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Yamaha FJR1300 Service Manual

Manual is about: Yamaha Motorcycles Service manual

Summary of FJR1300

  • Page 1

    Lit-11616-16-18 5jw-28197-10 fjr1300r fjr1300rc service manual.

  • Page 2

    Eas00001 fjr1300r/fjr1300rc service manual ©2002 by yamaha motor corporation, u.S.A. First edition, june 2002 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-16-18.

  • Page 3: Notice

    Eas00003 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4: How to Use This Manual

    Eas00007 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. 1 the manual is di...

  • Page 5: Gen

    Eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 chassis 5 engine 6 cooling system 7 fuel injection system 8 electrical system 9 troubleshooting sy...

  • Page 7: Table of Contents

    Eas00013 table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 chassis chas 4 engine eng 5 cooling system cool 6 fuel injection system fi 7 electrical system elec 8 troubleshooting trbl shtg 9 – +.

  • Page 8: Contents

    Contents chapter 1 general information motorcycle identification ..................................................................1-1 vehicle identification number .....................................................1-1 model code.......................................................................

  • Page 9: Chapter  3

    Tightening torques ..............................................................................2-19 engine tightening torques .........................................................2-19 chassis tightening torques .......................................................2-23 lubrication points and ...

  • Page 10

    Engine..........................................................................................................3-16 adjusting the valve clearance.................................................3-16 synchronizing the throttle bodies ........................................3-22 adjusting the engine ...

  • Page 11: Chapter  4

    Chapter 4 chassis front wheel and brake discs ............................................................4-1 removing the front wheel ............................................................4-3 checking the front wheel ............................................................4-3 checking the...

  • Page 12

    Front fork................................................................................................4-60 removing the front fork legs ..................................................4-63 disassembling the front fork legs ........................................4-63 checking the front fork le...

  • Page 13: Chapter  5

    Chapter 5 engine engine............................................................................................................5-1 mufflers and exhaust pipe assembly .......................................5-1 leads and hoses ..........................................................................

  • Page 14

    Clutch.........................................................................................................5-44 clutch cover ....................................................................................5-44 clutch ..............................................................................

  • Page 15: Chapter  6

    Connecting rods and pistons ..........................................................5-91 removing the connecting rods and pistons .......................5-92 checking the cylinders and pistons.......................................5-93 checking the piston rings .......................................

  • Page 16: Chapter  7

    Chapter 7 fuel injection system fuel injection system ............................................................................7-1 wiring diagram....................................................................................7-2 ecu’s self-diagnostic function ....................................

  • Page 17: Chapter  9

    Electric starting system ..................................................................8-14 circuit diagram ................................................................................8-14 starting circuit cut-off system operation ........................8-15 troubleshooting....................

  • Page 18

    Incorrect engine idling speed...........................................................9-2 engine .....................................................................................................9-2 fuel system .......................................................................................

  • Page 19: Gen

    1 - 1 gen info motorcycle identification eas00014 general information motorcycle identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the right side of the steering head pipe. Eas00018 model code the model code label 1 is affixed to the frame. Thi...

  • Page 20: Gen

    1 - 2 gen info features features outline the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ra...

  • Page 21: Gen

    1 - 3 gen info features fi system the fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 2.55 kg/cm 2 higher than the intake manifold pres- sure. Accordingly, when the energizing signal from the ecu ...

  • Page 22: Gen

    1 - 4 gen info features fuel control block the fuel control block consists of the following main components: an fi warning light is provided on meter panel. Component function control block ecu total fi system control throttle body air volume control pressure regulator fuel pressure adjustment senso...

  • Page 23: Gen

    1 - 5 gen info features components ecu (electronic control unit) the ecu is mounted underneath the seat, below the toolbox. The main functions of the ecu are ignition control, fuel control, self-diagnosis, and load control. • ecu’s internal construction and functions the main components and function...

  • Page 24: Gen

    1 - 6 gen info features • ignition control the ignition control function of the ecu controls the ignition timing and the duration of ignition energizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position ...

  • Page 25: Gen

    1 - 7 gen info features fuel pump the fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump. The pump consi...

  • Page 26: Gen

    1 - 8 gen info features pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamb...

  • Page 27: Gen

    1 - 9 gen info features fuel injector upon receiving injection signals from the ecu, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with the bottom of the core keeps the fuel passage closed. ...

  • Page 28: Gen

    1 - 10 gen info features crankshaft position sensor the crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the pick...

  • Page 29: Gen

    1 - 11 gen info features cylinder identification sensor the cylinder identification sensor is mounted on the exhaust head cover of the #4 cylinder. When the exhaust cam of the #4 cylinder rotates and the lift of the cam passes by the sensor, the sensor generates a signal and sends it to the ecu. Bas...

  • Page 30: Gen

    1 - 12 gen info features throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison wit...

  • Page 31: Gen

    1 - 13 gen info features intake air pressure sensor and atmospheric pressure sensor • intake air pressure sensor the intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake...

  • Page 32: Gen

    1 - 14 gen info features coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to ...

  • Page 33: Gen

    1 - 15 gen info features o 2 sensor the o 2 sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirco- nia type, utilizes the oxygen ion conductivity of the solid...

  • Page 34: Gen

    1 - 16 gen info features lean angle cut-off switch the lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 v (low level). When the motorcycl...

  • Page 35: Gen

    1 - 17 gen info features fuel injection system operation and control the fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ecu. To determine the basic injection timing, the ecu calculates the intake air volume through the signals fro...

  • Page 36: Gen

    1 - 18 gen info features determining the final injection duration the intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weathe...

  • Page 37: Gen

    1 - 19 gen info features composition of final injection duration 1 injection at start *1 2 after-start enrichment *2 3 warm-up enrichment *3 4 acceleration compen- sation *5 5 oxygen feedback *6 6 fuel cut-off deceleration compen- sation *5 7 basic injection dura- tion 8 voltage compensation duratio...

  • Page 38: Gen

    1 - 20 gen info features fuel control during normal driving in synchronous injection during normal driving, fuel is injected on a cylinder-by-cylinder basis when all of the conditions below are met: 1 other than the stop mode 2 cylinder identification completed 3 other than overrun to determine the ...

  • Page 39: Gen

    1 - 21 gen info features fuel injection compensation control • starting injection control the coolant temperature is used for determining the injection duration in order to ensure proper start ability. To suit the engine’s operating conditions, the starting injection duration is determined by applyi...

  • Page 40: Gen

    1 - 22 gen info features • starting cylinder control 1 injectors #1,4 2 injectors #2,3 3 starting asynchro- nous injection 4 group injection È cylinder identification sensor É crankshaft position sensor Ê injection Ë stop Ì synchronous injection • after-start enrichment after-start enrichment provid...

  • Page 41: Gen

    1 - 23 gen info features • warm-up enrichment when the coolant temperature is low, a warm-up coefficient is applied in accordance with the sig- nals from the coolant temperature sensor in order to effect fuel enrichment. Because the coolant temperature determines the coefficient, the coefficient cha...

  • Page 42: Gen

    1 - 24 gen info features • acceleration enrichment acceleration enrichment is provided in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throt- tle position sensor actuates in unison with th...

  • Page 43: Gen

    1 - 25 gen info features • deceleration control deceleration control is effected in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position sensor acutates in unison with the accelerato...

  • Page 44: Gen

    1 - 26 gen info features three-way catalytic converter system system outline this is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint effort by the fi system, o 2 sensor, and the three-way catalytic converter system. By effecting com- prehensive control of...

  • Page 45: Gen

    1 - 27 gen info features functions of components catalyst because the conditions in which nox is generated are directly opposed to those of co and hc, there is a limit to the extent to which the concentration levels of these harmful elements can be reduced in the combustion stage. Hence, the functio...

  • Page 46: Gen

    1 - 28 gen info features large amounts of both co and hc are generated when the mixture is rich (as indicated by insuffi- cient o 2 region a). Conversely, large amounts of nox are generated when the mixture is lean (as indicated by excessive o 2 region b). Under these conflicting characteristics, th...

  • Page 47: Gen

    1 - 29 gen info features air-fuel ratio compensation equipment an o 2 sensor is provided in the exhaust pipe upstream of the catalyst, to enable the catalyst to operate at a high degree of efficiency. The o 2 sensor detects the level of concentration of the oxy- gen remaining in the exhaust gases. A...

  • Page 48: Gen

    1 - 30 gen info features air induction system the air induction system (ai system) introduces fresh air into the exhaust port in order to burn the unburned gas (which is present in the exhaust gas) in the exhaust pipe. The burning of the unburned gases in this manner enhances the efficiency of the c...

  • Page 49: Gen

    1 - 31 gen info features components 1.Air cut-off valve the air cut-off valve consists of a plunger that is mounted inside the core of a solenoid coil, and a valve at the end of the plunger for opening and closing the air passage. Due to the force of a spring, the valve is in constant contact with v...

  • Page 50: Gen

    1 - 32 gen info features instrument panel function indication the indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the multi-function meter on the instrument panel. Based on the signals received from the sensors, the ecu inputs...

  • Page 51: Gen

    1 - 33 gen info features 2. Diag mode inspection and adjustment (multi-function meter) mode selection (make sure to disconnect the coupler from the fuel pump.) diag mode normal mode 1. While keeping both the select and reset buttons pressed, turn “on” the main switch. Keep the buttons pressed for 8 ...

  • Page 52: Gen

    1 - 34 gen info features 1 clock 2 trip meter 3 reset button 4 select button 5 engine trouble warning light 140 150 160 170 180 130 120 220 240 260 280 200 180 160 140 mph km/h f l h e select reset trip trip km mile km mile odo 1 2 3 4 5.

  • Page 53: Gen

    1 - 35 gen info eas00020 important information 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 equipment. Refer to the “special tools”. 3. When disassembling, always keep mated parts...

  • Page 54: Gen

    1 - 36 gen info eas00023 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals install bearings and oil seals...

  • Page 55: Gen

    1 - 37 gen info eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- eral times. 3. ...

  • Page 56: Gen

    1 - 38 gen info eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or...

  • Page 57: Gen

    1 - 39 gen info yu-33975 spanner wrench this tool is needed to loosen and tighten the steering stem ring nut. Yu-38411 oil filter wrench this tool is needed to remove and install the oil filter. Ym-01442 fork seal installer this tool is needed when installing the slide metal, oil seal and dust seal ...

  • Page 58: Gen

    1 - 40 gen info yu-08030 carburetor synchronizer this gauge is needed for throttle bodies synchronization. Yu-03097 dial indicator this tool is used to measure the middle gear backlash. Yu-03112 pocket tester this instrument is needed for checking the electrical system. Ym-33277-a timing light this ...

  • Page 59: Gen

    1 - 41 gen info 40 and 50 mm bearing driver ym-04058 water pump seal installer ym-33221 40 and 50 mm bearing driver water pump seal installer these tools are needed to install the water pump seal. Ym-91042 universal clutch holder this tool is needed to hold the clutch when removing or installing the...

  • Page 60: Gen

    1 - 42 gen info yb-35956 mity vac this tool used to measure the vacuum pressure. Yu-8036-b inductive tachometer this tool is used for check engine speed. Acc-11001-05-01 quick gasket ® this sealant is used to seal two mating surfaces (e. G., crankcase mating sur- faces). Ym-04140 bearing retainer wr...

  • Page 61: Spec

    2 - 1 spec specifications general specifications item standard limit model code 5jw7 (usa) ---- 5jw8 (california) ---- dimensions overall length 2,195 mm (86.4 in) ---- overall width 760 mm (29.9 in) ---- overall height 1,420 mm (55.9 in) ---- seat height 805 mm (31.7 in) ---- wheelbase 1,515 mm (59...

  • Page 62: Spec

    2 - 2 spec engine specifications engine specifications item standard limit engine engine type liquid-cooled, 4-stroke, dohc ---- displacement 1,298 cm 3 (79.2 cu.In) ---- cylinder arrangement forward-inclined parallel 4-cylinder ---- bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) ---- compression rat...

  • Page 63: Spec

    2 - 3 spec engine specifications oil filter oil filter type cartridge (paper) ---- bypass valve opening pressure 78.4 ~ 117.6 kpa (0.78 ~ 1.18 kg/cm 2 , 11.15 ~ 16.72 psi) ---- oil pump oil pump type trochoid ---- inner-rotor-to-outer-rotor-tip clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.16 mm (...

  • Page 64: Spec

    2 - 4 spec engine specifications camshafts drive system chain drive (right) ---- camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- camshaft-journal-to-camshaft-cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.00...

  • Page 65: Spec

    2 - 5 spec engine specifications timing chain model/number of links rh2015/136 ---- tensioning system automatic ---- valves, valve seats, valve guides valve clearance (cold) intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) ---- exhaust 0.18 ~ 0.25 mm (0.0071 ~ 0.0098 in) ---- valve dimensions valve head d...

  • Page 66: Spec

    2 - 6 spec engine specifications valve stem runout ---- 0.01 mm (0.0004 in) valve seat width intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) valve springs free length intake 39.7 mm (1.56 in) 37.7 mm (1.48 in) exhaust 39.7 mm (...

  • Page 67: Spec

    2 - 7 spec engine specifications cylinders cylinder arrangement forward inclined parallel 4-cylinder ---- bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) ---- compression ratio 10.8 : 1 ---- bore 79.00 ~ 79.01 mm (3.1102 ~ 3.1106 in) ---- max. Taper ---- 0.05 mm (0.002 in) max. Out-of-round ---- 0.05 ...

  • Page 68: Spec

    2 - 8 spec engine specifications 2nd ring ring type taper ---- dimensions (b × t) 1.0 × 2.9 mm (0.039 × 0.114 in) ---- end gap (installed) 0.75 ~ 0.85 mm (0.030 ~ 0.033 in) 1.2 mm (0.047 in) ring side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.0047 in) oil ring dimensions (b × t) 2.0 ×...

  • Page 69: Spec

    2 - 9 spec engine specifications clutch clutch type wet, multiple disc ---- clutch release method hydraulic inner push ---- operation left-hand operation ---- clutch cable free play (at the end of the clutch lever) 1.9 ~ 20.7 mm (0.075 ~ 0.815 in) ---- friction plates thickness 2.9 ~ 3.1 mm (0.114 ~...

  • Page 70: Spec

    2 - 10 spec engine specifications fuel pump pump type electrical ---- model (manufacturer) 5jw (denso) ---- consumption amperage 5.5 a ---- output pressure 294 kpa (2.94 kgf/cm 2 , 41.81 psi) ---- throttle bodies model (manufacturer) × quantity 42ehs (mikuni) × 4 ---- intake vacuum pressure 33.3 kpa...

  • Page 71: Spec

    2 - 11 spec chassis specifications chassis specifications item standard limit frame frame type diamond ---- caster angle 26° ---- trail 109 mm (4.29 in) ---- front wheel wheel type cast wheel ---- rim size 17 m/c × mt 3.50 ---- material aluminum ---- wheel travel 135 mm (5.31 in) ---- wheel runout m...

  • Page 72: Spec

    2 - 12 spec chassis specifications rear tire tire type tubeless ---- size 180/55 zr 17 m/c (73 w) ---- model (manufacturer) mez4j (metzeler)/ bt020r n (bridgestone) ---- tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kpa (2.5 kgf/cm 2 , 36 psi) ---- 90 ~ 202 kg (198 ~ 445 lb) (usa) 290 kpa (2.9 kgf...

  • Page 73: Spec

    2 - 13 spec chassis specifications clutch recommended fluid dot 4 ---- master cylinder inside diameter 14 mm (0.55 in) ---- release cylinder inside diameter 33.6 mm (1.32 in) ---- front suspension suspension type telescopic fork ---- front fork type coil spring/oil damper ---- front fork travel 135 ...

  • Page 74: Spec

    2 - 14 spec chassis specifications steering steering bearing type angular ---- lock to lock angle (left) 34° ---- lock to lock angle (right) 34° ---- rear suspension suspension type swingarm (link suspension) ---- rear shock absorber assembly type coil spring/gas-oil damper ---- rear shock absorber ...

  • Page 75: Spec

    2 - 15 spec electrical specifications electrical specifications item standard limit system voltage 12 v ---- ignition system ignition system type transistorized coil ignition (digital) ---- ignition timing 5° btdc at 1,050 r/min ---- advancer type electric ---- crankshaft position sensor resis- tanc...

  • Page 76: Spec

    2 - 16 spec electrical specifications bulbs (voltage/wattage × quantity) headlight 12 v 60 w/55 w × 2 ---- tail/brake light 12 v 5 w/21 w × 2 ---- front turn signal/position light 12 v 27 w 8 w × 2 ---- rear turn signal light 12 v 21 w × 2 ---- meter light 14 v 1.12 w × 4 ---- electric starting syst...

  • Page 77: Spec

    2 - 17 spec electrical specifications fuel pump maximum amperage 5.5 a ---- fuel injection system relay model (manufacturer) acm33211 m05 (matsushita) ---- radiator fan model (manufacturer) 5jw (denso) ---- running rpm 3,300 r/min ---- fan motor relay model (manufacturer) acm33211 m05 (omron) ---- a...

