 1 11 washer 1 12 drive sprocket 1 9 10 11 12 8 new 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 9 nm (0.9 m • kgf, 6.5...

  • Page 258: Chain Drive

    Chain drive 4-103 eas30229 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain “1” tip pus...

  • Page 259: Chain Drive

    Chain drive 4-104 • perform this procedure 2–3 times, at a different location each time. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • drive chain stiffness → clean and lubricate or replace. 3. Clean: • drive chain ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe the drive c...

  • Page 260: Chain Drive

    Chain drive 4-105 eas30231 checking the drive sprocket 1. Check: • drive sprocket more than 1/4 tooth “a” wear → replace the drive chain sprocket, drive chain, and rear wheel sprocket as a set. Bent teeth → replace the drive chain sprock- et, drive chain, and rear wheel sprocket as a set. Eas30232 c...

  • Page 261: Chain Drive

    Chain drive 4-106 4. Fit the space “a” between the side plates of the drive chain “1” onto the rib “b” on the drive chain guide “2”. 5. Install: • shift arm “1” • shift rod joint • shift rod • shift rod locknuts tip before installing, make sure to align the mark “a” of the shift shaft with the punch...

  • Page 262: Chain Drive

    Chain drive 4-107 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Adjust: • drive chain slack refer to“adjusting the drive chain slack” on page 3-17. Notice eca13550 a drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the...

  • Page 263: Engine

    5 engine engine inspection .................................................................................... 5-1 measure the compression pressure ........................................ 5-1 adjusting the exhaust gas volume ........................................... 5-2 checking the cylinder hea...

  • Page 264

    Clutch ........................................................................................................ 5-50 removing the clutch ..................................................................... 5-54 checking the friction plates..................................................... 5-55 c...

  • Page 265

    Crankshaft and balancer shaft ................................................... 5-86 removing the balancer shaft journal bearings .............. 5-87 removing the crankshaft journal bearings ...................... 5-87 checking the balancer shaft assembly ................................ 5-87 chec...

  • Page 266: Engine Inspection

    Engine inspection 5-1 eas20041 engine inspection eas30249 measure 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 “adj...

  • Page 267: Engine Inspection

    Engine inspection 5-2 warning ewa12940 to prevent sparking, ground all spark plug leads before cranking the engine. Tip the difference in compression pressure be- tween cylinders should not exceed 100 kpa (1 kg/cm², 14 psi). C. If the compression pressure is above the maximum specification, check th...

  • Page 268: Engine Inspection

    Engine inspection 5-3 3. Install: • fuel tank refer to “fuel tank” on page 7-1. • fuel tank front cover • fuel tank center cover • fuel tank cover (left) • fuel tank cover (right) • fuel tank top cover refer to “general chassis (4)” on page 4-11. • rider seat refer to “general chassis (1)” on page 4...

  • Page 269: Engine Removal

    Engine removal 5-4 eas20042 engine removal removing the muffler and exhaust pipe order job/parts to remove q’ty remarks pivot shaft protector (right) refer to “swingarm” on page 4-95. Footrest assembly (right) refer to “rear brake” on page 4-49. 1 o 2 sensor coupler 1 disconnect. 2 muffler assembly ...

  • Page 270: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Pivot shaft protectors/sidestand/footrest as- sembly (left) refer to “swingarm” on page 4-95. Brake fluid reservoir/footrest assembly (right) refer to “r...

  • Page 271: Engine Removal

    Engine removal 5-6 disconnecting the leads and hoses order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-24. Radiator/coolant reservoir refer to “radiator” on page 6-1. Oil cooler outlet hose/oil cooler inlet hose refer to “oil cooler” on page 6-4. Water p...

  • Page 272: Engine Removal

    Engine removal 5-7 disconnecting the leads and hoses order job/parts to remove q’ty remarks 3 fuel tank overflow hose 1 4 fuel tank breather hose 1 5 sidestand switch coupler 1 disconnect. 6 engine ground lead 2 disconnect. 7 gear position switch coupler 1 disconnect. 8 starter motor lead 1 disconne...

  • Page 273: Engine Removal

    Engine removal 5-8 removing the engine order job/parts to remove q’ty remarks 1 clutch cable guide 1 2 rear brake hose joint bracket bolt 1 3 rear shock absorber assembly bolt/nut (front side) 1/1 4 spacer 1 5 pivot shaft nut 1 loosen. 6 engine bracket bolt (left) 2 7 engine mounting bolt (left uppe...

  • Page 274: Engine Removal

    Engine removal 5-9 removing the engine order job/parts to remove q’ty remarks 12 engine mounting bolt (right front side) 1 13 engine mounting bolt (left front side) 1 14 engine mounting bolt/nut (rear lower side) 1/1 15 engine mounting bolt/nut (rear upper side) 1/1 16 engine 1 17 plate 1 install th...

  • Page 275: Engine Removal

    Engine removal 5-10 eas30250 removing the engine tip pass a suitable rod “1” through the holes in the brackets of the passenger footrests “2” and se- cure the rod to support the vehicle. 1. Remove: • engine mounting bolt (rear lower side) “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loos...

  • Page 276: Engine Removal

    Engine removal 5-11 tip temporarily tighten the bolts and nuts. 4. Tighten: • engine mounting nut (rear upper side) “4” • engine mounting nut (rear lower side) “6” • engine mounting bolt (left front side) “7” 5. Install: • engine mounting bolt (left upper side) “12” • engine bracket bolts (left) “13...

  • Page 277: Engine Removal

    Engine removal 5-12 a 1.

  • Page 278: Camshafts

    Camshafts 5-13 eas20043 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank top cover/fuel tank cover (left) refer to “general chassis (4)” on page 4-11. Coolant drain. Refer to “changing the coolant” on page 3-24. Radiator inlet hose/radiator refer to “radiat...

  • Page 279: Camshafts

    Camshafts 5-14 removing the cylinder head cover order job/parts to remove q’ty remarks 2 ignition coil coupler 2 disconnect. 3 ignition coil 2 4 spark plug 2 5 cylinder head cover 1 6 cylinder head cover gasket 1 7 breather plate 1 8 breather plate gasket 1 9 timing chain guide (upper side) 1 10 nm ...

  • Page 280: Camshafts

    Camshafts 5-15 removing the camshafts order job/parts to remove q’ty remarks 1 crankshaft end cover 1 2 timing mark accessing bolt 1 3 timing chain tensioner 1 4 timing chain tensioner gasket 1 5 intake camshaft cap 1 6 exhaust camshaft cap 1 7 dowel pin 4 8 intake camshaft 1 9 exhaust camshaft 1 10...

  • Page 281: Camshafts

    Camshafts 5-16 removing the camshafts order job/parts to remove q’ty remarks 12 decompressor lever #2 1 13 decompressor lever #1 1 14 decompressor lever pin 2 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 10 nm (1.0 m • kgf, 7...

  • Page 282: Camshafts

    Camshafts 5-17 eas30256 removing the camshafts 1. Remove: • crankshaft end cover “1” • timing mark accessing bolt “2” 2. Align: • mark “a” on the generator rotor (with the slot “b” in the generator rotor cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise...

  • Page 283: Camshafts

    Camshafts 5-18 7. Remove: • exhaust camshaft sprocket “1” tip while holding the exhaust camshaft with a suit- able tool, loosen the exhaust camshaft sprocket bolts. Eas30257 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: •...

  • Page 284: Camshafts

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

  • Page 285: Camshafts

    Camshafts 5-20 eas30266 checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage/rough movement → re- place. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Tip while pressi...

  • Page 286: Camshafts

    Camshafts 5-21 3. Install: • decompressor lever pins “1” • decompressor lever #1 “2” • decompressor lever #2 “3” tip • face the cutout “a” in each decompressor le- ver pin toward the exhaust camshaft sprocket. • install the decompressor lever pins, decom- pressor lever #1, and decompressor lever #2 ...

  • Page 287: Camshafts

    Camshafts 5-22 tip • when installing the timing chain, start with the exhaust camshaft and be sure to keep the tim- ing chain as tight as possible on the exhaust side. • make sure that the match marks “a” on the ex- haust camshaft sprocket and cam lobe #1 “b” are aligned with the cylinder head edge ...

  • Page 288: Camshafts

    Camshafts 5-23 c. Install a new timing chain tensioner gasket “3”, the timing chain tensioner “4”, and the timing chain tensioner bolts “5” on the cylin- der block. Tip be sure to install the timing chain tensioner gas- ket so that the portion “a” of the gasket is pro- truding from the upper inner s...

  • Page 289: Camshafts

    Camshafts 5-24 eas30274 installing the cylinder head cover 1. Install: • timing chain guide (top side) • cylinder head cover gasket “1” (to the cylinder head cover) • cylinder head cover “2” tip • apply yamaha bond no.1215 “3” onto the mat- ing surfaces of the cylinder head cover gasket and cylinder...

  • Page 290: Cylinder Head

    Cylinder head 5-25 eas20044 cylinder head removing the cylinder head * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank...