  • Page 78: Spec

    2 - 18 spec conversion table/ general tightening torque specifications eb201000 conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table eas00030 general tightening torque specificatio...

  • Page 79: Spec

    2 - 19 spec tightening torques tightening torques engine tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m·kg ft·lb spark plug — m10 4 13 1.3 9.4 camshaft sensor bolt m6 1 10 1.0 7.2 lt cylinder head cover bolt m6 8 10 1.0 7.2 camshaft cap bolt m6 20 1...

  • Page 80: Spec

    2 - 20 spec tightening torques oil pipe bolt m6 2 10 1.0 7.2 lt oil strainer bolt m6 2 10 1.0 7.2 lt oil pump assembly bolt m6 3 12 1.2 8.7 lt oil pump housing cover bolt m6 3 12 1.2 8.7 left middle gear cover bolt m6 9 12 1.2 8.7 right middle gear cover bolt m6 3 12 1.2 8.7 middle driven shaft asse...

  • Page 81: Spec

    2 - 21 spec tightening torques note: *1:tighten the cylinder head bolts to 25 nm (2.5 m • kg, 18 ft • lb) in the proper tightening sequence, loosen and retighten the cylinder head bolts to 25 nm (2.5 m • kg, 18 ft • lb) in the proper tighten- ing sequence, and then tighten the cylinder head bolts fu...

  • Page 82: Spec

    2 - 22 spec tightening torques cylinder head tightening sequence: crankcase tightening sequence:.

  • Page 83: Spec

    2 - 23 spec tightening torques chassis tightening torques part to be tightened thread size tightening torque remarks nm m·kg ft·lb engine mounting: rear lower mounting bolt m10 45 4.5 32 spacer bolt m16 18 1.8 13 rear upper mounting bolt and nut m10 45 4.5 32 front mounting bolt m12 55 5.5 40 pinch ...

  • Page 84: Spec

    2 - 24 spec tightening torques note: 1.First, tighten the lower ring nut approximately 52 nm (5.2 m • kg, 37 ft • lb) by using the torque wrench, then loosen the ring nut completely. 2.Retighten the lower ring nut to specification. Connecting arm and swingarm m10 48 4.8 35 connecting arm and relay a...

  • Page 85: Spec

    2 - 25 spec lubrication points and lubricant types lubrication points and lubricant types engine lubrication points and lubricant types lubrication point lubricant oil seal lips ls o-rings ls bearings e crankshaft pins e piston surfaces e piston pins e connecting rod bolts and nuts m crankshaft jour...

  • Page 86: Spec

    2 - 26 spec lubrication points and lubricant types lubrication point lubricant cylinder head cover mating surface sealant cylinder head cover sealant crankcase mating surface sealant clutch cover (crankcase mating surface) sealant generator cover (crankcase mating surface) sealant pickup coil rotor ...

  • Page 87: Spec

    2 - 27 spec lubrication points and lubricant types chassis lubrication points and lubricant types lubrication point lubricant steering bearings and bearing races (upper and lower) ls front wheel oil seal (right and left) ls rear wheel oil seal ls rear wheel drive hub oil seal ls rear wheel drive hub...

  • Page 88: Spec

    2 - 28 spec oil flow diagrams 1 crankshaft 2 oil pump 3 oil pipe 4 relief valve 5 oil filter cartridge 6 main axle lubrication points and lubricant types.

  • Page 89: Spec

    2 - 29 spec 1 crankshaft 2 main axle 3 drive axle oil flow diagrams.

  • Page 90: Spec

    2 - 30 spec 1 oil nozzle 2 main gallery bolt 3 crankshaft oil flow diagrams.

  • Page 91: Spec

    2 - 31 spec 1 main axle 2 drive axle 3 oil delivery pipe oil flow diagrams.

  • Page 92: Spec

    2 - 32 spec 1 exhaust camshaft 2 oil check bolt 3 intake camshaft oil flow diagrams.

  • Page 93: Spec

    2 - 33 spec 1 oil check bolt 2 crankshaft 3 oil cooler 4 oil pump 5 oil strainer 6 oil pipe oil flow diagrams.

  • Page 94: Spec

    2 - 34 spec 1 crank pin 2 crankshaft oil flow diagrams.

  • Page 95: Spec

    2 - 35 spec 1 rear balancer 2 oil delivery pipe 3 crankshaft 4 front balancer 5 crank pin oil flow diagrams.

  • Page 96: Spec

    2 - 36 spec 1 oil strainer 2 oil delivery pipe 3 oil cooler 4 engine oil drain bolt 5 oil level switch 6 oil filter cartridge 7 oil pan 8 oil pipe 9 oil pump oil flow diagrams.

  • Page 97: Spec

    2 - 37 spec 1 main axle 2 drive axle 3 middle drive shaft oil flow diagrams.

  • Page 98: Spec

    2 - 38 spec cooling system diagrams 1 radiator cooling system diagrams.

  • Page 99: Spec

    2 - 39 spec 1 water jacket joint 2 oil cooler cooling system diagrams.

  • Page 100: Spec

    2 - 40 spec 1 thermostat assembly 2 coolant reservoir 3 radiator 4 oil cooler cooling system diagrams.

  • Page 101: Spec

    2 - 41 spec 1 coolant reservoir 2 radiator 3 water pump cooling system diagrams.

  • Page 102: Spec

    2 - 42 spec cable routing cable routing 1 throttle cable 2 brake cable 3 clutch cable 4 main switch lead 5 headlight lead 6 fuse box 7 thermostat assembly breather hose 8 coolant reservoir hose 9 hazard switch 0 rectifier/regulator a plate b plunger control unit hose 2 c radiator d radiator fan coup...

  • Page 103: Spec

    2 - 43 spec cable routing È pass the right handlebar switch lead under the handlebar. É pass the left handlebar switch lead under the handlebar. Ê pass the wire harness, stator coil lead, coolant reservoir hose, and thermostat assembly breather hose through the left slit of the plate. Ë to the therm...

  • Page 104: Spec

    2 - 44 spec cable routing 1 brake cable 2 right handlebar switch lead 3 throttle cable 4 starter relay 5 battery 6 positive battery lead 7 main fuse 8 front turn signal lead 9 spark plug lead #4 0 spark plug lead #1 a ignition coil lead (#1, #4) b ignition coil (#1, #4) c coolant reservoir d coolant...

  • Page 105: Spec

    2 - 45 spec cable routing È fasten the positive battery lead with a plastic locking tie to the battery stay. É fasten the positive battery lead and main fuse lead with a plastic locking tie to the battery stay. Ê insert the front turn signal leads into the inner panel. Ë install the connector so tha...

  • Page 106: Spec

    2 - 46 spec cable routing Ñ support the coolant reservoir hose and coolant reservoir breather hose with the hose holder located under the coolant reservoir. Ò pass the coolant reservoir hose through the hole of the coolant reservoir hose guide. The end of the coolant reservoir hose should extend at ...

  • Page 107: Spec

    2 - 47 spec cable routing 1 tail/brake light lead.

  • Page 108: Spec

    2 - 48 spec cable routing 1 main switch lead 2 left handlebar switch lead 3 hazard switch 4 rectifier/regulator 5 clutch cable 6 fuel tank overflow hose 7 fuel tank breather hose 8 stator coil lead 9 sidestand switch 0 sidestand switch lead a oil level switch lead b brake cable c coolant reservoir h...

  • Page 109: Spec

    2 - 49 spec cable routing È to the radiator fan É pass the wire harness, stator coil lead, coolant reservoir hose, and thermostat assembly breather hose through the left slit of the plate. Ê to the right side of the frame Ë clamp the wire harness with the plastic band attached to the frame. Ì to the...

  • Page 110: Spec

    2 - 50 spec cable routing 1 ecu 2 tail/brake light lead 3 seat lock cable 4 fuel tank breather hose 5 fuel tank overflow hose 6 air filter case breather hose È to the intake air temperature sensor É fasten the wire harness with a plastic band to the frame. Ê to the inside of the u-lock storage box Ë...

  • Page 111: Spec

    2 - 51 spec 1 air cut-off valve 2 clutch cable 3 left handlebar switch lead 4 headlight lead 5 main switch lead 6 throttle cable 7 right handlebar switch lead 8 t-bar 9 spark plug lead #3 0 spark plug lead #2 a spark plug lead #1 b spark plug lead #4 c cable guide d throttle position sensor e fuel r...

  • Page 112: Spec

    2 - 52 spec È connect the wire harness and right handlebar switch lead. É pass the left handlebar switch lead, main switch lead, headlight lead, and clutch cable through the hole on the left side of the frame. Ê pass the right handlebar switch lead and throttle cables through the hole on the right s...

  • Page 113: Spec

    2 - 53 spec Ò support the throttle cables with the t-bar located behind the cable guide. Ó pass the throttle cables under spark plug leads #1, #2, #3, and #4, and the wire harness, head- light lead, main switch lead, right handlebar switch lead, and left handlebar switch lead. Install the thermostat...

  • Page 114: Spec

    2 - 54 spec 1 engine stop switch 2 starting circuit cut-off relay 3 atmospheric pressure sensor 4 cyclelock coupler 5 seat lock cable cable routing.

  • Page 115: Spec

    2 - 55 spec È to the rear brake light switch É pass the engine stop switch through the lead guide attached to the frame. Ê pass the cyclelock coupler through the inside of the storage box of the u-lock. Ë pass the cyclelock coupler through the lead guide. Ì pass the pressure sensor lead and engine s...

  • Page 116: Spec

    2 - 56 spec canister (california only) 1 fuel tank 2 fuel tank breather hose 3 fuel tank overflow hose 4 canister charge hose 5 canister purge hose 6 rollover valve 7 canister È to the left front of the fuel tank É to the left rear of the fuel tank Ê to the throttle bodies Ë align the white paint ma...

  • Page 117: Chk

    3 - 1 chk adj introduction/periodic maintenance chart for the emission control system/general maintenance and lubrication chart eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these prev...

  • Page 118: Chk

    3 - 2 chk adj general maintenance and lubrication chart * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. 4 * cooling system • check hoses for cracks or damage. • replace if necessary. √ √ √ √ √ • replace with ethylene glycol anti-freeze ...

  • Page 119: Chk

    3 - 3 chk adj general maintenance and lubrication chart note: • from 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months. • air filter • the air filter element needs to be replaced more frequently when riding in unusually wet or dusty ar...

  • Page 120: Chk

    3 - 4 chk adj seats and fuel tank eas00039 seats and fuel tank seats order job/part q’ty remarks removing the seats remove the parts in the order listed. 1 rider seat 1 2 passenger seat 1 for installation, reverse the removal procedure..

  • Page 121: Chk

    3 - 5 chk adj seats and fuel tank eas00040 fuel tank order job/part q’ty remarks removing the fuel tank remove the parts in the order listed. Rider seat fuel drain. 1 fuel tank side panel (left and right) 1/1 2 bolt 2 3 nut 1 4 fuel sender coupler 1 5 fuel pump coupler 1 6 fuel tank overflow hose 1 ...

  • Page 122: Chk

    3 - 6 chk adj t-bar order job/part q’ty remarks removing the t-bar remove the parts in the order listed. Rider seat/fuel tank refer to “seats and fuel tank”. 1 left rubber cover 1 2 right rubber cover 1 3 t-bar 1 4 rubber sheet 1 for installation, reverse the removal procedure. Seats and fuel tank.

  • Page 123: Chk

    3 - 7 chk adj removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel return hose • fuel hose caution: although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it...

  • Page 124: Chk

    3 - 8 chk adj installing the fuel pump 1. Install: • fuel pump note: • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • install the fuel pump as shown in the illustra- tion. • tighten the fuel pump bolts in stages in a cri...

  • Page 125: Chk

    3 - 9 chk adj eas00043 air filter case order job/part q’ty remarks removing the air filter case remove the parts in the order listed. Seats/fuel tank refer to “seats and fuel tank”. Side covers (left and right) refer to “cowlings and covers”. 1 air shroud 1 2 air filter case cover 1 3 air filter ele...

  • Page 126: Chk

    3 - 10 chk adj order job/part q’ty remarks 10 air induction system hose 5 1 disconnect. 11 clamp screw 4 loosen. 12 air filter case 1 13 air filter case breather hose 1 for installation, reverse the removal procedure. Air filter case.

  • Page 127: Chk

    3 - 11 chk adj cowlings and covers eas00041 cowlings and covers cowlings 1 2 3 4 5 6 7 8 9 10 11 12 13 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the cowlings remove the parts in the order listed. Rider seat/fuel tank refer to “seats and fuel tank”. 1 left side cowl...

  • Page 128: Chk

    3 - 12 chk adj cowlings and covers (7) 1 2 3 4 5 8 8 9 9 5 6 7 order job/part q’ty remarks disassembling the front cowling assembly remove the parts in the order listed. 1 windshield outer bracket 1 2 windshield 1 3 grommet 7 4 windshield inner bracket 1 5 rear view mirror (left and right) 2 6 panel...

  • Page 129: Chk

    3 - 13 chk adj 1 order job/part q’ty remarks removing the headlight assembly remove the parts in the order listed. 1 headlight assembly 1 for installation, reverse the removal procedure. Cowlings and covers.

  • Page 130: Chk

    3 - 14 chk adj (4) 9 8 7 4 6 5 3 2 1 order job/part q’ty remarks removing the windshield drive unit, meter assembly and relays remove the parts in the order listed. 1 windshield drive unit 1 2 windshield drive unit coupler 2 3 meter assembly 1 4 meter assembly coupler 1 5 headlight relay 1 1 6 headl...

  • Page 131: Chk

    3 - 15 chk adj cowlings and covers covers order job/part q’ty remarks removing the covers remove the parts in the order listed. Seats refer to “seats and fuel tank”. 1 left side cover 1 2 right side cover 1 3 rear carrier 1 4 rear cover 1 for installation, reverse the removal procedure..

  • Page 132: Chk

    3 - 16 chk adj adjusting the valve clearance eas00045 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: @ • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the pi...

  • Page 133: Chk

    3 - 17 chk adj adjusting the valve clearance 3. Remove: • hose holder 1 • lead holder 2 • pickup coil rotor cover 3 4. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the comp...

  • Page 134: Chk

    3 - 18 chk adj adjusting the valve clearance É degrees that the crankshaft is turned counter- clockwise Ê cylinder Ë combustion cycle ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remove: • rubber plug 1 • timing chain tensioner cap bolt 2 • gasket cylinder #2 180° cylinder #4 360° cylinder #...

  • Page 135: Chk

    3 - 19 chk adj adjusting the valve clearance note: @ • 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 installed in the correct place. B. Select the proper val...

  • Page 136: Chk

    3 - 20 chk adj adjusting the valve clearance e. Install the new valve pad 1 and the valve lifter 2. Note: @ • lubricate the valve pad with molybdenum disulfide grease. • lubricate the valve lifter with molybdenum disulfide oil. • the valve lifter must turn smoothly when rotated by hand. • install th...

  • Page 137: Chk

    3 - 21 chk adj intake exhaust measured clearance original valve pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 ~ 0.09 120 125 130 1...

  • Page 138: Chk

    3 - 22 chk adj adjusting the valve clearance/ synchronizing the throttle bodies 9. Install: • all removed parts note: @ for installation, reverse the removal proce- dure. Eas00050 synchronizing the throttle bodies note: @ prior to synchronizing the throttle bodies, the valve clearance and the engine...

  • Page 139: Chk

    3 - 23 chk adj synchronizing the throttle bodies 7. Measure: • engine idling speed out of specification → adjust. Refer to “adjusting the engine idling speed”. Engine idling speed 1,000 ~ 1,100 r/min 8. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. With...

  • Page 140: Chk

    3 - 24 chk adj synchronizing the throttle bodies 11.Adjust: • throttle cable free play refer to “adjusting the throttle cable free play”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 12.Remove: • engine tachometer • vacuum gauge 13.Remove: • fuel tank 14.In...

  • Page 141: Chk

    3 - 25 chk adj adjusting the engine idling speed eas00052 adjusting the engine idling speed note: @ prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression. ...

  • Page 142: Chk

    3 - 26 chk adj adjusting the engine idling speed/ adjusting the throttle cable free play 7. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 8. Install: • fuel tank front moun...

  • Page 143: Chk

    3 - 27 chk adj adjusting the throttle cable free play 3. Adjust: • throttle cable free play note: @ when the throttle is opened, the accelerator cable 1 is pulled. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ throttle body side a. Loosen the locknut 2 on the decelerator cable. B. Turn the adjus...

  • Page 144: Chk

    3 - 28 chk adj adjusting the throttle cable free play/ checking the spark plugs warning @ after adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 145: Chk

    3 - 29 chk adj checking the spark plugs/ checking the ignition timing 5. Check: • electrodes 1 damage/wear → replace the spark plug. • insulator 2 abnormal color → replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure...

  • Page 146: Chk

    3 - 30 chk adj checking the ignition timing 1. Remove: • rider seat • fuel tank • t-bar refer to “seats and fuel tank”. • right side cowling refer to “cowlings and covers”. • timing mark accessing screw 1 2. Attach: • timing light 1 • inductive tachometer (onto the spark plug lead of cylinder #1) 3....

  • Page 147: Chk

    3 - 31 chk adj checking the ignition timing/ measuring the compression pressure 5. Remove: • fuel tank • engine tachometer • timing light 6. Install: • timing mark accessing screw • right side cowling refer to “cowlings and covers”. • t-bar • fuel tank • rider seat refer to “seats and fuel tank”. Ea...

  • Page 148: Chk

    3 - 32 chk adj measuring the compression pressure 6. Install: • compression gauge adapter 1 • compression gauge 2 7. Install: • fuel tank 8. Measure: • compression pressure out of specification → refer to steps (c) and (d). ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to ...

  • Page 149: Chk

    3 - 33 chk adj measuring the compression pressure/ checking the engine oil level refer to the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Remove: • fuel tank compression pressure (with oil applied into the cylinder) reading diagnosis higher than with- out oil piston wear or...

  • Page 150: Chk

    3 - 34 chk adj checking the engine oil level 3. Check: • engine oil level the engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → add the recommended engine oil to the proper level. Caution: _ • engine oil also lubricates the clutch an...

  • Page 151: Chk

    3 - 35 chk adj changing the engine oil eas00073 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap 1 • engine oil drain bolt 2 (along with the gasket) 4. Drain: ...

  • Page 152: Chk

    3 - 36 chk adj changing the engine oil 6. Check: • engine oil drain bolt gasket damage → replace. 7. Install: • engine oil drain bolt t r . . 43 nm (4.3 m · kg, 31 ft · lb) 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) 9. Install: • engine oil filler cap 10.Start t...

  • Page 153: Chk

    3 - 37 chk adj changing the engine oil/ measuring the engine oil pressure 13.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1. B. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If ...

  • Page 154: Chk

    3 - 38 chk adj measuring the engine oil pressure 4. Remove: • main gallery bolt warning @ the engine, muffler and engine oil are extremely hot. 5. Install: • pressure gauge 1 • oil pressure adapter b 2 6. Measure: • engine oil pressure (at the following conditions) out of specification → adjust. 7. ...

  • Page 155: Chk

    3 - 39 chk adj adjusting the clutch lever/ checking the clutch fluid level eas00082 adjusting the clutch lever 1. Adjust: • clutch lever position (distance a from the handlebar grip to the clutch lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the clutch lever forward, turn...

  • Page 156: Chk

    3 - 40 chk adj checking the clutch fluid level/ bleeding the hydraulic clutch system warning @ • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the same type of clutch fluid that is alrea...

  • Page 157: Chk

    3 - 41 chk adj bleeding the hydraulic clutch system note: @ • be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over- flow. • when bleeding the hydraulic clutch system, make sure there is always enough clutch fluid before applying the clutch lever. Ignor- ing ...

  • Page 158: Chk

    3 - 42 chk adj bleeding the hydraulic clutch system/ cleaning the air filter element k. Add the recommended clutch fluid to the proper level. Refer to “checking the clutch fluid level”. Warning @ after bleeding the hydraulic clutch system, check the clutch operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 159: Chk

    3 - 43 chk adj cleaning the air filter element/ checking the throttle body joints 6. Install: • air filter element • air filter case cover caution: @ never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. O...

  • Page 160: Chk

    3 - 44 chk adj eas00096 checking the fuel and vacuum hoses the following procedure applies to all of the fuel and vacuum hoses. 1. Remove: • rider seat • fuel tank refer to “seats and fuel tank”. 2. Check: • vacuum hose • fuel hose cracks/damage → replace. Loose connection → connect properly. 3. Ins...

  • Page 161: Chk

    3 - 45 chk adj checking the exhaust system eas00099 checking the exhaust system the following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • side cowlings refer to “cowlings and covers”. 2. Check: • exhaust pipe 1 • muffler 2 cracks/damage → replace. • gasket 3 exhaust gas l...

  • Page 162: Chk

    3 - 46 chk adj checking the coolant level eas00102 checking the coolant level 1. Stand the motorcycle on a level surface. Note: @ • place the motorcycle on a suitable stand. • make sure the motorcycle is upright. 2. Remove: • right side cowling refer to “cowlings and covers”. 3. Check: • coolant lev...

  • Page 163: Chk

    3 - 47 chk adj checking the cooling system eas00104 checking the cooling system 1. Remove: • rider seat • fuel tank refer to “seats and fuel tank”. • side cowlings • front cowling assembly refer to “cowlings and covers”. 2. Check: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil c...

  • Page 164: Chk

    3 - 48 chk adj changing the coolant eas00105 changing the coolant 1. Stand the motorcycle on a level surface. Note: • place the motorcycle on a suitable stand. • make sure the motorcycle is upright. 2. Remove: • side cowlings • front cowling assembly refer to “cowlings and covers”. 3. Disconnect: • ...

  • Page 165: Chk

    3 - 49 chk adj changing the coolant 8. Check: • copper washer 1 (coolant drain bolt 2) damage → replace. 9. Install: • coolant drain bolt 10.Connect: • coolant reservoir hose t r . . 10 nm (1.0 m · kg, 7.2 ft · lb) 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) re...

  • Page 166: Chk

    3 - 50 chk adj changing the coolant caution: @ • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, if dis- tilled water i...

  • Page 167: Chk

    3 - 51 chk adj adjusting the front brake eas00107 chassis adjusting the front brake 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) note: @ • while pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. • ...

  • Page 168: Chk

    3 - 52 chk adj eas00110 adjusting the rear brake 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) out of specification → adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut 1...

  • Page 169: Chk

    3 - 53 chk adj adjusting the rear brake/ checking the brake fluid level 3. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch”. Eas00115 checking the brake fluid level 1. Stand the motorcycle on a level surface. Note: @ • place the motorcycle on a suitable stand. • mak...

  • Page 170: Chk

    3 - 54 chk adj checking the brake fluid level/ checking the brake pads/ adjusting the rear brake light switch caution: @ brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Note: @ in order to ensure a correct reading of the brake ...

  • Page 171: Chk

    3 - 55 chk adj adjusting the rear brake light switch/ checking the brake hoses 1. Check: • rear brake light operation timing incorrect → adjust. 2. Adjust: • rear brake light operation timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the right footrest bracket bolts 1. B. Hold the ...

  • Page 172: Chk

    3 - 56 chk adj bleeding the hydraulic brake system eas00134 bleeding the hydraulic brake system warning @ bleed the hydraulic brake system when- ever: the system is disassembled, a brake hose is loosened, disconnected or replaced, the brake fluid level is very low, brake operation is faulty. Note: @...

  • Page 173: Chk

    3 - 57 chk adj bleeding the hydraulic brake system/ adjusting the shift pedal g. Loosen the bleed screw. Note: @ loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. H. Tighten the bleed screw and then release ...

  • Page 174: Chk

    3 - 58 chk adj adjusting the shift pedal/checking the final drive oil level/changing the final drive oil note: make sure that the mark on the shift pedal is between the marks on the frame. C. Tighten both locknuts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00144 checking the final drive o...

  • Page 175: Chk

    3 - 59 chk adj changing the final drive oil/ checking and adjusting the steering head 3. Check: • final drive housing oil drain bolt gasket damage → replace. 4. Install: • final drive housing oil drain bolt t r . . 23 nm (2.3 m · kg, 17 ft · lb) 5. Fill: • final drive housing (with the specified amo...

  • Page 176: Chk

    3 - 60 chk adj checking and adjusting the steering head 4. Remove: • steering stem nut 1 • washer • upper bracket 2 (with the handlebars) 5. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. B. Tighte...

  • Page 177: Chk

    3 - 61 chk adj checking and adjusting the steering head/ checking the front fork g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. H. Install the lock washer. Note: @ make ...

  • Page 178: Chk

    3 - 62 chk adj adjusting the front fork legs eas00155 adjusting the front fork legs the following procedure applies to both of the front fork legs. Warning @ • always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • securely support the motor...

  • Page 179: Chk

    3 - 63 chk adj adjusting the front fork legs ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting knob 1 in direction a or b. *: from the fully turned-in position ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ direction a rebound damping is increased (suspension is harder). Dir...

  • Page 180: Chk

    3 - 64 chk adj adjusting the rear shock absorber assembly eas00157 adjusting the rear shock absorber assembly warning @ securely support the motorcycle so that there is no danger of it falling over. Spring preload 1. Adjust: • spring preload ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Move ...

  • Page 181: Chk

    3 - 65 chk adj adjusting the rear shock absorber assembly/checking the tires * from the fully turned-in position a ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ adjusting positions minimum: 20 clicks out* standard: 10 clicks out* maximum: 3 clicks out* eas00162 checking the tires the following p...

  • Page 182: Chk

    3 - 66 chk adj checking the tires warning @ it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. 1 tire tread depth 2 sidewall 3 wear indicator warning @ • do not use a tubele...

  • Page 183: Chk

    3 - 67 chk adj checking the tires/ checking the wheels front tire rear tire warning @ new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Note: @ for tire...

  • Page 184: Chk

    3 - 68 chk adj checking and lubricating the cables/ lubricating the levers and pedals/ lubricating the sidestand eas00170 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables. Warning @ damaged cable sheaths may cause the cable to corrode and int...

  • Page 185: Chk

    3 - 69 chk adj lubricating the centerstand/ lubricating the rear suspension eas00173 lubricating the centerstand lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant lithium soap base grease eas00174 lubricating the rear suspension lubricate the pivo...

  • Page 186: Chk

    3 - 70 chk adj checking and charging the battery eas00178 electrical system checking and charging the battery warning @ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...

  • Page 187: Chk

    3 - 71 chk adj checking and charging the battery note: @ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery...

  • Page 188: Chk

    3 - 72 chk adj checking and charging the battery 5. Charge: • battery (refer to the appropriate charging method illustration) warning @ do not quick charge a battery. Caution: @ • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage curre...

  • Page 189: Chk

    3 - 73 chk adj checking and charging the battery charging method using a variable voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? No...

  • Page 190: Chk

    3 - 74 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. No yes is the amperage higher than the standard charging amperage written on the batt...

  • Page 191: Chk

    3 - 75 chk adj checking and charging the battery/ checking the fuses 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) caution: @ first, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals dirt → clean with a wire brush....

  • Page 192: Chk

    3 - 76 chk adj checking the fuses note: @ set the pocket tester selector to “ Ω × 1”. B. If the pocket tester indicates “ ∞”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket tester yu-03112 3. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set t...

  • Page 193: Chk

    3 - 77 chk adj checking the fuses/ replacing the headlight bulbs warning @ never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to ...

  • Page 194: Chk

    3 - 78 chk adj replacing the headlight bulbs/ adjusting the headlight beams 5. Install: • headlight bulb secure the new headlight bulb with the headlight bulb holder. Caution: @ avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, t...

  • Page 195: Chk

    3 - 79 chk adj adjusting the headlight beams 2. Adjust: • headlight beam (horizontally) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. Left headlight right headlight ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ direction a headlight beam mov...

  • Page 196: Chk

    3 - 80 chk adj adjusting the headlight beams.

  • Page 197: Chas

    4 - 1 chas eas00514 chassis front wheel and brake discs order job/part q’ty remarks removing the front wheel and brake discs remove the parts in the order listed. Note: @ place the motorcycle on a suitable stand so that the front wheel is elevated. 1 brake caliper (left and right) 2 refer to “removi...

  • Page 198: Chas

    4 - 2 chas front wheel and brake discs eas00518 order job/part q’ty remarks disassembling the front wheel remove the parts in the order listed. 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly procedure..

  • Page 199: Chas

    4 - 3 chas front wheel and brake discs eas00521 removing the front wheel 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. Note: @ place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remov...

  • Page 200: Chas

    4 - 4 chas front wheel and brake discs 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 over the specified limits → replace. Radial wheel runout limit 1.0 mm (0.04 in) lateral wheel runout limit 0.5 mm (0.02 in) 4. Check: • wheel bearings front wheel turns roughly or is loose → replace t...

  • Page 201: Chas

    4 - 5 chas front wheel and brake discs eas00533 checking the brake discs the following procedure applies to all of the brake discs. 1. Check: • brake disc damage/galling → replace. 2. Measure: • brake disc deflection out of specification → correct the brake disc deflection or replace the brake disc....

  • Page 202: Chas

    4 - 6 chas front wheel and brake discs 4. Adjust: • brake disc deflection ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the brake disc. B. Rotate the brake disc by one bolt hole. C. Install the brake disc. Note: @ tighten the brake disc bolts in stages and in a crisscross pattern. D. M...

  • Page 203: Chas

    4 - 7 chas front wheel and brake discs 3. Install: • brake caliper warning @ make sure the brake hose is routed prop- erly. T r . . 40 nm (4.0 m · kg, 29 ft · lb) eas00549 adjusting the front wheel static balance note: @ • after replacing the tire, wheel or both, the front wheel static balance shoul...

  • Page 204: Chas

    4 - 8 chas front wheel and brake discs 3. Adjust: • front wheel static balance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “x”. Note: @ start with the lightest weight. B. Turn the front wheel 90° so that the heavy spo...

  • Page 205: Chas

    4 - 9 chas rear wheel and brake disc eas00551 rear wheel and brake disc order job/part q’ty remarks removing the rear wheel and brake disc remove the parts in the order listed. Note: @ place the motorcycle on a suitable stand so that the rear wheel is elevated. 1 brake torque rod nut/bolt 1/1 refer ...

  • Page 206: Chas

    4 - 10 chas rear wheel and brake disc as00560 order job/part q’ty remarks disassembling the rear wheel remove the parts in the order listed. 1 dust cover 1 2 rear wheel drive hub 1 3 dust seal 1 4 wheel bearing 2 5 rear wheel drive hub damper 6 6 oil seal 1 7 circlip 1 8 wheel bearing 1 9 spacer 1 0...

  • Page 207: Chas

    4 - 11 chas rear wheel and brake disc eeas00562 removing the rear wheel 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. Note: @ place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove:...

  • Page 208: Chas

    4 - 12 chas rear wheel and brake disc 3. Measure: • radial wheel runout • lateral wheel runout refer to “front wheel and brake discs”. Eeas00572 installing the rear wheel 1. Lubricate: • wheel axle • wheel bearings • oil seal lips recommended lubricant lithium soap base grease 2. Tighten: • brake to...

  • Page 209: Chas

    4 - 13 chas front and rear brakes eas00577 front and rear brakes front brake pads order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 1 brake hose holder bolt 1 2 brake caliper bolt 2 3 b...

  • Page 210: Chas

    4 - 14 chas front and rear brakes eas00578 rear brake pads order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. 1 retaining bolt 2 2 brake pad 2 3 brake pad shim 2 4 bleed screw 1 for installation, reverse the removal procedure..

  • Page 211: Chas

    4 - 15 chas front and rear brakes eas00579 caution: @ disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the entir...

  • Page 212: Chas

    4 - 16 chas front and rear brakes 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in) 4. Install: • brak...

  • Page 213: Chas

    4 - 17 chas front and rear brakes 5. Install: • brake pad pins • brake pad clips • brake caliper • brake hose holder t r . . 40 nm (4.0 m · kg, 29 ft · lb) t r . . 7 nm (0.7 m · kg, 5.1 ft · lb) 6. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the pro...

  • Page 214: Chas

    4 - 18 chas front and rear brakes 3. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad springs • brake pad shims (onto the brake pads) • brake pads note: @ always install new brake pads, brake pad s...

  • Page 215: Chas

    4 - 19 chas front and rear brakes 6. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 216: Chas

    4 - 20 chas front and rear brakes eas00584 front brake master cylinder order job/part q’ty remarks removing the front brake master cylinder remove the parts in the order listed. Brake fluid drain. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir dia- phragm holder 1 3 brake ...

  • Page 217: Chas

    4 - 21 chas front and rear brakes order job/part q’ty remarks 6 union bolt 1 refer to “disassembling/ assembling and installing the front brake master cylinder”. 7 copper washer 2 8 brake hose 1 disconnect. 9 brake master cylinder holder 1 10 brake master cylinder 1 11 front brake light switch 1 for...

  • Page 218: Chas

    4 - 22 chas front and rear brakes eas00585 order job/part q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder 1 for assembly, reverse the disassembly procedure..

  • Page 219: Chas

    4 - 23 chas front and rear brakes eas00586 rear brake master cylinder order job/part q’ty remarks removing the rear brake master cyl- inder remove the parts in the order listed. Side cover (right) refer to “cowlings and covers” in chapter 3. Brake fluid drain. 1 brake fluid reservoir cap 1 2 brake f...