  • Page 291: Cylinder Head

    Cylinder head 5-26 removing the cylinder head * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks muffler assembly refer to “engine removal” on page 5-4. Oil cooler inlet hose disconnect. Refer to “oil coo...

  • Page 292: Cylinder Head

    Cylinder head 5-27 removing the cylinder head * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks 4 engine mounting bolt (left upper side) 1 5 engine bracket (left) 1 6 engine bracket bolt (right) 2 7 engi...

  • Page 293: Cylinder Head

    Cylinder head 5-28 removing the cylinder head * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks 16 timing chain 1 17 timing chain guide (intake side) 1 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m...

  • Page 294: Cylinder Head

    Cylinder head 5-29 eas30276 removing the cylinder head 1. Remove: the following procedure applies to both of the engine bracket. • engine bracket bolts “1” • engine mounting bolt “2” • engine bracket “3” tip • place a suitable stand under the engine. • loosen the bolts in the proper sequence as show...

  • Page 295: Cylinder Head

    Cylinder head 5-30 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. B. Measure the warpage. C. If the limit is exceeded, resurface the cylinder head as follows. D. Place a 400–600 grit wet sandpaper on the surface plate...

  • Page 296: Valves and Valve Springs

    Valves and valve springs 5-31 eas20045 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 5-25. 1 valve lifter 8 2 valve pad 8 3 valve cotter 16 4 valve spring retainer 8 5 valve spring 8 6 exhaust valv...

  • Page 297: Valves and Valve Springs

    Valves and valve springs 5-32 eas30283 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 298: Valves and Valve Springs

    Valves and valve springs 5-33 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 299: Valves and Valve Springs

    Valves and valve springs 5-34 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 300: Valves and Valve Springs

    Valves and valve springs 5-35 tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice eca13790 do not let the lappi...

  • Page 301: Valves and Valve Springs

    Valves and valve springs 5-36 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 spring. Eas30287 checking the valve lifters the following procedure applies to all of the valve ...

  • Page 302: Valves and Valve Springs

    Valves and valve springs 5-37 4. Install: • valve spring seat “1” (into the cylinder head) • valve stem seal “2” • valve “3” • valve spring “4” • valve spring retainer “5” tip • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. ...

  • Page 303: Valves and Valve Springs

    Valves and valve springs 5-38 • each valve lifter and valve pad must be rein- stalled in their original position..

  • Page 304: Generator and Starter Clutch

    Generator and starter clutch 5-39 eas20140 generator and starter clutch removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank cover (left) refer to “general chassis (4)”...

  • Page 305: Generator and Starter Clutch

    Generator and starter clutch 5-40 removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks 2 crankshaft position sensor coupler 1 disconnect. 3 crankshaft end cover 1 4 timing mark accessing bolt 1 5 oil filler cap 1 6 generator cover 1 7 generator cover ga...

  • Page 306: Generator and Starter Clutch

    Generator and starter clutch 5-41 removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks 13 bearing 1 14 generator rotor 1 15 starter clutch 1 16 woodruff key 1 17 starter clutch idle gear shaft 1 18 starter clutch idle gear 1 19 starter clutch gear 1 10 ...

  • Page 307: Generator and Starter Clutch

    Generator and starter clutch 5-42 eas30867 removing the generator 1. Remove: • generator rotor bolt “1” • washer tip while holding the generator rotor “2” with the ro- tor holding tool “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff ke...

  • Page 308: Generator and Starter Clutch

    Generator and starter clutch 5-43 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 309: Generator and Starter Clutch

    Generator and starter clutch 5-44 3. Install: • bearing “1” tip make sure that the bearing does not protrude past the surface “a” of the cylinder. 4. Apply: • sealant (onto the stator coil lead grommet) 5. Install: • bearing “1” tip make sure that the bearing contacts the surface “a” of the generato...

  • Page 310: Electric Starter

    Electric starter 5-45 eas20052 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank center cover/fuel tank front cover refer to “general chassis (4)” on page 4-11. Fuel...

  • Page 311: Electric Starter

    Electric starter 5-46 removing the starter motor order job/parts to remove q’ty remarks 1 gear position switch coupler 1 2 fuel tank overflow hose 1 3 fuel tank breather hose 1 4 coupler and hose bracket 1 5 starter motor lead 1 disconnect. 6 starter motor 1 1 2 3 4 5 6 10 nm (1.0 m • kgf, 7.2 ft • ...

  • Page 312: Electric Starter

    Electric starter 5-47 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 starter motor yoke 1 4 armature assembly 1 5 gasket 2 6 brush holder set 1 7 starter motor rear cover 1 8 lead guide 1 5 5 2 7 8 6 1 3 4 ls new new new new 5 nm (0....

  • Page 313: Electric Starter

    Electric starter 5-48 eas30325 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification → cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of the ...

  • Page 314: Electric Starter

    Electric starter 5-49 7. Check: • bearing • oil seal damage/wear → replace the starter motor front cover. Eas30326 assembling the starter motor 1. Install: • lead guide “1” tip make sure that the slot “a” in the lead guide is facing in the direction shown in the illustration. 2. Install: • starter m...

  • Page 315: Clutch

    Clutch 5-50 eas20055 clutch removing the clutch cover and pull lever shaft order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-22. Water pump housing refer to “water pump” on page 6-9. 1 clutch cable 1 disconnect. 2 clutch cable holder 1 3 holder (o ...

  • Page 316: Clutch

    Clutch 5-51 removing the clutch cover and pull lever shaft order job/parts to remove q’ty remarks 6 dowel pin 2 7 circlip 1 8 pull lever 1 9 pull lever spring 1 10 circlip 1 11 pull lever shaft 1 12 oil seal 1 13 bearing 1 14 bearing 1 (8) 6 6 7 9 8 11 10 12 13 14 ls new new e e lt lt 12 nm (1.2 m •...

  • Page 317: Clutch

    Clutch 5-52 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 2 6 clutch plate 6 7 friction plate 2 5 8 clutch boss nut 1 9 conical spring washer 1 10 washer 1 11 clutch boss 1 lt lt e e e ls new e 8 9 5 5...

  • Page 318: Clutch

    Clutch 5-53 removing the clutch order job/parts to remove q’ty remarks 12 thrust plate 1 13 spacer 1 14 bearing 1 15 clutch housing 1 16 thrust plate 1 17 oil pump drive chain 1 18 oil pump drive chain guide 1 lt lt e e e ls new e (6) (6) 18 13 14 17 16 15 12 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . ...

  • Page 319: Clutch

    Clutch 5-54 eas30346 removing the clutch 1. Remove: • clutch cover “1” • gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compression springs • pressure pl...

  • Page 320: Clutch

    Clutch 5-55 eas30348 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the friction plates as a set. Tip me...

  • Page 321: Clutch

    Clutch 5-56 eas30352 checking the clutch housing 1. Check: • clutch housing dogs damage/pitting/wear → deburr the clutch housing dogs or replace the clutch housing. Tip pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: • oil pump drive sprocket “1” cracks/damage/wea...

  • Page 322: Clutch

    Clutch 5-57 2. Check: • pull rod bearing damage/wear → replace. Eas30363 installing the clutch 1. Install: • oil pump drive chain “1” • thrust plate • clutch housing “2” • bearing • spacer tip install the oil pump drive chain onto the oil pump drive sprocket “a”. 2. Install: • thrust plate • clutch ...

  • Page 323: Clutch

    Clutch 5-58 • clutch springs • clutch spring bolts “3” tip • apply lithium-soap-based grease onto the pull rod. • tighten the clutch spring bolts in stages and in a crisscross pattern. 5. Install: • bearings “1” • oil seal “2” (to the clutch cover) tip • lubricate the bearings with engine oil and lu...

  • Page 324: Clutch

    Clutch 5-59 • clutch cover gasket “2” • clutch cover “3” • clutch cable holder “4” tip • align the slit “a” in the impeller shaft with the projection “b” on the oil pump driven sprocket. • face the serrations on the clutch pull rod “5” rearward and align the rod with the hole “c” in the clutch cover...

  • Page 325: Shift Shaft

    Shift shaft 5-60 eas20057 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-50. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 circlip 1 6 washer 1 7 stopper lever 1 8 stopper lever spring 1 9 collar 1 22 nm ...

  • Page 326: Shift Shaft

    Shift shaft 5-61 removing the shift shaft and stopper lever order job/parts to remove q’ty remarks 10 shift shaft spring 1 11 shift shaft spring stopper 1 12 oil seal 1 13 bearing 1 22 nm (2.2 m • kgf, 16 ft • ibf) t.R. E e ls new new new lt e 12 13 11 10

  • Page 327: Shift Shaft

    Shift shaft 5-62 eas30377 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” • collar damage/wear → replace. Eas30378 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace the stopper le...