  • Page 220: Chas

    4 - 24 chas front and rear brakes order job/part q’ty remarks 9 union bolt 1 refer to “disassembling/ assembling the rear brake master cylinder”. 10 copper washer 2 11 brake hose 1 disconnect. 12 cotter pin 1 13 pin 1 14 brake master cylinder 1 for installation, reverse the removal procedure..

  • Page 221: Chas

    4 - 25 chas front and rear brakes eas00587 order job/part q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 push rod 1 4 brake master cylinder kit 1 5 brake master cylinder 1 for assembly, reverse the disassembly procedure..

  • Page 222: Chas

    4 - 26 chas front and rear brakes eas00588 disassembling the front brake master cylinder note: @ before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 note: @ to collect any remaining brak...

  • Page 223: Chas

    4 - 27 chas front and rear brakes eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) o...

  • Page 224: Chas

    4 - 28 chas front and rear brakes 5. Check: • brake hoses cracks/damage/wear → replace. Eas00606 assembling and installing the front brake master cylinder warning @ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solv...

  • Page 225: Chas

    4 - 29 chas front and rear brakes caution: @ when installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. Note: turn the handlebars to the left and to the right to make sure the brake hose does not touch other parts (e.G., wire harness, c...

  • Page 226: Chas

    4 - 30 chas front and rear brakes 5. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 227: Chas

    4 - 31 chas front and rear brakes warning • 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 har...

  • Page 228: Chas

    4 - 32 chas front and rear brakes 6. Adjust: • rear brake light operation timing refer to “adjusting the rear brake light switch” in chapter 3..

  • Page 229: Chas

    4 - 33 chas front and rear brakes eas00613 front brake calipers order job/part q’ty remarks removing the front brake calipers remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid drain. 1 brake hose holder bolt 1 refer to “disassembli...

  • Page 230: Chas

    4 - 34 chas front and rear brakes eas00615 order job/part q’ty remarks disassembling the front brake cali- pers remove the parts in the order listed. 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/brake pad s...

  • Page 231: Chas

    4 - 35 chas front and rear brakes eas00616 rear brake caliper order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Brake fluid drain. 1 union bolt 1 refer to “disassembling/ assembling and installing the rear brake caliper”. 2 copper washer 2 3 brake hose...

  • Page 232: Chas

    4 - 36 chas front and rear brakes eas00617 order job/part q’ty remarks disassembling the rear brake cali- per remove the parts in the order listed. 1 retaining bolt 2 2 brake pad/brake pad shim 2/2 3 brake pad spring 2 4 rear brake caliper bracket 1 5 brake caliper piston 1 refer to “disassembling t...

  • Page 233: Chas

    4 - 37 chas front and rear brakes eas00625 disassembling the front brake calipers the following procedure applies to both of the brake calipers. Note: @ before disassembling either brake caliper, drain the brake fluid from the entire brake sys- tem. 1. Remove: • union bolt 1 • copper washers 2 • bra...

  • Page 234: Chas

    4 - 38 chas front and rear brakes eas00626 disassembling the rear brake caliper note: @ before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 note: @ put the end of the brake hose into a container and p...

  • Page 235: Chas

    4 - 39 chas front and rear brakes eas00633 checking the front and rear brake calipers 1. Check: • brake caliper pistons 1 rust/scratches/wear → replace the brake caliper. • brake caliper cylinders 2 scratches/wear → replace the brake cali- per. • brake calipers cracks/damage → replace. • brake fluid...

  • Page 236: Chas

    4 - 40 chas front and rear brakes eas00638 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. Warning @ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use so...

  • Page 237: Chas

    4 - 41 chas front and rear brakes 3. Install: • brake pads • brake pad spring • brake caliper • brake hose holder refer to “replacing the front brake pads”. T r . . 40 nm (4.0 m · kg, 29 ft · lb) t r . . 7 nm (0.7 m · kg, 5.1 ft · lb) 4. Fill: • brake master cylinder reservoir (with the specified am...

  • Page 238: Chas

    4 - 42 chas front and rear brakes 6. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 239: Chas

    4 - 43 chas front and rear brakes 2. Tighten: • brake torque rod • wheel axle nut • wheel axle pinch bolt t r . . 30 nm (3.0 m · kg, 22 ft · lb) t r . . 125 nm (12.5 m · kg, 90 ft · lb) t r . . 16 nm (1.6 m · kg, 11 ft · lb) 3. Install: • brake caliper (temporarily) • copper washers 1 • brake hose 2...

  • Page 240: Chas

    4 - 44 chas front and rear brakes 6. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning @ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the...

  • Page 241: Chas

    4 - 45 chas front and rear brakes 9. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” in chapter 3..

  • Page 242: Chas

    4 - 46 chas eas00305 hydraulic clutch clutch master cylinder order job/part q’ty remarks removing the clutch master cylin- der remove the parts in the order listed. Clutch fluid drain. 1 clutch master reservoir cap 1 2 clutch master reservoir diaphram holder 1 3 clutch master reservoir diaphram 1 4 ...

  • Page 243: Chas

    4 - 47 chas order job/part q’ty remarks 7 union bolt 1 refer to “disassembling/ assembling and installing the clutch master cylinder”. 8 copper washer 2 9 clutch hose 1 disconnect. 10 clutch master cylinder holder 1 11 clutch master cylinder 1 refer to “assembling and installing the clutch master cy...

  • Page 244: Chas

    4 - 48 chas eas00306 order job/part q’ty remarks disassembling the clutch master cylinder remove the parts in the order listed. 1 clutch master cylinder push rod 1 2 dust seal 1 3 circlip 1 4 washer 1 5 clutch master cylinder kit 1 6 clutch master cylinder 1 for assembly, reverse the disassembly pro...

  • Page 245: Chas

    4 - 49 chas eas00307 caution: @ clutch components rarely require disas- sembly. Therefore, always follow these preventive measures: • never disassemble clutch components unless absolutely necessary. • if any connection on the hydraulic clutch system is disconnected, the entire clutch system must be ...

  • Page 246: Chas

    4 - 50 chas eas00308 checking the clutch master cylinder recommended clutch component replacement schedule piston seals every two years clutch hose every two years clutch fluid every two years and whenever the clutch is disassem- bled 1. Check: • clutch master cylinder body 1 cracks/damage → replace...

  • Page 247: Chas

    4 - 51 chas eas00309 eas00310 assembling and installing the clutch master cylinder warning @ • before installation, all internal clutch components must be cleaned and lubri- cated with clean or new clutch fluid. • never use solvents on internal clutch components as they will cause the piston seals t...

  • Page 248: Chas

    4 - 52 chas caution: @ when installing the clutch hose onto the clutch master cylinder, make sure the clutch pipe touches the projection a as shown. Note: turn the handlebars to the left and to the right to make sure the clutch hose does not touch other parts (e.G., wire harness, cables, leads). Cor...

  • Page 249: Chas

    4 - 53 chas 4. Bleed: • clutch system refer to “bleeding the hydraulic clutch system” in chapter 3. 5. Check: • clutch fluid level below the minimum level mark a → add the recommended clutch fluid to the proper level. Refer to “checking the clutch fluid level” in chapter 3. 6. Check: • clutch lever ...

  • Page 250: Chas

    4 - 54 chas eas00311 clutch release cylinder order job/part q’ty remarks removing the clutch release cylin- der remove the parts in the order listed. Clutch fluid drain. 1 union bolt 1 refer to “disassembling/ assembling and installing the clutch master cylinder”. 2 copper washer 2 3 clutch hose 1 d...

  • Page 251: Chas

    4 - 55 chas order job/part q’ty remarks disassembling the clutch release cylinder remove the parts in the order listed. 1 clutch release cylinder piston 1 refer to “disassembling the clutch release cylinder”. 2 clutch release cylinder spring 1 3 clutch release cylinder piston seal 1 4 bleed screw 1 ...

  • Page 252: Chas

    4 - 56 chas eas00313 disassembling the clutch release cylinder note: before disassembling the clutch release cylin- der, drain the clutch fluid from the entire clutch system. 1. Remove: • union bolt 1 • copper washers 2 • clutch hose 3 note: put the end of the clutch hose into a container and pump o...

  • Page 253: Chas

    4 - 57 chas eas00314 checking the clutch release cylinder 1. Check: • clutch release cylinder body 1 cracks/damage → replace the clutch release cylinder. Recommended clutch component replacement schedule piston seal every two years clutch hose every two years clutch fluid every two years and wheneve...

  • Page 254: Chas

    4 - 58 chas 2. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) warning @ • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the same t...

  • Page 255: Chas

    4 - 59 chas 5. Check: • clutch lever operation soft or spongy feeling → bleed the clutch system. Refer to “bleeding the hydraulic clutch system” in chapter 3. Hydraulic clutch.

  • Page 256: Chas

    4 - 60 chas front fork eas00647 front fork order job/part q’ty remarks removing the front fork legs remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling assembly refer to “cowlings” and “covers” in chapter 3. Front wheel refer to “front ...

  • Page 257: Chas

    4 - 61 chas front fork eas00648 order job/part q’ty remarks disassembling the front fork legs remove the parts in the order listed. The following procedure applies to both of the front fork legs. 1 cap bolt/o-ring 1/1 refer to “disassembling/ assembling the front fork legs”. 2 damper adjusting rod 1...

  • Page 258: Chas

    4 - 62 chas order job/part q’ty remarks b damper rod assembly 1 refer to “disassembling/ assembling the front fork legs”. C inner tube 1 d oil seal 1 refer to “assembling the front fork legs”. E seal spacer 1 f outer tube bushing 1 g inner tube bushing 1 h oil flow stopper 1 i outer tube 1 for assem...

  • Page 259: Chas

    4 - 63 chas front fork eas00649 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. Note: @ place the motorcycle on a suitable...

  • Page 260: Chas

    4 - 64 chas front fork 4. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) caution: @ do not scratch the inner tube. Note: @ • do not remove the fork leg protector from the outer tube. • if the front fork leg protector must be removed, always install a new one. 5. Remove: • was...

  • Page 261: Chas

    4 - 65 chas front fork eas00657 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 bends/damage/scratches → replace. Warning @ do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measur...

  • Page 262: Chas

    4 - 66 chas front fork 4. Check: • cap bolt o-ring damage/wear → replace. Eas00661 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning @ • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling ...

  • Page 263: Chas

    4 - 67 chas front fork 3. Tighten: • damper rod assembly bolt 1 note: @ • if the washer has not been removed during disassembly, strike the washer lightly, and then remove it. • while holding the damper rod assembly with the damper rod holder 2, tighten the damper rod assembly bolt. Damper rod holde...

  • Page 264: Chas

    4 - 68 chas front fork 6. Install: • oil seal clip 1 note: @ adjust the oil seal clip so that it fits into the groove of the outer tube. 7. Install: • dust seal 1 (with the fork seal driver) new 8. Fully compress the front fork leg. 9. Fill: • front fork leg (with the specified amount of the recom- ...

  • Page 265: Chas

    4 - 69 chas front fork 11.Slowly stroke the inner tube 1 up and down. 12.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. Note: @ be sure to bleed the front fork leg of any resid- ual air. 13.Measure: • front fork leg oil level a out...

  • Page 266: Chas

    4 - 70 chas front fork eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg note: • make sure that the inner tube end is flush with the top of the upper bracket. • temporarily tighten the upper and lower bracket pinch bo...

  • Page 267: Chas

    4 - 71 chas 3. Install: • collar 1 • collar 2 • front fender 3 • front fender bolts note: • install the collar 1 from the outside of the front fender. • install the collar 2 from the inside of the front fender. • when installing the front fender, make sure that there is no dirt between the front fen...

  • Page 268: Chas

    4 - 72 chas handlebars eas00665 handlebars left handlebar order job/part q’ty remarks removing the left handlebar remove the parts in the order listed. 1 clutch switch coupler 1 disconnect. 2 clutch master cylinder holder 1 refer to “removing/installing the handlebars”. 3 clutch master cylinder 1 4 ...

  • Page 269: Chas

    4 - 73 chas handlebars right handlebar order job/part q’ty remarks removing the right handlebar remove the parts in the order listed. 1 front brake light switch connector 2 disconnect. 2 brake master cylinder holder 1 refer to “removing/ installing the handlebars”. 3 brake master cylinder 1 4 grip e...

  • Page 270: Chas

    4 - 74 chas handlebars eas00667 removing the handlebars 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip note: @ blow compressed air between the left handle- bar and the handlebar grip, an...

  • Page 271: Chas

    4 - 75 chas handlebars eas00674 installing the handlebars 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. 2. Install: • right handlebar switch 1 note: @ align the projection a on the right handlebar switch with the ...

  • Page 272: Chas

    4 - 76 chas handlebars 4. Install: • brake master cylinder • brake master cylinder holder 1 note: @ • install the brake master cylinder holder with the “up” mark facing up. • first, tighten the upper bolt, and then the lower bolt. • align the mating surfaces of the brake mas- ter cylinder holder wit...

  • Page 273: Chas

    4 - 77 chas handlebars 7. Install: • clutch master cylinder • clutch master cylinder holder 1 note: @ align the slit in the clutch master cylinder holder with the punch mark a in the left han- dlebar. T r . . 10 nm (1.0 m · kg, 7.2 ft · lb) 8. Adjust: • throttle cable free play refer to “adjusting t...

  • Page 274: Chas

    4 - 78 chas steering head eas00676 steering head order job/part q’ty remarks removing the lower bracket remove the parts in the order listed. Front wheel refer to “front wheel and brake discs”. Front fork legs refer to “front fork”. Handlebars refer to “handlebars”. 1 lead guide 2 2 main switch coup...

  • Page 275: Chas

    4 - 79 chas steering head order job/part q’ty remarks 7 lock washer 1 refer to “removing the lower bracket” and “installing the steering head”. 8 upper ring nut 1 9 rubber washer 1 10 lower ring nut 1 11 lower bracket 1 12 bearing cover 1 13 bearing inner race 2 14 upper bearing 1 15 lower bearing 1...

  • Page 276: Chas

    4 - 80 chas steering head eas00677 removing the lower bracket 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • lower ring nut 1 (with the special tool 2) warning @ securely support the lower bracket so t...

  • Page 277: Chas

    4 - 81 chas steering head b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. C. Install a new rubber seal and new bearing races. Caution: @ if the bearing race is not installed properly, the steering head pipe could be damaged. Note: @ • always replace the bearings a...

  • Page 278: Chas

    4 - 82 chas steering head 3. Install: • upper bracket • steering stem nut note: @ temporarily tighten the steering stem nut. 4. Install: • front fork legs refer to “front fork”. Note: @ temporarily tighten the lower and upper bracket pinch bolts. 5. Tighten: • steering stem nut t r . . 115 nm (11.5 ...

  • Page 279: Chas

    4 - 83 chas rear shock absorber assembly and relay arm eas00685 rear shock absorber assembly and relay arm 5 5 8 2 2 3 3 4 13 11 1310 14 13 13 13 3 3 4 15 15 13 12 14 1 (3) 7 8 ls 9 6 ls t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ...

  • Page 280: Chas

    4 - 84 chas rear shock absorber assembly and relay arm 5 5 8 2 2 3 3 4 13 11 1310 14 13 13 13 3 3 4 15 15 13 12 14 1 (3) 7 8 ls 9 6 ls t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 5...

  • Page 281: Chas

    4 - 85 chas rear shock absorber assembly and relay arm eas00686 handling the rear shock absorber warning @ this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot...

  • Page 282: Chas

    4 - 86 chas rear shock absorber assembly and relay arm 2. Remove: • rear shock absorber assembly lower bolt 1 • connecting arms note: @ while removing the connecting arm bolt, hold the swingarm so that it does not drop down. 3. Remove: • rear shock absorber assembly upper bolt 1 • rear shock absorbe...

  • Page 283: Chas

    4 - 87 chas rear shock absorber assembly and relay arm 2. Check: • bearings • oil seals damage/pitting → replace. 3. Check: • spacers damage/scratches → replace. Installing the relay arm 1. Lubricate: • spacers • bearings 2. Install: • bearing 1, 2 (to the relay arm) recommended lubricant lithium so...

  • Page 284: Chas

    4 - 88 chas swingarm eas00701 swingarm order job/part q’ty remarks removing the swingarm remove the parts in the order listed. Mufflers refer to “engine” in chapter 5. Rear wheel refer to “rear wheel and brake disc”. Final drive assembly/universal joint refer to “shaft drive”. Rear shock absorber as...

  • Page 285: Chas

    4 - 89 chas swingarm order job/part q’ty remarks 9 oil seal 2 10 bearing 2 refer to “installing the swingarm”. 11 spacer 1 12 oil seal 1 13 bushing 1 14 oil seal 1 15 circlip 1 16 bearing 1 17 spacer 1 18 bearing 1 refer to “installing the swingarm”. For installation, reverse the removal procedure..

  • Page 286: Chas

    4 - 90 chas swingarm eas00702 removing the swingarm 1. Stand the motorcycle on a level surface. Warning @ securely support the motorcycle so that there is no danger of it falling over. Note: @ place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side pl...