  • Page 328: Oil Pump

    Oil pump 5-63 eas20054 oil pump removing the oil pump order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-50. 1 oil pump assembly 1 2 holder 1 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 12 nm (1.2 m • kgf, 8.7 ft • ibf) t.R . 12 nm (1.2 m • kgf, 8.7 ft • ibf) t.R . Lt 1 2.

  • Page 329: Oil Pump

    Oil pump 5-64 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump cover 1 2 oil pump rotor assembly 1 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 oil pump driven sprocket 1 7 circlip 1 hold down the washer when removing the circlip. 8 washer 1 9 spring 1 10 r...

  • Page 330: Oil Pump

    Oil pump 5-65 eas30336 checking the sprocket and chain 1. Check: • oil pump drive sprocket refer to “checking the clutch hous- ing” on page 5-56. • oil pump driven sprocket refer to “checking the oil pump” on page 5-65. 2. Check: • oil pump drive chain damage/stiffness → replace the oil pump drive c...

  • Page 331: Oil Pump

    Oil pump 5-66 2. Lubricate: • oil pump driven sprocket (with the recommended lubricant) 3. Install: • oil pump driven sprocket “1” • pin “2” • outer rotor “3” • inner rotor “4” • oil pump cover “5” • oil pump cover screw “6” tip align the pin in the oil pump shaft with the grooves “a” in the inner r...

  • Page 332: Oil Pan

    Oil pan 5-67 eas20177 oil pan removing the oil pan order job/parts to remove q’ty remarks pivot shaft protector (right) refer to “swingarm” on page 4-95. Footrest assembly (right) refer to “rear brake” on page 4-49. Muffler assembly refer to “engine removal” on page 5-4. Engine oil drain. Refer to “...

  • Page 333: Oil Pan

    Oil pan 5-68 eas31068 removing the oil pan 1. Remove: • oil pan “1” • oil pan gasket tip • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • insert a flat-head screwdriver into the slots “a” in the oil pan to ...

  • Page 334: Crankcase

    Crankcase 5-69 eas20059 crankcase separating the crankcase * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-4. Cylinder head cover refer to “camshafts” on page...

  • Page 335: Crankcase

    Crankcase 5-70 separating the crankcase * following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque. Order job/parts to remove q’ty remarks oil cooler refer to “oil cooler” on page 6-4. Drive sprocket refer to “chain drive” on page 4-101. 1 oil pressure...

  • Page 336: Crankcase

    Crankcase 5-71 eas30389 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolt ( ×27) 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 “1”–“11” in any ...

  • Page 337: Crankcase

    Crankcase 5-72 3. Install: • dowel pins 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: • crankcase “1” (onto the cylinder “2”) notice eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assem...

  • Page 338: Crankcase

    Crankcase 5-73 notice eca20890 do not use a torque wrench to tighten the bolt to the specified angle. Tip tighten the bolts in the tightening sequence cast on the crankcase. 8. Tighten: • crankcase bolts “7”–“27” tip • tighten the bolts “7”–“16” in the tightening se- quence cast on the crankcase. • ...

  • Page 339: Crankcase

    Crankcase 5-74 a 1 2 2 b 45˚ 10˚ 1.

  • Page 340: Connecting Rods and Pistons

    Connecting rods and pistons 5-75 eas20132 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks the following procedure applies to all of the connecting rods and pistons. Refer to “crankcase” on page 5-69. 1 connecting rod cap 1 2 big end lower b...

  • Page 341: Connecting Rods and Pistons

    Connecting rods and pistons 5-76 removing the connecting rods and pistons order job/parts to remove q’ty remarks 8 top ring 1 9 2nd ring 1 10 oil ring 1 9 10 8 1st 20 nm (2.0 m • kgf, 14 ft • ibf) 2nd specified angle 180˚ t.R. New new new new e e e e e m m.

  • Page 342: Connecting Rods and Pistons

    Connecting rods and pistons 5-77 eas30745 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” • connecting rod • big end bearings tip • identify the position of each connecting rod cap so that it ca...

  • Page 343: Connecting Rods and Pistons

    Connecting rods and pistons 5-78 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore with the cylinder bore gauge. Tip measure cylinder bore by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. B. If out of specific...

  • Page 344: Connecting Rods and Pistons

    Connecting rods and pistons 5-79 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 345: Connecting Rods and Pistons

    Connecting rods and pistons 5-80 eas30750 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following procedure applies to all of the connecting rods. Notic...

  • Page 346: Connecting Rods and Pistons

    Connecting rods and pistons 5-81 tip to install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment. F. Loosen the connecting rod bolts, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with...

  • Page 347: Connecting Rods and Pistons

    Connecting rods and pistons 5-82 l. Measure the compressed plastigauge® width on the crankshaft pin. If the crankshaft- pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Select: • big end bearings (p 1 ...

  • Page 348: Connecting Rods and Pistons

    Connecting rods and pistons 5-83 2. Tighten: • connecting rod bolts notice eca18390 tighten the connecting rod bolts using the plastic-region tightening angle method. Al- ways install new bolts. Tip install by carrying out the following procedures in order to assemble in the most suitable condition....

  • Page 349: Connecting Rods and Pistons

    Connecting rods and pistons 5-84 • reinstall each piston into its original cylinder. 5. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) 6. Offset: • piston ring end gaps 7. Lubricate: • crankshaft pin • connecting rod big end bearing inner surface (with the recommended...

  • Page 350: Connecting Rods and Pistons

    Connecting rods and pistons 5-85 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ tip tighten the connecting rod bolts using the fol- lowing procedure. A. Tighten the connecting rod bolts with a torque wrench. B. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap...

  • Page 351: 5-86

    Crankshaft and balancer shaft 5-86 eas20178 crankshaft and balancer shaft removing the crankshaft and balancer shaft order job/parts to remove q’ty remarks crankcase refer to “crankcase” on page 5-69. Connecting rod refer to “connecting rods and pis- tons” on page 5-75. 1 balancer shaft assembly 1 2...

  • Page 352: 5-87

    Crankshaft and balancer shaft 5-87 eas31072 removing the balancer shaft journal bearings 1. Remove: • balancer shaft journal lower bearings (from the crankcase) • balancer shaft journal upper bearings (from the cylinder) tip identify the position of each balancer shaft jour- nal bearing so that it c...

  • Page 353: 5-88

    Crankshaft and balancer shaft 5-88 tip do not put the plastigauge® over the oil hole in the balancer shaft journal. D. Install the balancer shaft journal lower bear- ings “3” into the crankcase and assemble the crankcase and cylinder. Tip • align the projections “c” of the balancer shaft journal low...

  • Page 354: 5-89

    Crankshaft and balancer shaft 5-89 for example, if the crankcase j 1 and balanc- er shaft web j 1 numbers are 6 and 5 respec- tively, then the bearing size for j 1 is: eas31075 checking the crankshaft 1. Check: • balancer drive gear damage/wear → replace the balancer drive gear and balancer shaft as...

  • Page 355: 5-90

    Crankshaft and balancer shaft 5-90 d. Install the crankshaft journal lower bearings “3” into the crankcase and assemble the crankcase and cylinder. Tip • align the projections “d” of the crankshaft jour- nal lower bearings with the notches “e” in the crankcase. • do not move the crankshaft until the...

  • Page 356: 5-91

    Crankshaft and balancer shaft 5-91 eas31077 installing the crankshaft 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) tip • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b...

  • Page 357: Transmission

    Transmission 5-92 eas20062 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase refer to “crankcase” on page 5-69. 1 drive axle assembly 1 2 shift drum retainer 1 3 shift fork guide bar 2 4 shift fork “l” 1 5 shift fork “r” 1 6...

  • Page 358: Transmission

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

  • Page 359: Transmission

    Transmission 5-94 disassembling the main axle assembly order job/parts to remove q’ty remarks 13 main axle 1 m m m m m m m new new 13.

  • Page 360: Transmission

    Transmission 5-95 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 1st wheel gear 1 2 collar 1 3 5th wheel gear 1 4 circlip 1 5 washer 1 6 3rd wheel gear 1 7 collar 1 8 toothed lock washer 1 9 toothed lock washer retainer 1 10 4th wheel gear 1 11 collar 1 12 washer 1 10...

  • Page 361: Transmission

    Transmission 5-96 disassembling the drive axle assembly order job/parts to remove q’ty remarks 13 circlip 1 14 6th wheel gear 1 15 circlip 1 16 washer 1 17 collar 1 18 2nd wheel gear 1 19 oil seal 1 20 circlip 1 21 bearing 1 22 collar 1 23 drive axle 1 13 14 15 16 17 18 20 19 21 22 23 ls m m m m m m...

  • Page 362: Transmission

    Transmission 5-97 eas30430 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainer “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • bearing retainer • main axle assembly bearing housing “1” • main axle assembly “2” ...

  • Page 363: Transmission

    Transmission 5-98 eas30433 checking the transmission 1. Measure: • main axle runout (with a centering device and dial gauge “1”) out of specification → replace the main axle. 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3...

  • Page 364: Transmission

    Transmission 5-99 2. Install: • toothed lock washer retainer “1” • toothed lock washer “2” tip • with the toothed lock washer retainer in the groove “a” in the axle, align the projection “b” on the retainer with an axle spline “c”, and then install the toothed lock washer. • be sure to align the pro...

  • Page 365: Transmission

    Transmission 5-100 4. Check: • transmission rough movement → repair. Tip oil each gear, shaft, and bearing thoroughly. 3 2 1 c b a.

  • Page 366: Transmission

    Transmission 5-101.

  • Page 367: Cooling System

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

  • Page 368: Radiator

    Radiator 6-1 eas20063 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-24. Fuel tank top cover/fuel tank side cover (left) refer to “general chassis (4)” on page 4-11. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant ...

  • Page 369: Radiator

    Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 6 radiator side cover (left) 1 7 radiator side cover (right) 1 8 horn connector 2 disconnect. 9 horn 1 10 radiator fan motor coupler 1 disconnect. 11 radiator outlet hose 1 12 radiator inlet hose 1 13 radiator 1 14 radiator fa...

  • Page 370: Radiator

    Radiator 6-3 eas30439 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses cracks/damage → replace. • radia...

  • Page 371: Oil Cooler

    Oil cooler 6-4 eas20064 oil cooler removing the oil cooler order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-24. Engine oil drain. Refer to “changing the engine oil” on page 3-22. Coolant reservoir refer to “radiator” on page 6-1. 1 oil filter cartridge ...

  • Page 372: Oil Cooler

    Oil cooler 6-5 removing the oil cooler order job/parts to remove q’ty remarks 4 oil cooler inlet hose 1 5 oil cooler outlet hose 1 6 oil filter cartridge union bolt 1 7 oil cooler 1 8 gasket 1 ls new new e e ls 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 2.0 nm (0.20 m • kgf, 1.4 ft • ibf) t.R. 40 nm (4....

  • Page 373: Oil Cooler

    Oil cooler 6-6 eas30441 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 cracks/damage → replace. Eas31123 checking the water jacket joint 1. Check: • water jacket joint mineral deposits/rust →...

  • Page 374: Thermostat

    Thermostat 6-7 eas20065 thermostat removing the thermostat order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-24. 1 coolant temperature sensor coupler 1 disconnect. 2 coolant temperature sensor 1 3 radiator inlet hose 1 disconnect. 4 thermostat cover 1 5 ...

  • Page 375: Thermostat

    Thermostat 6-8 eas30443 checking the thermostat 1. Check: • thermostat does not open at 80–84 °c (176–183.2 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in...

  • Page 376: Water Pump

    Water pump 6-9 eas20066 water pump removing the water pump order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-24. Engine oil refer to “changing the engine oil” on page 3-22. 1 clutch cable 1 disconnect. 2 water pump outlet hose 1 disconnect. 3 oil cooler ...

  • Page 377: Water Pump

    Water pump 6-10 removing the water pump order job/parts to remove q’ty remarks 6 water pump outlet pipe 1 7 water pump housing 1 8 clutch cover 1 9 impeller shaft 1 10 water pump seal assembly 1 11 oil seal 1 12 bearing 1 lt lt ls ls ls new new new new new new new e ls lt 10 nm (1.0 m • kgf, 7.2 ft ...

  • Page 378: Water Pump

    Water pump 6-11 eas30446 disassembling the water pump 1. Remove: • mechanical seal (impeller side) “1” (from the impeller, with a thin, flat-head screwdriver) tip do not scratch the impeller shaft. 2. Remove: • mechanical seal (housing side) “1” tip remove the mechanical seal (housing side) from the...

  • Page 379: Water Pump

    Water pump 6-12 3. Install: • mechanical seal (impeller side) “1” tip before installing the mechanical seal (impeller side), apply tap water or coolant onto its outer surface. 4. Measure: • mechanical seal (impeller side) out of specification → repeat steps (3) and (4). Notice eca14090 make sure the...

  • Page 380: Water Pump

    Water pump 6-13 eas31117 installing the clutch cover 1. Install: • dowel pins “1” • clutch cover gasket “2” • clutch cover “3” tip • align the slit “a” in the impeller shaft with the projection “b” on the oil pump driven sprocket. • face the serrations on the clutch pull rod “4” rearward and align t...

  • Page 381: Fuel System

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

  • Page 382: Fuel Tank

    Fuel tank 7-1 eas20067 fuel tank removing the fuel tank and fuel pump order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank center cover/fuel tank front cover “general chassis (4)” on page 4-11. 1 air temperature ...

  • Page 383: Fuel Tank

    Fuel tank 7-2 removing the fuel tank and fuel pump order job/parts to remove q’ty remarks 7 intake air temperature sensor 1 8 fuel pump 1 9 front fuel tank bracket 1 10 rear fuel tank bracket 1 (4) new 3.8 nm (0.38 m • kgf, 2.8 ft • ibf) t.R . 4.0 nm (0.40 m • kgf, 2.9 ft • ibf) t.R . 10 nm (1.0 m •...

  • Page 384: Fuel Tank

    Fuel tank 7-3 eas30450 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 ewa17320 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when...

  • Page 385: Fuel Tank

    Fuel tank 7-4 eas31081 installing the fuel tank bracket 1. Install: • grommets • collars • front fuel tank bracket “1” tip make sure that the arrow mark “a” on the front fuel tank bracket points toward the hole “b” in the fuel tank. 2. Install: • grommets • collars • rear fuel tank bracket “1” tip m...

  • Page 386: Fuel Tank

    Fuel tank 7-5 • intake air temperature sensor 4. Tighten: • rear fuel tank bracket bolts 5. Tighten: • front fuel tank bracket bolt t r . . Rear fuel tank bracket bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) t r . . Front fuel tank bracket bolt 30 nm (3.0 m·kgf, 22 ft·lbf).

  • Page 387: Air Filter Case Valve

    Air filter case valve 7-6 eas20179 air filter case valve removing the air filter case valve and air filter element a: 1xb1, 1xb5, 1xb6 b: 1xb2, 1xb7, 1xb8 order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank cent...

  • Page 388: Air Filter Case Valve

    Air filter case valve 7-7 removing the air filter case valve and air filter element a: 1xb1, 1xb5, 1xb6 b: 1xb2, 1xb7, 1xb8 order job/parts to remove q’ty remarks 3 air duct 1 4 plug 1 5 air filter case valve 1 6 air filter element 1 a b (4) new 3 5 6 4 1.6 nm (0.16 m • kgf, 1.2 ft • ibf) t.R. 1.6 n...

  • Page 389: Air Filter Case Valve

    Air filter case valve 7-8 eas31090 checking the air filter case valve 1. Check: • air filter case valve operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the air duct bracket (with the air filter case valve). B. Connect the vacuum/pressure pump gauge set “1” to the air filter cas...

  • Page 390: Throttle Bodies

    Throttle bodies 7-9 eas20070 throttle bodies removing the air filter case and throttle bodies order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank center cover/fuel tank front cover refer to “general chassis (4)”...

  • Page 391: Throttle Bodies

    Throttle bodies 7-10 removing the air filter case and throttle bodies order job/parts to remove q’ty remarks 3 injector coupler 2 disconnect. 4 isc (idle speed control) unit coupler 1 disconnect. 5 intake solenoid vacuum hose (throttle body to one way valve) 1 disconnect. 6 intake air pressure senso...

  • Page 392: Throttle Bodies

    Throttle bodies 7-11 removing the fuel injectors order job/parts to remove q’ty remarks 1 isc (idle speed control) valve plate 1 2 isc (idle speed control) valve 1 3 spring 1 4 throttle position sensor 1 5 fuel rail 1 6 fuel injector 2 new new new new new 3.5 nm (0.35 m • kgf, 2.5 ft • ibf) t.R . 3....

  • Page 393: Throttle Bodies

    Throttle bodies 7-12 eas30475 checking the injectors (before removing) 1. Check: • injectors use the diagnostic code numbers “36–37”. Refer to “self-diagnostic function and diagnostic code table” on page 9-5. Eas30476 removing the injectors warning ewa17330 • check the injectors in a well-ventilated...

  • Page 394: Throttle Bodies

    Throttle bodies 7-13 • do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place the throttle bodies on a flat surface with the air filter case side facing up. B. Install the caps (895-14169-00) ...

  • Page 395: Throttle Bodies

    Throttle bodies 7-14 notice eca21230 • be sure to use the recommended cleaning agent. • do not spray the cleaning agent directly onto the isc valve or throttle bodies and do not immerse them in the cleaning agent. • to prevent scratching the components, do not use a brush, metal file, or other abra-...

  • Page 396: Throttle Bodies

    Throttle bodies 7-15 eas30485 adjusting the throttle position sensor warning ewa16690 • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: • throttle position sensor r...