  • Page 287: Chas

    4 - 91 chas swingarm 2. Check: • pivot shaft roll the pivot shaft on a flat surface. Bends → replace. Warning @ do not attempt to straighten a bent pivot shaft. 3. Wash: • pivot shaft • spacers • bushing • bearings recommended cleaning solvent kerosene 4. Check: • spacers • bushing • oil seals damag...

  • Page 288: Chas

    4 - 92 chas 3. Install: • bearing 1 (to the swingarm) installed depth a 4.0 mm (0.16 in) swingarm.

  • Page 289: Chas

    4 - 93 chas shaft drive eas00715 shaft drive troubleshooting note: @ causes a, b, and c may be extremely difficult to diagnose. The symptoms are quite subtle and dif- ficult to distinguish from normal operating noises. If there is reason to believe that these compo- nents are damaged, remove them an...

  • Page 290: Chas

    4 - 94 chas shaft drive inspection notes 1. Investigate any unusual noises. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following noises may indicate a mechanical defect: a. A rolling “rumble” during coasting, accelera- tion or deceleration (increases with the rear wheel speed, but does no...

  • Page 291: Chas

    4 - 95 chas shaft drive eas00716 troubleshooting chart when causes (a) or (b) shown in the table at the beginning of the “troubleshooting” section exist, check the following points. Place the motorcycle on a suitable stand so that the front wheel is elevated and then spin the front wheel. Is the whe...

  • Page 292: Chas

    4 - 96 chas shaft drive eas00717 checking the final drive oil for contamination and checking the shaft drive for leaks 1. Drain: • final drive oil (from the final drive housing) refer to “changing the final drive oil” in chapter 3. 2. Check: • final drive oil large amount of metal particles → check ...

  • Page 293: Chas

    4 - 97 chas shaft drive eas00719 measuring the ring gear backlash 1. Secure the final drive assembly in a vise. 2. Remove: • final drive oil drain bolt 3. Drain: • final drive oil (from the final drive assembly) 4. Measure: • ring gear backlash out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 294: Chas

    4 - 98 chas shaft drive eas00720 adjusting the ring gear backlash 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts note: @ working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts. @ 2. Remove: • ...

  • Page 295: Chas

    4 - 99 chas shaft drive eas00721 measuring the ring-gear-to- stopper-bolt clearance 1. Remove: • ring gear bearing housing (along with the ring gear) refer to “adjusting the ring gear backlash”. 2. Measure: • ring-gear-to-stopper-bolt clearance a out of specification → adjust. 1 stopper bolt 2 ring ...

  • Page 296: Chas

    4 - 100 chas shaft drive 3. Install: • stopper bolt shim(s) 1 • stopper bolt 2 • ring gear 3 • ring gear bearing housing caution: @ • the stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise. • apply loctite ® onto the stopper bolt. @ 4. Measure: • ring-gear-to...

  • Page 297: Chas

    4 - 101 chas shaft drive eas00718 order job/part q’ty remarks removing the final drive assembly remove the parts in the order listed. Final gear oil drain. Rear wheel refer to “rear wheel and brake disc”. 1 final drive assembly 1 refer to “installing the universal joint and final drive assembly”. Fo...

  • Page 298: Chas

    4 - 102 chas order job/part q’ty remarks removing the universal joint remove the parts in the order listed. Final drive assembly 1 shift arm 1 refer to “installing the universal joint and final drive assembly”. 2 left footrest bracket 1 refer to “removing the left footrest bracket”. 3 dust cover 1 4...

  • Page 299: Chas

    4 - 103 chas shaft drive eas00723 order job/part q’ty remarks disassembling the final drive assembly remove the parts in the order listed. 1 circlip 2 2 oil seal 1 3 drive shaft 1 4 spring 1 5 ring gear bearing housing/oil seal 1/1 6 dust cover 1 refer to “aligning the final drive pinion gear and ri...

  • Page 300: Chas

    4 - 104 chas shaft drive order job/part q’ty remarks b nut 1 left-hand threads. Refer to “disassembling the final drive assembly” and “aligning the final drive pinion gear and ring gear”. C gear coupling 1 d bearing retainer/oil seal 1/1 left-hand threads. E final drive pinion gear/bearing 1/1 f fin...

  • Page 301: Chas

    4 - 105 chas shaft drive removing the left footrest bracket 1. Remove: • left footrest bracket bolt 1 (with the t50 torx wrench) eas00724 disassembling the final drive assembly 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts note: @ working in a crisscross pattern, loos...

  • Page 302: Chas

    4 - 106 chas shaft drive 4. Remove: • bearing retainer (with the piston bearing retainer remover 1) caution: @ the bearing retainer has left-hand threads. To loosen the bearing retainer, turn it clockwise. @ 5. Remove: • final drive pinion gear warning @ always use new bearings. @ caution: @ the fin...

  • Page 303: Chas

    4 - 107 chas shaft drive 3. Remove: • bearing 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final drive housing to approxi- mately 150 °c (302 °f). B. Remove the bearing outer races with an appropriately shaped punch 2. C. Remove the inner race from the final drive pinion gear. Not...

  • Page 304: Chas

    4 - 108 chas shaft drive eas00726 aligning the final drive pinion gear and ring gear note: @ aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: • final drive housing • ring gear bearing housing • any bearing @ 1. Select: • final drive pinion...

  • Page 305: Chas

    4 - 109 chas shaft drive therefore, the calculated final drive pinion gear shim thickness is 0.51 mm (0.02 in). Shim sizes are supplied in the following thicknesses. Since the final drive pinion gear shims are only available in 0.10 mm (0.004 in) increments, round off to the hundredths digit. In the...

  • Page 306: Chas

    4 - 110 chas shaft drive example: if the final drive housing is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “– 05”, and “ f” is 13.00: b = (45 + 51/100) + (3 + 35/100) – [(35.40 – 5/100) + 13] = (45 + 0.51) + (3 + 0.35) – [(35.40 – 0.05) + 13] = 45.51 + 3.35 – ...

  • Page 307: Chas

    4 - 111 chas shaft drive 2. Install: • shims (as calculated) • final drive pinion gear • bearing retainer (with the piston bearing retainer remover 1) caution: @ the bearing retainer has left-hand threads. To tighten the bearing retainer, turn it counterclockwise. @ piston bearing retainer remover y...

  • Page 308: Chas

    4 - 112 chas shaft drive 7. Measure: • ring-gear-to-thrust-washer clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the ring gear bearing housing (along with the ring gear). B. Place four pieces of plastigauge ® between the original thrust washer and the ring gear. C. Install the...

  • Page 309: Chas

    4 - 113 chas shaft drive eas00727 checking the drive shaft 1. Check: • drive shaft splines damage/wear → replace the drive shaft. Eas00728 installing the universal joint and final drive assembly 1. Lubricate: • universal joint splines • drive shaft splines 2. Install: • universal joint • final drive...

  • Page 310: Eng

    5 - 1 eng engine eas00188 engine engine mufflers and exhaust pipe assembly order job/part q’ty remarks removing the mufflers and exhaust pipe assembly remove the parts in the order listed. Seats/fuel tank/t-bar/rubber seat refer to “seats and fuel tank” in chapter 3. Side cowlings/front cowling asse...

  • Page 311: Eng

    5 - 2 eng engine leads and hoses order job/part q’ty remarks removing the leads and hoses remove the parts in the order listed. Air filter case refer to “air filter case” in chapter 3. Throttle bodies refer to “fuel injection system” in chapter 7. Air cut-off valve assembly/hoses/reed valves refer t...

  • Page 312: Eng

    5 - 3 eng engine order job/part q’ty remarks left footrest bracket/dust cover refer to “shaft drive” in chapter 4. 1 clutch release cylinder 1 2 dowel pin 2 3 sidestand switch coupler 1 disconnect. 4 crankcase breather hose 1 5 starter motor lead 1 disconnect. 6 stator assembly coupler 1 disconnect....

  • Page 313: Eng

    5 - 4 eng engine eas00191 engine 7 7 11 9 14 9 5 6 12 4 4 15 1 2 3 6 5 8 10 13 10 16 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 16 nm (1.6 m • kg, 1...

  • Page 314: Eng

    5 - 5 eng 7 7 11 9 14 9 5 6 12 4 4 15 1 2 3 6 5 8 10 13 10 16 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 16 nm (1.6 m • kg, 11 ft • ib) t r . . T r ...

  • Page 315: Eng

    5 - 6 eng engine eas00192 installing the engine 1. Install: • spacer 1 • spacer bolt 2 • rear lower mounting bolt 3 • rear upper mounting bolt 4 • front mounting bolts 5, 6 • engine bracket 2 7 • engine bracket 1 8 note: @ do not fully tighten the bolts. 2. Tighten the bolts in the following order. ...

  • Page 316: Eng

    5 - 7 eng 4. Tighten the bolts in the following order. • bolts (engine bracket 2 and engine) 1 • bolts (engine bracket 2 and frame) 2 t r . . 36 nm (3.6 m · kg, 25 ft · lb) t r . . 16 nm (1.6 m · kg, 11 ft · lb) 5. Temporarily tighten the bolt (engine bracket 1 and frame) 1 and bolts (engine bracket...

  • Page 317: Eng

    5 - 8 eng camshafts eas00194 camshafts cylinder head cover 1 lt ls new 4 5 6 2 3 (8) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the cylinder head cover remove the parts in the order list...

  • Page 318: Eng

    5 - 9 eng camshafts eas00196 camshafts order job/part q’ty remarks removing the camshafts remove the parts in the order listed. Throttle bodies refer to “fuel injection system” in chapter 7. Pickup coil rotor cover refer to “pickup coil rotor”. 1 timing chain tensioner 1 refer to “removing/installin...

  • Page 319: Eng

    5 - 10 eng order job/part q’ty remarks 10 timing chain guide (exhaust side) 1 11 pin 1 12 timing chain guide (intake side) 1 for installation, reverse the removal procedure. Camshafts.

  • Page 320: Eng

    5 - 11 eng camshafts eas00198 removing the camshafts 1. Align: • “t” mark on the pickup coil rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark a on ...

  • Page 321: Eng

    5 - 12 eng camshafts 5. Remove: • intake camshaft 1 • exhaust camshaft 2 note: @ to prevent the timing chain from falling into the crankcase, fasten it with a wire 3. Eas00204 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: •...

  • Page 322: Eng

    5 - 13 eng camshafts ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). B. Position a strip of plastigauge ® 1 onto the camshaft journal as shown. C. Install the dowel pins and camshaft caps. Note: @ • tighten ...

  • Page 323: Eng

    5 - 14 eng camshafts eas00210 checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage/rough movement → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise wi...

  • Page 324: Eng

    5 - 15 eng camshafts 2. Install: • exhaust camshaft 1 • intake camshaft 2 (with the camshaft sprockets) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark a on the pickup coil rotor with the ...

  • Page 325: Eng

    5 - 16 eng camshafts 4. Install: • camshaft cap bolts note: @ tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Caution: @ • lubricate the camshaft cap bolts with the engine oil. • the camshaft cap bolts must be tightened evenly or damage to the c...

  • Page 326: Eng

    5 - 17 eng camshafts d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Cap bolt 10 nm (1.0 m · kg, 7.2 ft · lb) 6. Turn: • crankshaft (several turns clockwis...

  • Page 327: Eng

    5 - 18 eng camshafts 9. Install: • cylinder head cover gasket • cylinder head cover note: out of specification → adjust. • apply bond t1541 1 onto the mating sur- faces of the cylinder head cover and cylinder head cover gasket. • apply bond ygk8624-c1 2 onto the mating surfaces of the cylinder head ...

  • Page 328: Eng

    5 - 19 eng cylinder head eas00221 cylinder head new new e 3 3 2 new 1 (10) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) order job/part q’ty remarks removing the cylinder head remove the parts in the order listed. Radiator refer to “radiator” in chapter 6. Exhaust pi...

  • Page 329: Eng

    5 - 20 eng cylinder head eas00222 removing the cylinder head 1. Remove: • cylinder head bolts note: @ loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them. Eas00229 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounde...

  • Page 330: Eng

    5 - 21 eng cylinder head d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. Note: @ to ensure an even surface, rotate the cylinder head several times. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00232 installing...

  • Page 331: Eng

    5 - 22 eng cylinder head d. Loosen and retighten the cylinder head bolts in the proper tightening sequence as shown. T r . . Cylinder head bolt (m10) 2nd 25 nm (2.5 m · kg, 18 ft · lb) e. Tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence as s...

  • Page 332: Eng

    5 - 23 eng valves and valve springs eas00236 valves and valve springs 1 2 3 4 5 8 9 3 1 2 3 4 5 8 9 3 m m m m 10 7 10 6 m new new order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 valve lifter 16 refer to...

  • Page 333: Eng

    5 - 24 eng valves and valve springs eas00237 removing the valves the following procedure applies to all of the valves and related components. Note: @ before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: •...

  • Page 334: Eng

    5 - 25 eng valves and valve springs 3. Remove: • valve cotters 1 note: @ remove the valve cotters by compressing the valve spring with the valve spring compressor set 2 and attachment 3. Valve spring compressor set ym-03153 attachment ym-04108 4. Remove: • upper spring seat 1 • valve spring 2 • valv...

  • Page 335: Eng

    5 - 26 eng valves and valve springs 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. Valve-stem-to-valve-guide clearance = valve guide inside diameter a – valve stem diameter b valve-stem-to-valve-guide clear- ance intake 0.010 ~ 0.037 mm (0.0004 ~ 0....

  • Page 336: Eng

    5 - 27 eng valves and valve springs 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thic...

  • Page 337: Eng

    5 - 28 eng valves and valve springs 3. Measure: • valve seat width a out of specification → replace the cylinder head. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply mechanic’s blueing dye (dykem) b onto the valve face. B. Install the valve into the cylinder head. C. Press the valve thro...

  • Page 338: Eng

    5 - 29 eng valves and valve springs c. Install the valve into the cylinder head. D. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. Note: @ for the best lapping results, lightly tap the valve seat while rotating the valve back and f...

  • Page 339: Eng

    5 - 30 eng valves and valve springs 2. Measure: • compressed valve spring force a out of specification → replace the valve spring. B installed length compressed valve spring force (installed) 13.9 ~ 16.1 kg at 33 mm (30.6 ~ 35.5 lb at 1.30 in) 3. Measure: • valve spring tilt a out of specification →...

  • Page 340: Eng

    5 - 31 eng valves and valve springs eas00249 installing the valves the following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) recommended lubricant molybdenum ...

  • Page 341: Eng

    5 - 32 eng valves and valve springs 4. Install: • valve cotters 1 note: @ install the valve cotters by compressing the valve spring with the valve spring compressor set 2 and attachment 3. Valve spring compressor set ym-04019 attachment ym-04108 5. To secure the valve cotters onto the valve stem, li...

  • Page 342: Eng

    5 - 33 eng eas00343 generator and starter clutch generator rotor and starter clutch order job/part q’ty remarks removing the generator rotor and starter clutch remove the parts in the order listed. Fuel tank/seats/t-bar/rubber seat refer to “seats and fuel tank” in chapter 3. Side covers/front cowli...

  • Page 343: Eng

    5 - 34 eng order job/part q’ty remarks 5 starter clutch idle gear shaft 1 6 starter clutch idle gear 1 7 generator rotor 1 refer to “removing/installing the generator”. 8 woodruff key 1 9 starter clutch gear 1 refer to “removing/installing the starter clutch”. 10 starter clutch 1 for installation, r...

  • Page 344: Eng

    5 - 35 eng stator assembly order job/part q’ty remarks removing the stator assembly remove the parts in the order listed. 1 lead holder 1 refer to “installing the genera- tor”. 2 stator assembly 1 for installation, reverse the removal procedure. Generator and starter clutch.

  • Page 345: Eng

    5 - 36 eng eas00346 removing the generator 1. Remove: • generator cover 1 note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor bolt 1 • washer note: @ while holding the generator ...

  • Page 346: Eng

    5 - 37 eng removing the starter clutch 1. Remove: • starter clutch bolts 1 • starter clutch note: @ while holding the generator rotor with the pri- mary sheave holder, remove the starter clutch bolts. Primary sheave holder ys-01880-a eas00351 checking the starter clutch 1. Check: • starter clutch ro...

  • Page 347: Eng

    5 - 38 eng b. When turning the starter clutch drive gear clockwise È, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch drive gear counterclockwise É, it should turn freely, otherwise th...

  • Page 348: Eng

    5 - 39 eng 2. Install: • stator assembly 1 • lead holder 2 t r . . 10 nm (1.0 m · kg, 7.2 ft · lb) lt t r . . 6 nm (0.6 m · kg, 4.3 ft · lb) 3. Install: • woodruff key • generator rotor • washer • generator rotor bolt note: @ • clean the tapered portion of the crankshaft and the generator rotor hub....