  • Page 397: Throttle Bodies

    Throttle bodies 7-16 eas30481 checking the injector pressure tip • after installing the fuel injectors, perform the following steps to check the injector pressure. • do not allow any foreign materials to enter the fuel lines. 1. Check: • injector pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 398: Throttle Bodies

    Throttle bodies 7-17 c. Connect the pressure gauge “3” and adapter “4” to the fuel hose “2”. D. Start the engine. E. Measure the fuel pressure. Faulty → replace the fuel pump. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • fuel tank refer to “fuel tank” on page 7-1. • fuel tank fron...

  • Page 399: Throttle Bodies

    Throttle bodies 7-18 a b c a b c 1.

  • Page 400: Intake Solenoid

    Intake solenoid 7-19 eas20181 intake solenoid removing the intake solenoid order job/parts to remove q’ty remarks rider seat refer to “general chassis (1)” on page 4-1. Fuel tank top cover/fuel tank covers/fuel tank center cover/fuel tank front cover refer to “general chassis (4)” on page 4-11. Fuel...

  • Page 401: Intake Solenoid

    Intake solenoid 7-20 removing the intake solenoid order job/parts to remove q’ty remarks 4 one-way valve 1 5 intake solenoid vacuum hose (one-way valve to intake solenoid) 1 6 surge tank hose 1 7 intake solenoid 1 8 surge tank 1 6 8 7 4 5 3.8 nm (0.38 m • kgf, 2.8 ft • ibf) t.R ..

  • Page 402: Intake Solenoid

    Intake solenoid 7-21 eas31093 checking the vacuum line 1. Check: • hoses loose connections → connect properly. Cracks/damage → replace. 2. Check: • surge tank cracks/damage → replace. 3. Check: • one-way valve cracks/damage/faulty → replace. Tip check that air flows smoothly only in the direc- tion ...

  • Page 403: Electrical System

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

  • Page 404

    Abs (anti-lock brake system)........................................................... 8-87 circuit diagram ................................................................................ 8-87 abs coupler location chart ...................................................... 8-89 maintenance of the...

  • Page 406: Ignition System

    Ignition system 8-1 eas20072 ignition system eas30490 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y r ...

  • Page 407: Ignition System

    Ignition system 8-2 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 22.Relay unit 25.Joint coupler 26.Sidestand switch 27.Crankshaft position sensor 30.Ignition coil #1 31.Ignition coil #2 32.Spark plug 37.Ecu (engine control unit) 41.Lean angle...

  • Page 408: Ignition System

    Ignition system 8-3 eas30491 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 ecu does not flow to the ignition coils or fuel injectors when the ge...

  • Page 409: Ignition System

    Ignition system 8-4 eas30492 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Drive sprocket cover 7. Headlight a...

  • Page 410: 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 8-123. • the start/engine stop switch is faulty. • replace the right handlebar switch. 9. Check the gear position switch. Refer to “checking...

  • Page 411: Ignition System

    Ignition system 8-6.

  • Page 412: Electric Starting System

    Electric starting system 8-7 eas20073 electric starting system eas30493 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ ...

  • Page 413: Electric Starting System

    Electric starting system 8-8 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 19.Starter relay 20.Starter motor 22.Relay unit 23.Starting circuit cut-off relay 25.Joint coupler 26.Sidestand switch 37.Ecu (engine control unit) 63.Gear position swi...

  • Page 414: Electric Starting System

    Electric starting system 8-9 eas30494 starting circuit cut-off system operation if the main switch is turned to “on” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutral (th...

  • Page 415: Electric Starting System

    Electric starting system 8-10 eas30495 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Drive sprocket cover 7. Headlight assembly ng → ok ↓ ng → ok ↓ ...

  • Page 416: Electric Starting System

    Electric starting system 8-11 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-123. Replace the main switch/immobilizer unit. 9. Check the gear position switch. Refer to “checking the gear position switch” on page 8-140....

  • Page 417: Electric Starting System

    Electric starting system 8-12.

  • Page 418: Charging System

    Charging system 8-13 eas20074 charging system eas30496 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y r...

  • Page 419: Charging System

    Charging system 8-14 13.Ac magneto 14.Rectifier/regulator 15.Battery 16.Engine ground 18.Main fuse.

  • Page 420: Charging System

    Charging system 8-15 eas30497 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank cover (left) ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “...

  • Page 421: Charging System

    Charging system 8-16.

  • Page 422: Lighting System

    Lighting system 8-17 eas20075 lighting system eas30498 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y r...

  • Page 423: Lighting System

    Lighting system 8-18 1. Main switch 7. Ignition fuse 8. Signaling system fuse 9. Headlight fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 25.Joint coupler 37.Ecu (engine control unit) 49.Meter assembly 52.Meter light 58.High beam indicator light 69.Handlebar switch (left...

  • Page 424: Lighting System

    Lighting system 8-19 eas30499 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers ...

  • Page 425: Lighting System

    Lighting system 8-20 ng → ok ↓ ng → ok ↓ 7. Check the headlight relay. Refer to “checking the re- lays” on page 8-131. Replace the headlight relay. 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-17. Properly connect or replace the wiring har- ness. Replace the ecu, ...

  • Page 426: Signaling System

    Signaling system 8-21 eas20076 signaling system eas30500 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y...

  • Page 427: Signaling System

    Signaling system 8-22 1. Main switch 4. Parking lighting fuse 5. Abs control unit fuse 7. Ignition fuse 8. Signaling system fuse 10.Fuel injection system fuse 11.Backup fuse 15.Battery 16.Engine ground 18.Main fuse 21.Rear brake light switch 22.Relay unit 25.Joint coupler 37.Ecu (engine control unit...

  • Page 428: Signaling System

    Signaling system 8-23 eas30501 troubleshooting • any of the following fail to light: turn signal light, brake light or an 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. ...

  • Page 429: Signaling System

    Signaling system 8-24 ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-21....

  • Page 430: Signaling System

    Signaling system 8-25 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the oil pressure warning light fails to come on when the main switch is set to “on”. Ng → ok ↓ ng → ok ↓ 5. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-21. P...

  • Page 431: Signaling System

    Signaling system 8-26 the oil pressure warning light remains on after the engine is started. Ng → ok ↓ ng → ok ↓ the fuel meter, fuel level warning light, or both fail to come on. Ng → ok ↓ ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the entire sign...

  • Page 432: Signaling System

    Signaling system 8-27 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) (black–black) • between abs ecu coupler and joint coupler. (blue/black–blue/black) (bl...

  • Page 433: Signaling System

    Signaling system 8-28.

  • Page 434: Cooling System

    Cooling system 8-29 eas20077 cooling system eas30502 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y r /...

  • Page 435: Cooling System

    Cooling system 8-30 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 12.Radiator fan motor fuse 15.Battery 16.Engine ground 18.Main fuse 25.Joint coupler 37.Ecu (engine control unit) 39.Coolant temperature sensor 85.Radiator fan motor 86.Radiator fan motor relay a. Wire harness c. Sub-w...

  • Page 436: Cooling System

    Cooling system 8-31 eas30503 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check th...

  • Page 437: Cooling System

    Cooling system 8-32 ng → ok ↓ 7. Check the entire cooling system wiring. Refer to “circuit diagram” on page 8-29. Properly connect or replace the wiring har- ness. Replace the ecu. Refer to “replac- ing the ecu (engine control unit)” on page 8-128..

  • Page 438: Fuel Injection System

    Fuel injection system 8-33 eas20078 fuel injection system eas30504 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l...

  • Page 439: Fuel Injection System

    Fuel injection system 8-34 1. Main switch 5. Abs control unit fuse 7. Ignition fuse 9. Headlight fuse 10.Fuel injection system fuse 11.Backup fuse 15.Battery 16.Engine ground 18.Main fuse 22.Relay unit 23.Starting circuit cut-off relay 24.Fuel pump relay 25.Joint coupler 26.Sidestand switch 27.Crank...

  • Page 440: Fuel Injection System

    Fuel injection system 8-35 eas30505 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 441: Fuel Injection System

    Fuel injection system 8-36 b. Identify the faulty system with the fault code number. C. Identify the probable cause of the malfunction. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲▲▲ ▲ 2. Check and repair the probable cause of the malfunction....

  • Page 442: Fuel Injection System

    Fuel injection system 8-37 functions of the yamaha diagnostic tool however, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad- justing the ignition timing. Connecting the yamaha diagnostic tool remove the protective cap “1”, and then connect the yamaha diagn...

  • Page 443: Fuel Injection System

    Fuel injection system 8-38 1. Recovered the item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected the item list of the malfunction currently occurred are displayed. 3. Code the following icons and the fault code numbers for the detected malfunctions are dis...

  • Page 444: Fuel Injection System

    Fuel injection system 8-39 6. Condition the current conditions are displayed. (detected/recovered) 7. Symptom the symptoms of the detected malfunction are displayed. 8. Diagnosis code the diagnosis codes related to the detected malfunction are displayed. 9. Ffd (only for models that can display free...

  • Page 445: Fuel Injection System

    Fuel injection system 8-40 fault code no. 13 tip if fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken ter...

  • Page 446: Fuel Injection System

    Fuel injection system 8-41 item probable cause of malfunc- tion and check maintenance job confirmation of service com- pletion 1 connection of intake air pres- sure sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and loc...

  • Page 447: Fuel Injection System

    Fuel injection system 8-42 fault code no. 14 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...

  • Page 448: Fuel Injection System

    Fuel injection system 8-43 fault code no. 15 1 condition of intake air pressure sensor hose. Check the intake air pressure sensor hose condition. Clogged or detached hose → repair or replace the sensor hose. Start the engine and let it idle for approximately 5 seconds. Fault code number is not dis- ...

  • Page 449: Fuel Injection System

    Fuel injection system 8-44 1 connection of throttle position sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place the wire...

  • Page 450: Fuel Injection System

    Fuel injection system 8-45 fault code no. 19 7 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-128. Fault code no. 15 item throttle position sensor: open or short circuit detected. Fault code no. 19 item sidestand switch: a break or disconnection of ...

  • Page 451: Fuel Injection System

    Fuel injection system 8-46 fault code no. 21 5 defective sidestand switch. Execute the diagnostic mode. (code no. 20) shift the transmission into gear. Sidestand retracted: “on” sidestand extended: “off” replace if defective. Turn the main switch to “on”, and then extend and retract the sidestand. F...

  • Page 452: Fuel Injection System

    Fuel injection system 8-47 fault code no. 22 3 wire harness continuity. Open or short circuit → replace the wire harness. Between coolant temperature sensor coupler and sub-wire harness coupler. Green/white–green/white black/blue–black/blue between sub-wire harness cou- pler and ecu coupler. Green/w...

  • Page 453: Fuel Injection System

    Fuel injection system 8-48 1 connection of intake air temper- ature sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place t...

  • Page 454: Fuel Injection System

    Fuel injection system 8-49 fault code no. 24 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 malfunc- tion and check maintenance...

  • Page 455: Fuel Injection System

    Fuel injection system 8-50 fault code no. 30 5 check fuel pressure. Refer to “checking the fuel pressure” on page 7-16. 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 displ...

  • Page 456: Fuel Injection System

    Fuel injection system 8-51 fault code no. 33 3 defective lean angle sensor. Execute the diagnostic mode. (code no. 08) replace if defective. Refer to “checking the lean angle sensor” on page 8-135. Turn the main switch to “on”, then to “off”, and then back to “on”. Fault code number is not dis- play...

  • Page 457: Fuel Injection System

    Fuel injection system 8-52 fault code no. 34 4 installed condition of cylinder-#1 ignition coil. Check for looseness or pinch- ing. Improperly installed ignition coil → reinstall or replace the igni- tion coil. Start the engine and let it idle for approximately 5 seconds. Fault code number is not di...

  • Page 458: Fuel Injection System

    Fuel injection system 8-53 fault code no. 37 tip • if fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number “46” first. • if fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number “42” first. 3 wire harnes...

  • Page 459: Fuel Injection System

    Fuel injection system 8-54 a-1 locate the malfunction. Execute the diagnostic mode. (code no. 54) fully closes the isc (idle speed control) valve, and then fully opens the valve. Isc operating sound is heard → go to item a-2. Isc operating sound is not heard → go to item b-2 for the defective isc (i...

  • Page 460: Fuel Injection System

    Fuel injection system 8-55 b-1 locate the malfunction. Execute the diagnostic mode. (code no. 54) fully closes the isc (idle speed control) valve, and then fully opens the valve. Isc operating sound is heard → go to item a-2 for the compo- nent other than isc (idle speed control) unit is defective. ...

  • Page 461: Fuel Injection System

    Fuel injection system 8-56 fault code no. 39 b-7 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-128. B-8 delete the fault code. Start the engine and let it idle for approximately 10 seconds. Check that the fault code num- ber is not displayed. Fault...

  • Page 462: Fuel Injection System

    Fuel injection system 8-57 fault code no. 41 3 defective fuel injector #1 and/or fuel injector #2. Measure the fuel injector resis- tance. Replace if out of specification. Refer to “checking the fuel injectors” on page 8-141. Execute the diagnostic mode. (code nos. 36, 37) no operating sound → go to...

  • Page 463: Fuel Injection System

    Fuel injection system 8-58 fault code no. 42 1 connection of lean angle sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- pla...

  • Page 464: Fuel Injection System

    Fuel injection system 8-59 procedure check that the number increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped. Item probable cause of malfunc- tion and check maintenance job confirmation of service com- pletion a-1 locate the malfunct...

  • Page 465: Fuel Injection System

    Fuel injection system 8-60 a-5 wire harness continuity. Open or short circuit → replace the wire harness. Between rear wheel sensor cou- pler and abs ecu coupler. Black–black white–white between abs ecu coupler and ecu coupler. White/yellow–white/yellow execute the diagnostic mode. (code no. 07) rot...

  • Page 466: Fuel Injection System

    Fuel injection system 8-61 b-1 locate the malfunction. Execute the diagnostic mode. (code no. 07) rotate the rear wheel by hand and check that the indicated val- ue increases. Value does not increase → go to item a-2 for the rear wheel sensor. Execute the diagnostic mode. (code no. 21) when the tran...

  • Page 467: Fuel Injection System

    Fuel injection system 8-62 b-4 wire harness continuity. Open or short circuit → replace the wire harness. Between ecu coupler and joint coupler. Black/yellow–black/yellow between joint coupler and relay unit coupler. Black/yellow–black/yellow between relay unit coupler and sub-wire harness coupler. ...

  • Page 468: Fuel Injection System

    Fuel injection system 8-63 b-9 delete the fault code. Turn the main switch to “on”, and then rotate the rear wheel by hand. Start the engine, and input the vehicle speed signals by operat- ing the vehicle at 20 to 30 km/h (12 to 19 mph). Check that the fault code num- ber is not displayed. The fault...

  • Page 469: Fuel Injection System

    Fuel injection system 8-64 c-2 clutch lever adjustment. Refer to “adjusting the clutch lever free play” on page 3-12. Execute the diagnostic mode. (code no. 21) when the clutch lever is re- leased with the transmission in gear and when the sidestand is retracted: “off” when the clutch lever is squee...

  • Page 470: Fuel Injection System

    Fuel injection system 8-65 c-5 wire harness continuity. Open or short circuit → replace the wire harness. Between clutch switch coupler and left handlebar switch cou- pler. Black/red–black/red black/yellow–black/yellow between left handlebar switch coupler and joint coupler. Black/red–black/red blac...

  • Page 471: Fuel Injection System

    Fuel injection system 8-66 fault code no. 43 c-9 delete the fault code. Turn the main switch to “on”, and then rotate the rear wheel by hand. Start the engine, and input the vehicle speed signals by operat- ing the vehicle at 20 to 30 km/h (12 to 19 mph). Check that the fault code num- ber is not di...

  • Page 472: Fuel Injection System

    Fuel injection system 8-67 fault code no. 44 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place the wire ha...

  • Page 473: Fuel Injection System

    Fuel injection system 8-68 fault code no. 46 meter display eeprom fault code display • 00 (no history) • 01–02: cylinder fault code number (history exists) if more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defective cylin- d...

  • Page 474: Fuel Injection System

    Fuel injection system 8-69 fault code no. 50 fault code no. 89 (yamaha diagnostic tool) meter display — procedure — item probable cause of malfunc- tion and check maintenance job confirmation of service com- pletion 1 malfunction in charging system. Check the charging system. Refer to “charging syst...

  • Page 475: Fuel Injection System

    Fuel injection system 8-70 fault code no. Err (meter display) 1 connection of meter assembly coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler secur...

  • Page 476: Fuel Injection System

    Fuel injection system 8-71 1 connection of meter assembly coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place the wire harness. ...

  • Page 477: Fuel Injection System

    Fuel injection system 8-72.

  • Page 478: Fuel Pump System

    Fuel pump system 8-73 eas20081 fuel pump system eas30513 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l g /y...

  • Page 479: Fuel Pump System

    Fuel pump system 8-74 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 22.Relay unit 24.Fuel pump relay 25.Joint coupler 37.Ecu (engine control unit) 47.Fuel pump 64.Handlebar switch (right) 67.Start/engine stop switch.

  • Page 480: Fuel Pump System

    Fuel pump system 8-75 eas30514 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Headlight assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ...

  • Page 481: Fuel Pump System

    Fuel pump system 8-76 ng → ok ↓ 7. Check the entire fuel pump system wiring. Refer to “circuit diagram” on page 8-73. Properly connect or replace the wiring har- ness. Replace the ecu. Refer to “replac- ing the ecu (engine control unit)” on page 8-128..

  • Page 482: Immobilizer System

    Immobilizer system 8-77 eas20084 immobilizer system eas30519 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l/ r b l/ r l l/ r l ...

  • Page 483: Immobilizer System

    Immobilizer system 8-78 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 11.Backup fuse 15.Battery 16.Engine ground 17.Immobilizer unit 18.Main fuse 25.Joint coupler 37.Ecu (engine control unit) 49.Meter assembly 50.Immobilizer system indicator light 54.Multi-function meter.