  • Page 349: Eng

    5 - 40 eng pickup coil rotor order job/part q’ty remarks removing the pickup coil rotor remove the parts in the order listed. Fuel tank/seats/t-bar/rubber seat refer to “seats and fuel tank” in chapter 3. Air filter case refer to “air filter case” in chapter 3. Side covers/front cowling assembly ref...

  • Page 350: Eng

    5 - 41 eng order job/part q’ty remarks 3 dowel pin 2 4 crankshaft position sensor coupler 1 disconnect. 5 crankshaft position sensor 1 refer to “installing the pickup coil rotor”. 6 pickup coil rotor 1 refer to “removing/installing the pickup coil rotor”. For installation, reverse the removal proced...

  • Page 351: Eng

    5 - 42 eng removing the pickup coil rotor 1. Remove: • pickup coil rotor cover 1 note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • pickup coil rotor bolt 1 • washer • pickup coil rotor 2 note:...

  • Page 352: Eng

    5 - 43 eng 2. Tighten: • pickup coil rotor bolt 1 note: @ while holding the generator rotor 2 with the primary sheave holder 3, tighten the pickup coil rotor bolt. Primary sheave holder ys-01880-a t r . . 45 nm (4.5 m · kg, 32 ft · lb) 3. Apply: • sealant • (onto the crankshaft position sensor lead ...

  • Page 353: Eng

    5 - 44 eng eas00273 clutch clutch cover 1 2 5 4 3 3 (10) (5) lt new t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) order job/part q’ty remarks removing the clutch cover remove the parts in the order listed. Right side cowling refer to “cowlings and covers” in chapter...

  • Page 354: Eng

    5 - 45 eng eas00274 clutch order job/part q’ty remarks removing the clutch remove the parts in the order listed. Clutch release cylinder refer to “hydraulic clutch” in chap- ter 4. Rear balancer refer to “balancers”. 1 oil guide plate 1 refer to “removing/installing the clutch”. 2 clutch spring plat...

  • Page 355: Eng

    5 - 46 eng order job/part q’ty remarks 12 lock washer 1 refer to “removing/installing the clutch”. 13 clutch boss 1 14 wire circlip 1 15 clutch plate 2 1 16 friction plate 3 1 17 clutch damper spring 1 18 clutch damper spring seat 1 19 thrust washer 1 20 spacer 1 21 clutch housing 1 for installation...

  • Page 356: Eng

    5 - 47 eng eas00275 eas00277 removing the clutch 1. Remove: • rear balancer weight refer to “balancers”. 2. Remove: • clutch cover 1 note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3. Straighten the lock...

  • Page 357: Eng

    5 - 48 eng clutch 6. Remove: • spacer 1 note: @ • insert a cross-headed screwdriver into one of the holes of the clutch housing and primary driven gear, and then rotate the inner pri- mary driven gear until both primary driver gears are aligned. The teeth of both primary driven gears must be aligned...

  • Page 358: Eng

    5 - 49 eng eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1) out of specification → replace the clutch ...

  • Page 359: Eng

    5 - 50 eng eas00285 checking the clutch boss 1. Check: • clutch boss splines damage/pitting/wear → replace the clutch boss. Note: @ pitting on the clutch boss splines will cause erratic clutch operation. Eas00286 checking the pressure plate 1. Check: • pressure plate 1 cracks/damage → replace. • bea...

  • Page 360: Eng

    5 - 51 eng eas00294 installing the clutch 1. Install: • clutch housing 1 note: @ • make sure that the slots a into the clutch housing align with the tabs b onto the oil pump drive sprocket. • make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • insert a cross-h...

  • Page 361: Eng

    5 - 52 eng 4. Install: • thrust washer • clutch boss 1 • lock washer • clutch boss nut 2 note: @ while holding the clutch boss with the univer- sal clutch holder 3, tighten the clutch boss nut. 5. Bend the lock washer tab along a flat side of the nut. Universal clutch holder ym-91042 new t r . . 90 ...

  • Page 362: Eng

    5 - 53 eng 9. Install: • friction plates • clutch plates note: @ first, install a friction plate and then alternate between a clutch plate and a friction plate. 10.Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 • clutch spring plate retainer 4 note: @ tighten the cl...

  • Page 363: Eng

    5 - 54 eng eas00326 shift shaft order job/part q’ty remarks removing the shift shaft remove the parts in the order listed. Engine oil drain. Refer to “changing the engine oil” in chapter 3. Clutch housing refer to “clutch”. 1 oil baffle plate 1 2 shift arm 1 3 circlip 1 4 shift shaft 1 refer to “ins...

  • Page 364: Eng

    5 - 55 eng order job/part q’ty remarks 6 stopper lever spring 1 refer to “installing the shift shaft”. 7 stopper lever 1 8 circlip 1 9 collar 1 10 shift shaft spring stopper 1 for installation, reverse the removal procedure. Shift shaft.

  • Page 365: Eng

    5 - 56 eng eas00329 checking the shift shaft 1. Check: • shift shaft 1 • shift shaft pawl 2 bends/damage/wear → replace. • shift shaft spring 3 damage/wear → replace. Eas00330 checking the stopper lever 1. Check: • stopper lever 1 bends/damage → replace. • roller turns roughly → replace the stopper ...

  • Page 366: Eng

    5 - 57 eng 3. Install: • shift arm 1 note: @ align the punch mark a in the shift shaft with the slot in the shift arm. T r . . 10 nm (1.0 m · kg, 7.2 ft · lb) shift shaft.

  • Page 367: Eng

    5 - 58 eng eas00356 oil pan and oil pump order job/part q’ty remarks removing the oil pan and oil pump remove the parts in the order listed. Exhaust pipe assembly refer to “engine”. Air filter case refer to “air filter case” in chapter 3. Engine oil drain. Refer to “changing the engine oil” in chapt...

  • Page 368: Eng

    5 - 59 eng order job/part q’ty remarks 9 oil strainer 1 refer to “installing the oil strainer”. 10 dowel pin 2 11 oil pump 1 refer to “installing the oil pump”. 12 relief valve assembly 1 for installation, reverse the removal procedure. Oil pan and oil pump.

  • Page 369: Eng

    5 - 60 eng eas00360 oil pump order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 oil pump housing cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump shaft 1 8 oil pump housing 1 for assembly, reverse the disassem...

  • Page 370: Eng

    5 - 61 eng eas00362 removing the oil pan 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas00363 checking the oil pump 1. Check: • oil p...

  • Page 371: Eng

    5 - 62 eng 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas00365 checking the relief valve 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • o-ring 4 damage/wear → replace the defective part(s). Eas00367 checking the oil deliv...

  • Page 372: Eng

    5 - 63 eng 2. Check: • oil pump operation refer to “checking the oil pump”. Eas00376 installing the oil pump 1. Install: • oil pump 1 warning align the projection a on the oil pump with the slit b on the impeller shaft. Caution: @ after tightening the bolts, make sure the oil pump turns smoothly. T ...

  • Page 373: Eng

    5 - 64 eng warning @ always use new copper washers. Note: @ • tighten the oil pan bolts in stages and in a crisscross pattern. • lubricate the oil level switch o-ring with engine oil. Oil pan and oil pump.

  • Page 374: Eng

    5 - 65 eng eas00431 middle gear order job/part q’ty remarks removing the middle gear remove the parts in the order listed. Engine refer to “engine”. Oil pan/oil pump refer to “oil pan and oil pump”. 1 left middle gear cover 1 2 left middle gear cover gasket 1 3 dowel pin 2 4 right middle gear cover ...

  • Page 375: Eng

    5 - 66 eng order job/part q’ty remarks 11 middle drive pinion gear nut 1 refer to “removing the middle gear” and “installing the middle drive shaft assembly”. 12 lock washer 1 13 middle drive pinion gear 1 14 middle drive shaft assembly 1 15 spacer 1 16 middle driven gear 1 17 bearing retainer 1 ref...

  • Page 376: Eng

    5 - 67 eng order job/part q’ty remarks disassembling the middle drive shaft assembly remove the parts in the order listed. 1 spring retainer 2 refer to “disassembling/assem- bling the middle drive shaft assembly”. 2 spring seat 1 3 damper spring 1 4 damper driven cam 1 5 damper drive cam 1 6 middle ...

  • Page 377: Eng

    5 - 68 eng order job/part q’ty remarks disassembling the middle driven shaft assembly remove the parts in the order listed. 1 middle driven pinion gear nut 1 2 middle driven shaft 1 3 middle driven pinion gear 1 4 bearing retainer 1 refer to “disassembling/assem- bling the middle driven shaft assemb...

  • Page 378: Eng

    5 - 69 eng eas00432 removing the middle gear 1. Straighten the punched point of the middle driven shaft nut. 2. Loosen: • middle driven shaft nut 1 note: while holding the middle drive shaft 2. 3. Straighten the lock washer tab. 4. Loosen: • middle drive shaft nut 1 note: while holding the middle dr...

  • Page 379: Eng

    5 - 70 eng eas00433 disassembling the middle drive shaft assembly 1. Remove: • spring retainers 1 note: @ while compressing the spring with the spring compressor push plate 2, remove the spring retainers. Spring compressor push plate ym-33286 disassembling the middle driven shaft assembly 1. Straigh...

  • Page 380: Eng

    5 - 71 eng eas00439 checking the middle driven shaft assembly 1. Check: • middle driven gear galling/pitting/wear → replace the middle driven shaft assembly. 2. Check: • bearings damage/pitting → replace the middle drive shaft bearing housing assembly. 3. Check: • o-ring • oil seal damage → replace ...

  • Page 381: Eng

    5 - 72 eng note: @ lock the threads on the bearing retainer by staking them with a center punch. 2. Install: • middle driven shaft nut 1 note: @ temporarily tighten the middle driven shaft nut. Installing the middle drive shaft assembly 1. Install: • middle drive shaft shim • bearing • bearing retai...

  • Page 382: Eng

    5 - 73 eng note: while holding the middle drive shaft 2. 3. Bend the lock washer tab along a flat side of the nut. Installing the middle driven shaft assembly 1. Install: • middle driven shaft assembly 1 • middle driven shaft shims 2 • middle driven shaft bearing housing bolts note: @ finger tighten...

  • Page 383: Eng

    5 - 74 eng 3. Tighten: • middle driven shaft bearing housing bolts note: @ before tightening the bolts: 1. Adjust the middle gear backlash. Refer to “adjusting the middle gear backlash”. 2. Check that the middle driven gear turns smoothly. T r . . 25 nm (2.5 m · kg, 18 ft · lb) eas00449 measuring th...

  • Page 384: Eng

    5 - 75 eng d. While gently turning the middle driven shaft back and forth, measure the middle gear backlash. Note: @ measure the middle gear backlash at four positions. Rotate the middle driven shaft 90° each time and observe the reading on the dial gauge. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 385: Eng

    5 - 76 eng note: @ • tighten the middle driven shaft bearing housing bolts carefully, one thread turn at a time only. Push in the middle driven shaft bearing housing and then tighten the bolts to specification. • clearance between the crankcase and the middle driven shaft bearing housing should be a...

  • Page 386: Eng

    5 - 77 eng 7. Select: • shim(s) 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Shims can only be selected in 0.05 mm (0.002 in) increments, therefore round off to the hundredth’s digit of the calculated thick- ness and select the appropriate shim with the following chart. B. For example, the...

  • Page 387: Eng

    5 - 78 eng eas00452 aligning the middle gear note: @ aligning the middle gear is necessary when any of the following parts are replaced: • crankcase • middle drive shaft • middle driven shaft bearing housing 1. Select: • middle drive shaft shim(s) 1 • middle driven shaft shim(s) 2 note: @ select the...

  • Page 388: Eng

    5 - 79 eng note: @ in the above example, the calculated number is 0.51. The chart instructs you to round off the 1 to 0. Thus, the shim thickness is 0.50 mm (0.002 in). Shims are supplied in the following thick- nesses. Hundredth rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 middle drive shaft shi...

  • Page 389: Eng

    5 - 80 eng shims are supplied in the following thick- nesses. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ hundredth rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 middle drive shaft shim thickness (mm) 0.10 0.15 0.30 0.40 0.50 0.60 middle gear.

  • Page 390: Eng

    5 - 81 eng crankcase up 9 3 2 1 4 5 6 10 7 8 10 10 lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks separating the crankcase remove the parts in the order listed. Engine refer to “engine”. Cylinder head refer to “cylinder head”. Generator...

  • Page 391: Eng

    5 - 82 eng up 9 3 2 1 4 5 6 10 7 8 10 10 lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 5 collar 1 6 spacer 1 7 neutral switch 1 8 speed sensor 1 9 lower crankcase 1 refer to “disassembling/assem- bling the crankcase”. 10 dowel pin 3 fo...

  • Page 392: Eng

    5 - 83 eng 10 ls 2 lt lt lt 4 8 3 lt 5 7 6 1 9 11 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 70 nm (7.0 m • kg, 50 ft • lb) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) order job/part q’ty remarks removing the oil baffle plates and bearings remove the parts in the order listed. Connecting rod assemb...

  • Page 393: Eng

    5 - 84 eng 10 ls 2 lt lt lt 4 8 3 lt 5 7 6 1 9 11 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 70 nm (7.0 m • kg, 50 ft • lb) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) order job/part q’ty remarks 6 oil seal 1 7 bearing 1 8 upper crankcase 1 9 bearing 1 10 oil filter bolt 1 11 lower crankcase 1 for ...

  • Page 394: Eng

    5 - 85 eng eas00384 disassembling the crankcase 1. Remove: • crankcase bolts note: @ • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerical order (refer to the numbers in th...

  • Page 395: Eng

    5 - 86 eng eas00399 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air. Eas00401...

  • Page 396: Eng

    5 - 87 eng eas00208 checking the timing chain and oil pump drive chain the following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: • timing chain 1 damage/stiffness → replace the timing chain and camshaft sprockets as a set. • oil pump drive chain 2 damage/sti...

  • Page 397: Eng

    5 - 88 eng 2. Apply: • sealant (onto the crankcase mating surfaces) note: @ do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 ~ 3 mm (0.08 ~ 0.12 in) of the crankshaft journal bear- ings. 3. Install: • dowel pins qui...

  • Page 398: Eng

    5 - 89 eng 6. Install: • crankcase bolts note: @ • lubricate the bolt threads and washers with engine oil. • finger tighten the crankcase bolts. M9 × 115 mm bolts: 1 ~ 0 m8 × 65 mm bolts: a m8 × 50 mm bolts: b m6 × 80 mm bolts: m, o m6 × 65 mm bolts: c, d m6 × 65 mm bolts: i, l, n, p m6 × 55 mm bolt...

  • Page 399: Eng

    5 - 90 eng c. Tighten the crankcase bolts further to reach the specified angle 120° in the proper tight- ening sequence as shown. Warning when the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and per- form the proced...

  • Page 400: Eng

    5 - 91 eng eas00252 connecting rods and pistons 1 2 7 6 5 4 3 8 9 10 3 e e e e new new m m m new new new order job/part q’ty remarks removing the connecting rods and pistons remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 connecting rod cap 4 refer to “removing the ...

  • Page 401: Eng

    5 - 92 eng eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap 1 • big end bearings note: @ identify the position of each big end bearing so that it can be reinstalled in its original place. 2. R...

  • Page 402: Eng

    5 - 93 eng 3. Remove: • top ring • 2nd ring • oil ring note: @ when removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Eas00258 checking the cylinders and pistons the following procedure applies to all of the cylinders and pistons. 1...

  • Page 403: Eng

    5 - 94 eng c. Measure piston skirt diameter “p” with the micrometer. A 5 mm (0.20 in) from the bottom edge of the pis- ton d. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clearance with the following formula. F. If out of specification, r...

  • Page 404: Eng

    5 - 95 eng 2. Install: • piston ring (into the cylinder) note: @ level the piston ring in the cylinder with the piston crown. A 5 mm (0.20 in) 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: @ the oil ring expander spacer’s end gap cannot be measured. If the o...

  • Page 405: Eng

    5 - 96 eng 2. Measure: • piston pin outside diameter a out of specification → replace the piston pin. Piston pin outside diameter 18.991 ~ 19.000 mm (0.7477 ~ 0.7480 in) : 19.045 mm (0.7498 in) 3. Measure: • piston pin bore diameter (in the piston) b out of specification → replace the piston. Piston...

  • Page 406: Eng

    5 - 97 eng eas00396 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following procedure applies to all of the connecting rods. Caution: @ do not interch...

  • Page 407: Eng

    5 - 98 eng e. Tighten the connecting rod nuts. Refer to “installing the connecting rods and pistons”. F. Remove the connecting rod and big end bearings. Refer to “removing the connecting rods and pistons”. G. Measure the compressed plastigauge ® width e on the crankshaft pin. If the crankshaft-pin-t...

  • Page 408: Eng

    5 - 99 eng eas00271 eas00404 installing the connecting rods and pistons the following procedure applies to all of the pistons and connecting rods. 1. Install: • top ring • 2nd ring • oil ring note: @ be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install:...