  • Page 484: Immobilizer System

    Immobilizer system 8-79 eas30520 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 485: Immobilizer System

    Immobilizer system 8-80 * 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 486: Immobilizer System

    Immobilizer system 8-81 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 standard...

  • Page 487: Immobilizer System

    Immobilizer system 8-82 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 sta...

  • Page 488: Immobilizer System

    Immobilizer system 8-83 eas30522 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 ↓ eas30523 self-diagnosis fault code indication when a system malfunction occurs, the fault code number ...

  • Page 489: Immobilizer System

    Immobilizer system 8-84 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 52 immobilizer unit codes between the key and immobilizer unit do no...

  • Page 490: Immobilizer System

    Immobilizer system 8-85 a. Light on b. Light off.

  • Page 491: Immobilizer System

    Immobilizer system 8-86.

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

    Abs (anti-lock brake system) 8-87 eas20166 abs (anti-lock brake system) eas30988 circuit diagram p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b /w b r www b /g l/ w r /w l/ wr /w r /w l/ r b /lb /l r /w br /w br /w br /w g /l l/ b b /y b /y b /r b /r yg ch ch ch ch ch ch gy l...

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

    Abs (anti-lock brake system) 8-88 1. Main switch 2. Abs solenoid fuse 3. Abs motor fuse 5. Abs control unit fuse 7. Ignition fuse 8. Signaling system fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 21.Rear brake light switch 25.Joint coupler 37.Ecu (engine control unit) 4...

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

    Abs (anti-lock brake system) 8-89 eas30990 abs coupler location chart w b gy w gy w b w l/r l/b r/w b (b) r/w r/l w b b w g g/r w/y y g g br/w l/r l/b b/l b b/g g/r g/w l/r l/b sb/w y dg ch g/r gy o w/r y/w p w r/w r/g g/b b/w (gy) 2 5 3 1 4.

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

    Abs (anti-lock brake system) 8-90 1. Abs ecu coupler 2. Rear wheel sensor coupler 3. Yamaha diagnostic tool coupler 4. Meter assembly coupler 5. Front wheel sensor coupler.

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

    Abs (anti-lock brake system) 8-91 eas30991 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler c...

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

    Abs (anti-lock brake system) 8-92 self-diagnosis and servicing the abs ecu has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the abs ecu also stores the mal- function history. The fault codes r...

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

    Abs (anti-lock brake system) 8-93 eas30994 basic process for troubleshooting [a-1] does only the abs warning light fail to come on? [a-2] do all indicator lights fail to come on? [a-4] only the abs ecu fails to communicate. [a-5] abs ecu and fi ecu fail to communicate. The abs warning light (led) is...

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

    Abs (anti-lock brake system) 8-94 warning ewa16710 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. Tip to final check, refer to “[c-1] final check” on page 8-116. Eas30995 [a] checking th...

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

    Abs (anti-lock brake system) 8-95 eas31135 [a-4] only the abs ecu fails to communicate (the select unit screen does not appear.) 1. Abs control unit fuse • check the abs control unit fuse for continuity. Refer to “checking the fuses” on page 8-127. • if the abs control unit fuse is blown, replace th...

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

    Abs (anti-lock brake system) 8-96 removing the protective cap “1”, and then connect the yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [...

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

    Abs (anti-lock brake system) 8-97 4. Ecu the types of the control units are displayed. (e.G., fi, abs) 5. Item the item names of the detected malfunction are displayed. 6. Condition the current conditions are displayed. (detected/recovered) 7. Symptom the symptoms of the detected malfunction are dis...

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

    Abs (anti-lock brake system) 8-98 13* 26* front wheel sensor (abnor- mal pulse period) front wheel sensor signal is not received properly. (the pulse period is abnormal while the vehicle is traveling.) • foreign material adhered around the front wheel sen- sor • incorrect installation of the front w...

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

    Abs (anti-lock brake system) 8-99 18* 46* rear wheel sensor (missing pulses) rear wheel sensor signal is not received properly. (miss- ing pulses are detected in the signal while the vehicle is traveling.) • foreign material adhered around the rear wheel sen- sor • incorrect installation of the rear...

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

    Abs (anti-lock brake system) 8-100 41 front wheel abs (intermit- tent wheel speed pulses or incorrect depressurization) • pulses from the front wheel sensor are received inter- mittently while the vehicle is traveling. • front wheel will not recover from the locking tendency even though the signal i...

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

    Abs (anti-lock brake system) 8-101 * the fault code number varies according to the vehicle conditions. Fault code no. 11, 25 tip with the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code no. 11) or for longer than about 2 seconds (fault code no. 25). 53 ve...

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

    Abs (anti-lock brake system) 8-102 fault code no. 12 fault code no. 13, 26 tip • if the front brake abs operates continuously for 20 seconds or more, fault code no. 26 will be record- ed. If the front brake abs operates continuously for 36 seconds or more, fault code no. 13 will be re- corded. Fault...

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

    Abs (anti-lock brake system) 8-103 • vehicle possibly ridden on uneven roads. Fault code no. 14, 27 tip • if the rear brake abs operates continuously for 20 seconds or more, fault code no. 27 will be record- ed. If the rear brake abs operates continuously for 36 seconds or more, fault code no. 14 wi...

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

    Abs (anti-lock brake system) 8-104 fault code no. 15 tip turn the main switch to “off” before disconnecting or connecting a coupler. 4 defective rear wheel sensor or incorrect installation of the sensor check the wheel sensor for damage and the installed condition of the sensor. Repair or replace th...

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

    Abs (anti-lock brake system) 8-105 fault code no. 16 tip turn the main switch to “off” before disconnecting or connecting a coupler. 3 defective front wheel sensor or hydraulic unit assembly if the above items were performed and no malfunctions were found, the wheel sensor or hydraulic unit assembly...

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

    Abs (anti-lock brake system) 8-106 fault code no. 17, 45 tip if pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code no. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code no. 45 will be recorded f...

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

    Abs (anti-lock brake system) 8-107 fault code no. 21 fault code no. 24 fault code no. 18 46 item rear wheel sensor (missing pulses) symptom rear wheel sensor signal is not received properly. (missing pulses are detected in the signal while the vehicle is traveling.) order item/components and probabl...

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

    Abs (anti-lock brake system) 8-108 fault code no. 31 tip turn the main switch to “off” before disconnecting or connecting a coupler. 3 open or short circuit in the wire harness between the signaling system (tail/brake light or brake light switch) and the hydrau- lic unit assembly • between abs ecu c...

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

    Abs (anti-lock brake system) 8-109 fault code no. 32 fault code no. 33 tip turn the main switch to “off” before disconnecting or connecting a coupler. Fault code no. 34 fault code no. 32 item hydraulic unit assembly (short circuit in abs solenoid power supply circuit) symptom short circuit is detect...

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

    Abs (anti-lock brake system) 8-110 fault code no. 41 fault code no. 42, 47 fault code no. 41 item front wheel abs (intermittent wheel speed pulses or incorrect de- pressurization) symptom • pulses from the front wheel sensor are received intermittently while the vehicle is traveling. • front wheel w...

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

    Abs (anti-lock brake system) 8-111 fault code no. 43 3 rear brake dragging check that the brake fluid pressure is correctly transmit- ted to the brake caliper when the brake pedal is operat- ed and that the pressure decreases when the pedal is released. Refer to “checking the rear brake disc” on pag...

  • Page 517: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-112 fault code no. 44 fault code no. 51, 52 fault code no. 53 tip turn the main switch to “off” before disconnecting or connecting a coupler. Fault code no. 44 item rear wheel sensor (missing pulses) symptom rear wheel sensor signal is not received properly. (missing p...

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

    Abs (anti-lock brake system) 8-113 fault code no. 54 tip turn the main switch to “off” before disconnecting or connecting a coupler. Fault code no. 53 item vehicle system power supply (voltage of abs ecu power supply is low) symptom power voltage supplied to the abs ecu in the hydraulic unit assem- ...

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

    Abs (anti-lock brake system) 8-114 fault code no. 55 fault code no. 56 fault code no. 63 fault code no. 55 item hydraulic unit assembly (defective abs ecu) symptom abnormal data is detected in the hydraulic unit assembly. Order item/components and probable cause check or maintenance job 1 defective ...

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

    Abs (anti-lock brake system) 8-115 fault code no. 64 2 defective front wheel sensor • check that there is no short circuit between the gray terminal “1” and the white terminal “2”. • if there is a short circuit, the wheel sensor is defective. Repair or replace the wheel sensor. 3. Abs ecu 4. Front w...

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

    Abs (anti-lock brake system) 8-116 eas31139 [b-3] deleting the fault codes to delete the fault codes, use the yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the yamaha diagnostic tool. Check that all the displayed fault codes are deleted. Con...

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

    Abs (anti-lock brake system) 8-117 checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir. Refer to “checking the brake fluid level” on page 3-15. 2. Check the wheel sensors for proper installation. Refer to “installing the front wheel (di...