  • Page 409: Eng

    5 - 100 eng 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) recommended lubricant engine oil 5. Lubricate: • bolt threads • nut seats (with the recommended lubricant) recommended lubricant molybdenum disulfide grease 6. Lubricate: • crankshaft pins • big end bearing...

  • Page 410: Eng

    5 - 101 eng • make sure the “y” marks a on the connect- ing rods face towards the left side of the crankshaft. • make sure the characters b on both the con- necting rod and connecting rod cap are aligned. 8. Align: • bolt heads (with the connecting rod) piston ring compressor ym-08037 6d 9. Tighten:...

  • Page 411: Eng

    5 - 102 eng warning when the nuts are tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the nut with a new one and per- form the procedure again. Caution: • do not use a torque wrench to tighten the nut to the specified angle. • tighten the nut until it is...

  • Page 412: Eng

    5 - 103 eng eas00381 crankshaft 2 1 3 3 e e order job/part q’ty remarks removing the crankshaft remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. Connecting rod caps refer to “connecting rods and pistons”. 1 crankshaft 1 refer to “removing/installing the crankshaft”. 2 ...

  • Page 413: Eng

    5 - 104 eng eas00387 removing the crankshaft 1. Remove: • crankshaft 1 • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) note: @ identify the position of each crankshaft journal bearing so that it can be reinstalled in its o...

  • Page 414: Eng

    5 - 105 eng caution: @ do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 415: Eng

    5 - 106 eng h. Measure the compressed plastigauge ® width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2 2 2 2 2 1 2 2 1 4...

  • Page 416: Eng

    5 - 107 eng eas00407 installing the crankshaft 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) note: @ • align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcas...

  • Page 417: Eng

    5 - 108 eng eas00419 transmission order job/part q’ty remarks removing the transmission, shift drum assembly, and shift forks remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 drive axle assembly 1 refer to “installing the transmis- sion”. 2 bearing 1 3 washer 1 4 shi...

  • Page 418: Eng

    5 - 109 eng order job/part q’ty remarks 10 shift drum assembly 1 refer to “installing the transmis- sion”. 11 shift fork “c” 1 12 main axle assembly 1 refer to “removing/installing the transmission”. For installation, reverse the removal procedure. Transmission.

  • Page 419: Eng

    5 - 110 eng new m m m m new order job/part q’ty remarks disassembling the main axle assem- bly remove the parts in the order listed. 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 5th pinion gear 1 5 toothed spacer 1 6 toothed washer 2 7 circlip 2 8 3rd pinion gear 1 ...

  • Page 420: Eng

    5 - 111 eng new m m m m new order job/part q’ty remarks a main axle/1st pinion gear 1 b bearing 1 c main axle bearing housing 1 for assembly, reverse the disassembly procedure. Transmission.

  • Page 421: Eng

    5 - 112 eng m m m m m m order job/part q’ty remarks disassembling the drive axle assembly remove the parts in the order listed. 1 middle drive gear 1 2 bearing 1 3 washer 1 4 2nd wheel gear 1 5 collar 1 6 washer 1 7 5th wheel gear 1 8 circlip 2 9 toothed washer 2 0 3rd wheel gear 1 transmission.

  • Page 422: Eng

    5 - 113 eng m m m m m m order job/part q’ty remarks a toothed spacer 1 b toothed lock washer 1 c toothed lock washer retainer 1 d 4th wheel gear 1 e washer 1 f 1st wheel gear 1 g bearing 1 h washer 1 i drive axle 1 for assembly, reverse the disassembly procedure. Transmission.

  • Page 423: Eng

    5 - 114 eng eas00420 removing the transmission 1. Remove: • bearing housing bolts 1 (with the torx wrench t30) 2. Remove: • main axle assembly (from the clutch side) note: @ remove the main axle assembly with the slide hammer bolt 1 and weight. Slide hammer bolt yu-01083-1 weight j-6125-7 eas00421 c...

  • Page 424: Eng

    5 - 115 eng 2. Check: • shift fork guide bar roll the shift fork guide bar on a flat surface. Bends → replace. Warning @ do not attempt to straighten a bent shift fork guide bar. 3. Check: • shift fork movement (along the shift fork guide bar) rough movement → replace the shift forks and shift fork ...

  • Page 425: Eng

    5 - 116 eng 2. Measure: • drive axle runout (with a centering device and dial gauge 1) out of specification → replace the drive axle. Drive axle runout limit 0.08 mm (0.003 in) 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cr...

  • Page 426: Eng

    5 - 117 eng installing the transmission 1. Install: • main axle assembly • shift fork “c” • shift drum assembly • shift fork “r” • shift fork “l” • shift fork guide bars • shift drum retainer • drive axle assembly note: @ • when installing the main axle assembly, use a pin to align the bearing housi...

  • Page 427: Eng

    5 - 118 eng balancers front balancer order job/part q’ty remarks removing the front balancer remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 balancer lever 1 refer to “installing the front balancer”. 2 balancer shaft 1 3 washer 2 4 bearing 2 5 balancer gear 1 6 abso...

  • Page 428: Eng

    5 - 119 eng rear balancer order job/part q’ty remarks removing the rear balancer remove the parts in the order listed. Throttle bodies refer to “fuel injection system” in chapter 7. Clutch cover refer to “clutch”. 1 balancer cover 1 2 balancer cover gasket 1 3 balancer lever 1 refer to “installing t...

  • Page 429: Eng

    5 - 120 eng checking the balancer 1. Check: • front balancer gear damage/wear → replace the front bal- ancer gear and crankshaft. • rear balancer gear damage/wear → replace the rear balancer gear and primary driven gear. 2. Check: • balancer shaft 1 cracks/damage/wear → replace the bal- ancer shaft ...

  • Page 430: Eng

    5 - 121 eng 3. Install: • balancer shaft 1 note: @ • align the punch mark a in the balancer weight with the oil hole b in the upper crank- case. • make sure that the front balancer gear teeth and the primary drive gear teeth mesh cor- rectly. • make sure that the slot c is facing in the direction in...

  • Page 431: Eng

    5 - 122 eng 7. Start the engine and check that there is no abnormal noise coming from the balancer gear. If noise is abnormal, adjust the gear lash by turning the balancer shaft. Note: with each adjustment, turn the balancer shaft one scale. Clockwise decrease gear lash counterclockwise increase gea...

  • Page 432: Eng

    5 - 123 eng 3. Install: • balancer shaft 1 note: @ • align the punch marks a in the balancer weight with the oil hole b in the upper crank- case. • make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • make sure that the balancer gear punch mark c is align...

  • Page 433: Eng

    5 - 124 eng 5. Tighten: • balancer shaft 1 note: tighten the balancer shaft to the specified torque by turning it counterclockwise, and then turn it two scales back on the balancer lever scale. T r . . 0.4 nm (0.04 m · kg, 0.29 ft · lb) 6. Tighten: • balancer lever bolt 1 • balancer shaft pinch bolt...

  • Page 434: Cool

    6 - 1 cool radiator eas00454 cooling system radiator order job/part q’ty remarks removing the radiator remove the parts in the order listed. Rider seat/fuel tank refer to “seats and fuel tank” in chapter 3. Side cowlings/front cowling assembly refer to “cowlings and covers” in chapter 3. Coolant dra...

  • Page 435: Cool

    6 - 2 cool radiator order job/part q’ty remarks 8 radiator outlet hose 1 9 thermostat assembly breather hose 1 disconnect. 10 conduit 1 11 conduit hose 1 12 radiator inlet hose 1 disconnect. 13 plunger control unit hose 2 1 disconnect. 14 oil cooler outlet hose 1 disconnect. 15 horn connector 4 disc...

  • Page 436: Cool

    6 - 3 cool radiator eas00455 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Note: @ straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses cracks/damage → repl...

  • Page 437: Cool

    6 - 4 cool radiator eas00456 installing the radiator 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: • cooling system leaks → repair or replace any faulty part. 3. Measure: • radiator cap opening pressure belo...

  • Page 438: Cool

    6 - 5 cool oil cooler eas00457 oil cooler order job/part q’ty remarks removing the oil cooler remove the parts in the order listed. Engine oil drain. Refer to “changing the engine oil” in chapter 3. Radiator assembly refer to “radiator”. 1 water pump outlet hose 1 2 water pump outlet pipe 1 3 water ...

  • Page 439: Cool

    6 - 6 cool oil cooler eas00458 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear → replace. Eas00459 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a c...

  • Page 440: Cool

    6 - 7 cool oil cooler 4. Check: • cooling system leaks → repair or replace any faulty part. 5. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator”..

  • Page 441: Cool

    6 - 8 cool thermostat eas00460 thermostat order job/part q’ty remarks removing the thermostat assembly remove the parts in the order listed. Side cowlings/front cowling assembly refer to “cowlings and covers” in chapter 3. Coolant drain. Refer to “changing the coolant” in chapter 3. Air cut-off valv...

  • Page 442: Cool

    6 - 9 cool thermostat eas00461 order job/part q’ty remarks disassembling the thermostat assembly remove the parts in the order listed. 1 thermostat housing cover 1 refer to “assembling the thermo- stat assembly”. 2 thermostat 1 3 thermostat housing 1 for assembly, reverse the disassembly procedure..

  • Page 443: Cool

    6 - 10 cool thermostat eas00463 checking the thermostat 1. Check: • thermostat 1 does not open at 71 ~ 85 °c (159.8 ~ 185.0 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. W...

  • Page 444: Cool

    6 - 11 cool thermostat eas00464 assembling the thermostat assembly 1. Install: • thermostat housing 1 • thermostat 2 • thermostat housing cover note: @ install the thermostat with its breather hole a a facing up. Eas00466 installing the thermostat assembly 1. Lubricate: • o-ring (thermostat assembly...

  • Page 445: Cool

    6 - 12 cool water pump eas00468 water pump order job/part q’ty remarks removing the water pump remove the parts in the order listed. Note: it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Right side cowling refer to “cowlings ...

  • Page 446: Cool

    6 - 13 cool water pump order job/part q’ty remarks 1 water pump breather hose 1 disconnect. 2 radiator outlet hose 1 disconnect. 3 water pump outlet hose 1 disconnect. 4 water pump 1 refer to “installing the water pump”. For installation, reverse the removal procedure..

  • Page 447: Cool

    6 - 14 cool water pump eas00469 order job/part q’ty remarks disassembling the water pump remove the parts in the order listed. 1 water pump housing cover 1 refer to “assembling the water pump”. 2 o-ring 1 3 circlip 1 4 impeller shaft 1 5 rubber damper holder 1 6 rubber damper 1 7 water pump seal 1 8...

  • Page 448: Cool

    6 - 15 cool water pump eas00470 disassembling the water pump 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flat-head screwdriver) note: @ do not scratch the impeller shaft. 2. Remove: • water pump seal 1 note: @ tap out the water pump seal from the inside of ...

  • Page 449: Cool

    6 - 16 cool water pump eas00475 assembling the water pump 1. Install: • oil seal 1 (into the water pump housing 2) note: @ • before installing the oil seal, apply tap water or coolant onto its out surface. • install the oil seal with a socket that matches its outside diameter. 2. Install: • water pu...

  • Page 450: Cool

    6 - 17 cool water pump 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: @ make sure the rubber damper and rubber damper holder are flush with the impeller. 1 straightedge 2 impeller max. Impeller shaft tilt 0.15 mm (0.006 in) 5. Install: • impeller 1 • circ...

  • Page 451: Cool

    6 - 18 cool water pump eas00478 installing the water pump 1. Install: • o-ring • water pump assembly 1 warning @ • align the slit a on the impeller shaft with the projection b on the oil pump shaft. • lubricate the o-ring with a thin coat of lithium soap base grease. New t r . . 12 nm (1.2 m · kg, 8...

  • Page 452: Fuel Injection System

    7 - 1 fi fuel injection system fuel injection system fuel injection system 1 ignition coil 2 air filter case 3 intake temperature sensor 4 fuel delivery hose 5 fuel tank 6 fuel pump 7 fuel return hose 8 intake air pressure sensor 9 throttle position sensor 0 fuel injector a o 2 sensor b catalytic co...

  • Page 453

    7 - 2 fi fuel injection system wiring diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y b /y l /y (black) (black) r b...

  • Page 454

    7 - 3 fi fuel injection system ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute cha...

  • Page 455

    7 - 4 fi fuel injection system engine trouble warning light indication and fi system operating conditions (normal mode) warning light indication ecu’s operating condition fi operating condition starting and driving on and off *1 self-diagnostic func- tion in operation fi function in operation able b...

  • Page 456

    7 - 5 fi fuel injection system *3 function to check for blown warning light bulb the engine trouble warning light illuminates 1 for 1.4 seconds after the main switch has been turned “on” and while the starter switch is being pressed. If the warning light does not illuminate under these conditions, a...

  • Page 457

    7 - 6 fi fuel injection system * table of self-diagnostic fault code numbers displayed on meter • how to erase the self-diagnostic fault code from memory: if the ecu detects a normal signal upon the completion of the repair of the malfunction, the self- diagnostic fault code disappears from the mete...

  • Page 458

    7 - 7 fi fuel injection system substitute characteristics operation control (fail-safe action) if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven, the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operati...

  • Page 459

    7 - 8 fi fuel injection system troubleshooting diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected) by entering a diagnostic code in the ecu through the use of the “select” and “reset” buttons on the multi-function meter, the sensor output values can be displayed and the actuators...

  • Page 460

    7 - 9 fi fuel injection system verifying the operation of various sensors and actuators 1. Disconnect the wiring harness coupler from the fuel pump. 2. Turn the engine stop switch “off”. · turn the engine stop switch “on” if diag- nostic code numbers 03 and 09 are shown. 3. Select the diagnostic cod...

  • Page 461

    7 - 10 fi fuel injection system erase the codes appearing on the meter upon the completion of the operation (reinstating the ecu). * verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera- tion that is applicable to the malfunctionin...

  • Page 462

    7 - 11 fi fuel injection system self-diagnostic fault codes, symptoms, and probable causes diagnostic code indication code no. Symptom probable cause of malfunction diagnostic code 11 no normal signals are received from the cylinder identification sensor. • open or short circuit in wiring sub lead. ...

  • Page 463

    7 - 12 fi fuel injection system code no. Symptom probable cause of malfunction diagnostic code 23 atmospheric pressure sensor - open or short circuit detected. • open or short circuit in wiring harness. • defective atmospheric pressure sensor. • improperly installed sensor. • malfunction in ecu. 02 ...

  • Page 464

    7 - 13 fi fuel injection system sensor operation data display verification table note: • check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted. • if it is not possible to check it with an atmospheric pressure gauge, judge it b...

  • Page 465

    7 - 14 fi fuel injection system actuator operation verification table diag code item description of action data displayed on meter (reference value) 30 ignition coil #1, 4 after 1 second has elapsed from the time the engine stop switch has been turned from off to on, it actuates ignition coils #1, a...

  • Page 466

    7 - 15 fi fuel injection system troubleshooting basic procedure 1 inspect battery and fuse ok ng replace fuse recharge or replace battery check engine trouble warning light after main switch is turned on, light turns on 1.4 seconds and then turns off. Ng ok light does not turn off. Check the startin...

  • Page 467

    7 - 16 fi fuel injection system troubleshooting details troubleshooting the self-diagnostic fault code code no. 11 symptom no normal signals are received from the cylinder identification sensor. Used diagnostic code no. Inspection operation item operation item and countermeasure reinstatement method...

  • Page 468

    7 - 17 fi fuel injection system code no. 13 symptom intake air pressure sensor - open or short circuit detected. Used diagnostic code no. 03 (intake air pressure sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method defective intake air pressure ...

  • Page 469

    7 - 18 fi fuel injection system code no. 14 symptom 1 intake air pressure sensor - pipe system malfunction (clogged or detached hose). 2 intake air pressure sensor - open or short circuit detected. 3 stuck throttle position sensor detected. Used diagnostic code no. 03 (intake air pressure sensor) no...

  • Page 470

    7 - 19 fi fuel injection system code no. 15 symptom throttle position sensor - open or short circuit detected. Used diagnostic code no. 01 (throttle position sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method defective throttle position sensor...

  • Page 471

    7 - 20 fi fuel injection system code no. 16 symptom 1 stuck throttle position sensor detected. 2 intake air pressure sensor - pipe system malfunction (clogged or detached hose). Used diagnostic code no. 03 (intake air pressure sensor) no. 02 (atmospheric pressure sensor) no. 01 (throttle position se...

  • Page 472

    7 - 21 fi fuel injection system code no. 19 symptom open circuit is detected in the input line from the sidestand switch to the ecu. Used diagnostic code no. 20 (sidestand switch) inspection operation item and probable cause operation item and countermeasure reinstatement method defective sidestand ...

  • Page 473

    7 - 22 fi fuel injection system code no. 23 symptom open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code no. 02 (atmospheric pressure sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method defective atmospheric...

  • Page 474

    7 - 23 fi fuel injection system code no. 30 symptom the motorcycle has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) inspection operation item and probable cause operation item and countermeasure reinstatement method defective lean angle cut-off switch replace if defective. Rei...