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

    Abs (anti-lock brake system) 8-118.

  • Page 524: Electrical Components

    Electrical components 8-119 eas20089 electrical components 1 2 3 4 5 5 6 7 8 9 11 12 13 14 10 15 16 17 18.

  • Page 525: Electrical Components

    Electrical components 8-120 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Rectifier/regulator 5. Ignition coil 6. Battery 7. Fuse box 1 8. Fuse box 2 9. Main fuse 10. Starter relay 11. Rear brake light switch 12. Sidestand switch 13. O 2 sensor 14. Gear position switch 15. Oil press...

  • Page 526: Electrical Components

    Electrical components 8-121 1 3 4 5 6 8 9 13 14 15 16 7 2 12 10 10 11.

  • Page 527: Electrical Components

    Electrical components 8-122 1. Intake air temperature sensor 2. Hydraulic unit assembly 3. Intake solenoid 4. Intake air pressure sensor 5. Fuel pump 6. Lean angle sensor 7. Rear wheel sensor 8. Coolant temperature sensor 9. Crankshaft position sensor 10. Fuel injector 11. Throttle position sensor 1...

  • Page 528: Electrical Components

    Electrical components 8-123 eas30549 checking the switches dg br/w l/b b/y b/r ch g b/w y br r/w l/w b b/l b/l br/w r/b dg ch br y b b 11 10 9 8 7 6 5 4 3 2 1 y l/b g l/b y br/w ch dg br b/w b/r b/y br/r on off p r/w br/l br/r b l/w r/b r/w ch dg br/w r/w br/l b/l b/l.

  • Page 529: Electrical Components

    Electrical components 8-124 1. Start/engine stop switch 2. Hazard switch 3. Front brake light switch 4. Rear brake light switch 5. Sidestand switch 6. Main switch 7. Clutch switch 8. Horn switch 9. Turn signal switch 10. Pass switch 11. Dimmer switch.

  • Page 530: Electrical Components

    Electrical components 8-125 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 eca18520 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes...

  • Page 531: Electrical Components

    Electrical components 8-126 eas30550 checking the bulbs and bulb sockets 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 both. Improperly connected → properly connect. No c...

  • Page 532: Electrical Components

    Electrical components 8-127 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 533: Electrical Components

    Electrical components 8-128 4. Install: • center cover refer to “general chassis (2)” on page 4-3. • rider seat • passenger seat refer to“general chassis (1)” on page 4-1. Eas31006 replacing the ecu (engine control unit) 1. Turn the main switch to “off”. 2. Replace the ecu (engine control unit). Ref...

  • Page 534: Electrical Components

    Electrical components 8-129 3. Remove: • battery refer to “general chassis (1)” on page 4-1. 4. Check: • battery charge ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals. Tip • the charge state of a vrla (valve regulated lead acid) battery can be...

  • Page 535: Electrical Components

    Electrical components 8-130 • as shown in the following illustration, the open-circuit voltage of a vrla (valve reg- ulated lead acid) battery stabilizes about 30 minutes after charging has been com- pleted. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit vol...

  • Page 536: Electrical Components

    Electrical components 8-131 6. Install: • battery refer to “general chassis (1)” on page 4-1. 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 with a...

  • Page 537: Electrical Components

    Electrical components 8-132 headlight relay radiator fan motor relay eas30794 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and replace the wi...

  • Page 538: Electrical Components

    Electrical components 8-133 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30795 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Tip the pocket tester or the ...

  • Page 539: Electrical Components

    Electrical components 8-134 c. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30558 checking the ignition coils the following procedure applies to all of the igni- tion coils. 1. Check: • primary co...

  • Page 540: Electrical Components

    Electrical components 8-135 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. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30560 ch...

  • Page 541: Electrical Components

    Electrical components 8-136 c. Set the main switch to “on”. D. Turn the lean angle sensor to 65°. E. Measure the lean angle sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30562 checking the starter motor operation 1. Check: • starter motor operation does not operate → ...

  • Page 542: Electrical Components

    Electrical components 8-137 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 543: Electrical Components

    Electrical components 8-138 eas30577 checking the radiator fan motor 1. Check: • radiator fan motor faulty/rough movement → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. B. Connect the battery (dc 12 v) as shown. C. Mea...

  • Page 544: Electrical Components

    Electrical components 8-139 eas30581 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) warning ewa16690 • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shocks. If the throttle position ...

  • Page 545: Electrical Components

    Electrical components 8-140 c. Set the main switch to “on”. D. Measure the intake air pressure sensor out- put voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas30594 checking the intake air temperature sensor 1. Remove: • intake air temperature sensor warning ewa14110 • handle the intak...

  • Page 546: Electrical Components

    Electrical components 8-141 2. Check: • gear position switch out of specification → replace the gear posi- tion switch. Eas30681 checking the fuel injectors the following procedure applies to all of the fuel injectors. 1. Remove: • fuel injector refer to “throttle bodies” on page 7-9. 2. Check: • fu...

  • Page 547: Troubleshooting

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

  • Page 548: Troubleshooting

    Troubleshooting 9-1 eas20090 troubleshooting eas30599 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 549: 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 550: Troubleshooting

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

  • Page 551: Troubleshooting

    Troubleshooting 9-4 rear shock absorber assembly • faulty rear shock absorber spring • leaking oil or gas 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 or loose whe...

  • Page 552: 9-5

    Self-diagnostic function and diagnostic code table 9-5 eas20116 self-diagnostic function and diagnostic code table eas31118 self-diagnostic function table tip for details of the fault code, refer to “troubleshooting method” on page 8-35. Fault code no. Item 12 crankshaft position sensor: no normal s...

  • Page 553: 9-6

    Self-diagnostic function and diagnostic code table 9-6 eas31119 communication error with the meter tip for details of the fault code, refer to “troubleshooting method” on page 8-35. Eas31120 diagnostic code: sensor operation table fault code no. Item 89 (yamaha diagnostic tool) err (meter display) m...

  • Page 554: 9-7

    Self-diagnostic function and diagnostic code table 9-7 20 sidestand switch extend and retract the side- stand (with the transmission in gear). • stand retracted on • stand extended off 21 neutral switch and clutch switch operate the transmission, clutch lever, and sidestand. • transmission is in gea...

  • Page 555: 9-8

    Self-diagnostic function and diagnostic code table 9-8 eas31121 diagnostic code: actuator operation table 62 malfunction history code era- sure • no history 00 — • history exists • displays the total number of malfunctions, including the current malfunction, that have occurred since the history was ...

  • Page 556: 9-9

    Self-diagnostic function and diagnostic code table 9-9 31 cylinder-#2 ignition coil actuates cylinder-#2 ignition coil five times at one-second intervals. The “check” indicator and “ ” on the yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Check that a spark is gener...

  • Page 557: 9-10

    Self-diagnostic function and diagnostic code table 9-10 52 headlight relay actuates the headlight relay five times at five-second in- tervals. The “check” indicator and “ ” on the yamaha diag- nostic tool screen come on each time the relay is actuat- ed. Check that the headlight re- lay is actuated ...

  • Page 558: Event Code Table

    Event code table 9-11 eas20164 event code table no. Item symptom possible cause remarks 192 intake air pressure sen- sor brief abnormality de- tected in intake air pres- sure sensor same as for fault code number 13 perform the checks and maintenance jobs for fault code number 13. 193 throttle positi...

  • Page 559: Event Code Table

    Event code table 9-12 242 isc (idle speed control) (correction value re- mains at upper limit) correction value re- mains at upper limit while the engine is idling low engine idling speed • clogged throttle body • improperly adjusted throttle cable • improperly adjusted clutch cable • defective fuel...

  • Page 560: Wiring Diagram

    Eas20091 wiring diagram mt07a 2014 1. Main switch 2. Abs solenoid fuse 3. Abs motor fuse 4. Parking lighting fuse 5. Abs control unit fuse 6. Auxiliary fuse 7. Ignition fuse 8. Signaling system fuse 9. Headlight fuse 10. Fuel injection system fuse 11. Backup fuse 12. Radiator fan motor fuse 13. Ac m...

  • Page 563

    Mt07a 2014 wiring diagram mt07a 2014 schÉma de cblage mt07a 2014 schaltplan mt07a 2014 schema elettrico mt07a 2014 diagrama elÉctrico p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a b/w b r w w w b/g b/g l/w r/w l/w r/w r/w l/r b/l b/l r/w br/w br/w br/w g/l l/b b/y b/y b/r b/r ...

  • Page 564

    Mt07a 2014 wiring diagram mt07a 2014 schÉma de cblage mt07a 2014 schaltplan mt07a 2014 schema elettrico mt07a 2014 diagrama elÉctrico p on off b b c c c c c c c b b b b b b b b b b b a c a d c b a a b a (b) (b) (b) (b) (gy) (b) (b) (b) (b) (gy) (b) (b) (o) (o) (b) (b) (b) (b) (b) (gy) (gy) (gy) (gy)...