  • Page 475

    7 - 24 fi fuel injection system code no. 32 symptom the amount of air-fuel ratio feedback compensation is maintained contin- uously in the vicinity of the lower limit (air-fuel ratio is rich). Used diagnostic code no. 01 (throttle position sensor) inspection operation item and probable cause operati...

  • Page 476

    7 - 25 fi fuel injection system code no. 33 symptom malfunction detected in the primary wire of the ignition coil (#1, 4). Used diagnostic code no. 30 (ignition coil #1, 4) inspection operation item and probable cause operation item and countermeasure reinstatement method defective ignition coil (te...

  • Page 477

    7 - 26 fi fuel injection system code no. 42 symptom 1 no normal signals are received from the speed sensor. 2 open or short circuit is detected in the neutral switch. Used diagnostic code no. 07 (speed sensor) no. 21 (neutral switch) inspection operation item and probable cause operation item and co...

  • Page 478

    7 - 27 fi fuel injection system code no. 50 symptom faulty ecu memory. (when this malfunction is detected in the ecu, the fault code number might not appear on the meter.) used diagnostic code no. Inspection operation item and probable cause operation item and countermeasure reinstatement method mal...

  • Page 479

    7 - 28 fi fuel injection system diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected) even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self-diagnostic function, they can be inspected in the diagnosis mode. Basic pro...

  • Page 480

    7 - 29 fi fuel injection system symptom the headlight does not turn on or off. Probable mal- function area • malfunction in the headlight relay 1 • malfunction in the headlight • open or short circuit in the headlight wiring harness • malfunction in the handlebar switch • open circuit in the headlig...

  • Page 481

    7 - 30 fi fuel injection system symptom fan does not operate. Probable mal- function area • malfunction in radiator fan motor relay • malfunction in fan • open or short circuit in fan wiring harness inspection method 1 inspection by diagnosis mode inspection method 2 inspection of a malfunction that...

  • Page 482

    7 - 31 fi fuel injection system symptom clock lcd displays “er-2”. (no signals are received from the ecu within the specified duration.) probable mal- function area • improper operation of communication line • malfunction in meter • malfunction in ecu inspection method 1 inspection by diagnosis mode...

  • Page 483

    7 - 32 fi fuel injection system symptom sidestand switch does not function (the engine does not stop when the stand is extended). Probable mal- function area • short circuit in the input line to ecu • malfunction in the starter circuit cut-off relay inspection method 1 inspection by diagnosis mode i...

  • Page 484

    7 - 33 fi fuel injection system throttle bodies 9 10 2 4 1 5 5 5 5 11 11 3 8 8 7 11 11 6 order job/part q’ty remarks removing the throttle bodies remove the parts in the order listed. Seats/fuel tank/t-bar/rubber sheet refer to “seats and fuel tank” in chapter 3. Air filter case refer to “air filter...

  • Page 485

    7 - 34 fi fuel injection system 9 10 2 4 1 5 5 5 5 11 11 3 8 8 7 11 11 6 order job/part q’ty remarks 8 throttle cable 2 disconnect. 9 plunger control unit hose 1 1 disconnect. 10 plunger control unit hose 2 1 disconnect. 11 throttle body joint 4 for installation, reverse the removal procedure..

  • Page 486

    7 - 35 fi fuel injection system 10 12 4 5 6 7 2 8 3 9 11 13 14 15 1 order job/part q’ty remarks removing the injector remove the parts in the order listed. 1 canister purge hose 1 disconnect. 2 throttle position sensor coupler 1 disconnect. 3 intake air pressure sensor 1 disconnect. 4 cylinder #1-in...

  • Page 487

    7 - 36 fi fuel injection system 10 12 4 5 6 7 2 8 3 9 11 13 14 15 1 order job/part q’ty remarks 12 intake air pressure sensor 1 13 fuel distributor 1 14 injector 4 15 throttle position sensor 1 for installation, reverse the removal procedure..

  • Page 488

    7 - 37 fi caution: the throttle bodies should not be disas- sembled unnecessarily. Checking the injector 1. Check: • injector damage → replace. Checking the throttle body 1. Check: • throttle body cracks/damage → replace the throttle bodies. 2. Check: • fuel passages obstruction → clean. ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 489

    7 - 38 fi checking the fuel pump and pressure regulator operation 1. Check: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank. Refer to “seats and fuel tank” in chap- ter 3. B. Disconnect the negative pressure hose 1 from the pressure regulator ...

  • Page 490

    7 - 39 fi h. Use the mity vac set to adjust the fuel pres- sure in relation to the vacuum pressure as described below. Note: the vacuum pressure should not exceed 100 kpa (1 mm hg, 0.039 in hg). Faulty → replace the pressure regulator. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ increase the v...

  • Page 491

    7 - 40 fi air induction system eas00507 air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve ...

  • Page 492

    7 - 41 fi air induction system eas00509 air induction system diagrams 1 air cut-off valve 2 reed valve 3 air-filter case È to cylinder #4 É to cylinder #3 Ê to cylinder #2 Ë to cylinder #1 12 4 3.

  • Page 493

    7 - 42 fi air induction system air cut-off valve assembly and air induction system hoses 1 5 3 6 2 3 4 2 2 7 10 8 9 order job/part q’ty remarks removing the air cut-off valve assembly and hoses remove the parts in the order listed. Rider seat/fuel tank/t-bar/rubber sheet refer to “seats and fuel tan...

  • Page 494

    7 - 43 fi air induction system reed valves order job/part q’ty remarks removing the reed valves remove the parts in the order listed. Air cut-off valve assembly/hoses thermostat assembly refer to “thermostat” in chapter 6. Spark plug caps 1 reed valve cover (1) 1 2 reed valve cover (2, 3) 1 3 reed v...

  • Page 495

    7 - 44 fi air induction system eas00510 checking the air induction system 1. Check: • hoses loose connection → connect properly. Cracks/damage → replace. • pipes cracks/damage → replace. 2. Check: • fibre reed • fibre reed stopper • reed valve seat cracks/damage → replace the reed valve assembly. 3....

  • Page 496

    7 - 45 fi canister (for california only) canister (for california only) order job/part q’ty remarks removing the canister remove the parts in the order listed. Seats/fuel tank/t-bar/rubber sheet refer to “seats and fuel tank” in chapter 3. Air filter case refer to “air filter case” in chapter 3. 1 c...

  • Page 497: Elec

    8 - 1 – + elec electrical components eas00729 electrical electrical components 1 windshield drive unit 2 battery 3 starter relay 4 fuel injection system fuse 5 front brake switch 6 clutch switch 7 fuse box 8 radiator fan motor 9 wire harness 0 neutral switch a sidestand switch b oil level switch c r...

  • Page 498: Elec

    8 - 2 – + elec electrical components 1 coolant temperature sensor 2 intake air pressure sensor 3 intake air temperature sensor 4 atmospheric pressure sensor 5 lean angle cut-off switch 6 ecu 7 starting circuit cut-off relay 8 speed sensor 9 cylinder identification sensor 0 o 2 sensor a crankshaft po...

  • Page 499: Elec

    8 - 3 – + elec checking switch continuity eas00730 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: @ never insert the tester probes into the cou...

  • Page 500: Elec

    8 - 4 – + elec checking the switches eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 501: Elec

    8 - 5 – + elec 1 main fuse 2 main switch 3 clutch switch 4 dimmer switch 5 horn switch 6 windshield position switch 7 turn signal switch 8 front brake light switch 9 engine stop switch 0 start switch a rear brake light switch b neutral switch c sidestand switch d hazard switch e fuse checking the sw...

  • Page 502: Elec

    8 - 6 – + elec eas00732 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. No continuity →...

  • Page 503: Elec

    8 - 7 – + elec checking the bulbs and bulb sockets warning @ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Caution: @ • be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may b...

  • Page 504: Elec

    8 - 8 – + elec checking the bulbs and bulb sockets 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. Note: @ check each bulb socket for continuity in the sa...

  • Page 505: Elec

    8 - 9 – + elec ignition system eas00735 ignition system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y b /...

  • Page 506: Elec

    8 - 10 – + elec ignition system eas00737 troubleshooting procedure check: 1. Main and ignition fuses 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Crankshaft position sensor resistance 8. Main switch 9. Engine stop switch 10.Neutral switc...

  • Page 507: Elec

    8 - 11 – + elec ignition system eas00743 no yes eas00745 yes no eas00747 4. Ignition spark gap the following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. • disconnect the spark plug cap from the spark plug. • connect the ignition checker 1 as shown....

  • Page 508: Elec

    8 - 12 – + elec ignition system yes no eas00748 yes no eas00749 yes no eas00750 yes no eas00751 yes no tester negative probe → spark plug lead 1 tester positive probe → spark plug lead 2 • measure the secondary coil resistance. Secondary coil resistance 12 ~ 18 k Ω at 20 °c (68 °f) • is the ignition...

  • Page 509: Elec

    8 - 13 – + elec ignition system eas00752 yes no eas00753 yes no eas00754 yes no 11.Sidestand switch • check the sidestand switch for continuity. Refer to “checking the switches”. • is the sidestand switch ok? Replace the side- stand switch. 12.Starting circuit cut-off relay • disconnect the starting...

  • Page 510: Elec

    8 - 14 – + elec electric starting system eas00755 electric starting system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (b...

  • Page 511: Elec

    8 - 15 – + elec electric starting system eas00756 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission...

  • Page 512: Elec

    8 - 16 – + elec electric starting system eas00757 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter circuit cut-off relay (diode) 6. Starter relay 7. Main switch 8. Engine stop switch 9. Neutral switch 10.Sidestand switch 11.Cl...

  • Page 513: Elec

    8 - 17 – + elec electric starting system eas00759 yes no eas00760 4. Starting circuit cut-off relay • disconnect the starting circuit cut-off relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay terminals as shown. Battery posit...

  • Page 514: Elec

    8 - 18 – + elec electric starting system yes no eas00761 yes no eas00749 yes no eas00750 yes no eas00751 yes no eas00752 yes no note: @ when you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. @ • are the testing readings correct? Replace the start...

  • Page 515: Elec

    8 - 19 – + elec electric starting system eas00763 yes no eas00764 yes no eas00766 yes no 11.Clutch switch • check the clutch switch for continuity. Refer to “checking the switches”. • is the clutch switch ok? Replace the clutch switch. 12.Start switch • check the start switch for continuity. Refer t...

  • Page 516: Elec

    8 - 20 – + elec starter motor eas00767 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Throttle bodies refer to “fuel injection system” in chapter 7. 1 starter motor lead 1 disconnect. 2 starter motor 1 for installation, reverse the removal ...

  • Page 517: Elec

    8 - 21 – + elec new new new 1 2 6 5 4 3 3 7 8 c a b a 0 9 t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty remarks disassembly the starter motor remove the parts in the order listed. 1 o-ring 1 2 starter motor front cover 1 3 brush 2 4 brush seat 1 5 washer 1 6 lock washer 1 7 oil seal 1 8...

  • Page 518: Elec

    8 - 22 – + elec new new new 1 2 6 5 4 3 3 7 8 c a b a 0 9 t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty remarks a o-ring 1 b starter motor yoke 1 c armature assembly 1 for assembly, reverse the disassembly procedure. Starter motor.

  • Page 519: Elec

    8 - 23 – + elec starter motor eas00770 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. Commutator wear limit 23.5 mm (0.93 in) 3. Measure: • mica undercut a out of specificat...

  • Page 520: Elec

    8 - 24 – + elec starter motor 4. Measure: • armature assembly resistances (commuta- tor and insulation) out of specification → replace the starter motor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the armature assembly resis- tances with the pocket tester. B. If any resistance is o...

  • Page 521: Elec

    8 - 25 – + elec starter motor eas00772 assembling the starter motor 1. Install: • brush seat 1 note: @ align the slot a on the brush seat with the tab b in the starter motor front cover. 2. Install: • starter motor yoke 1 • starter motor front cover 2 • starter motor rear cover 3 note: @ align the m...

  • Page 522: Elec

    8 - 26 – + elec charging system eas00773 charging system circuit diagram on off 1 5 r r r br/l w/l l/y y br dg ch br/w br/w ch dg br/w br/g b/r r/b b/r r/b br y b b b b (red) (red) br r/w r/b l/w y b r/w b/w b/r b r/w l/w (black) (black) l/y b/y b/y l/y (black) (black) r br r r r br/l (black) (gray)...

  • Page 523: Elec

    8 - 27 – + elec charging system eas00774 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator assembly resistance 5. Wiring connections (of the entire charging system) note: @ • before troubleshooting, remove the following part(s): 1) front cowling assembly 2) fuel tank 3) ai...

  • Page 524: Elec

    8 - 28 – + elec charging system no yes eas00776 yes no eas00779 yes no note: @ make sure the battery is fully charged. @ • is the charging voltage within specification? The charging circuit is ok. 4. Stator assembly resistance • remove the generator cover. • connect the pocket tester ( Ω × 1) to the...

  • Page 525: Elec

    8 - 29 – + elec lighting system eas00780 lighting system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y b ...

  • Page 526: Elec

    8 - 30 – + elec lighting system eas00781 troubleshooting check: 1. Main, tail/position light and headlight fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Headlight relay 1 6. Headlight relay 2 7. Wiring connections (of the entire lighting system) note: @ • before troubleshooting, remove the fol...

  • Page 527: Elec

    8 - 31 – + elec lighting system eas00784 yes no yes no 4. Dimmer switch • check the dimmer switch for continuity. Refer to “checking the switches”. • is the dimmer switch ok? The dimmer switch is faulty. Replace the left handlebar switch. 5. Headlight relay 1 • disconnect the headlight relay 1 from ...

  • Page 528: Elec

    8 - 32 – + elec lighting system yes no eas00787 yes no eas00788 checking the lighting system 1. The headlight and the high beam indicator light fail to come on. Yes no battery positive terminal → green/black 3 battery negative terminal → black 4 tester positive probe → green/blue 5 tester negative p...

  • Page 529: Elec

    8 - 33 – + elec lighting system yes no eas00789 2. The meter light fails to come on. Yes no yes no high beam indicator light tester positive probe → yellow 4 tester negative probe → black/white 5 meter assembly coupler • set the main switch to “on”. • set the dimmer switch to “ ” or “ ”. • measure t...

  • Page 530: Elec

    8 - 34 – + elec eas00790 3. The tail/brake light fails to come on. Yes no yes no 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. • are the tail/brake light bulb and socket ok? Replace the tail/ brake light bulb, socket or both. 2. Voltage • connect th...

  • Page 531: Elec

    8 - 35 – + elec lighting system.

  • Page 532: Elec

    8 - 36 – + elec signaling system eas00793 signaling system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y ...

  • Page 533: Elec

    8 - 37 – + elec signaling system 1 main switch 4 backup fuse (odometer, clock and windshield) 5 main fuse 6 battery a starting circuit cut-off relay b neutral switch d fuel pump y oil level warning light z neutral indicator light [ multi-function meter \ engine trouble warning light _ left turn sign...

  • Page 534: Elec

    8 - 38 – + elec signaling system eas00794 troubleshooting check: 1. Main, signaling system, hazard lighting, windshield motor and backup fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: @ • before troubleshooting, remove the following part(s): 1) fuel tank...

  • Page 535: Elec

    8 - 39 – + elec signaling system eas00796 checking the signaling system 1. The horn fails to sound. Yes no yes no no yes 1. Horn switch • check the horn switch for continuity. Refer to “checking the switches”. • is the horn switch ok? Replace the left han- dlebar switch. 2. Voltage • connect the poc...

  • Page 536: Elec

    8 - 40 – + elec signaling system eas00797 2. The tail/brake light fails to come on. Yes no yes no yes no 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. • are the tail/brake light bulb and socket ok? Replace the tail/ brake light bulb, socket or both....

  • Page 537: Elec

    8 - 41 – + elec signaling system eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. Yes no yes no yes no 1. Turn signal indicator light bulb and socket • check the turn signal light bulb and socket for continuity. • are the turn signal light bulb and socket ok? Rep...

  • Page 538: Elec

    8 - 42 – + elec signaling system yes no yes no eas00800 4. The neutral indicator light fails to come on. Yes no yes no • set the main switch to “on”. • set the turn signal switch to “ ” or “ ”. • measure the voltage (12 v) on brown/white 1 at the turn signal relay coupler. • is the voltage within sp...

  • Page 539: Elec

    8 - 43 – + elec signaling system eas00753 yes no yes no 3. Starting circuit cut-off relay • disconnect the starting circuit cut-off relay from the wire harness. • connect the pocket tester ( Ω × 1) to the starting circuit cut-off relay terminals as shown. • check the starting circuit cut-off relay f...

  • Page 540: Elec

    8 - 44 – + elec signaling system eas00802 5. The oil level warning light fails to come on. Yes no yes no yes no 1. Oil level warning light bulb and socket • check the oil level warning light bulb and socket for continuity. • are the oil level warning light bulb and socket ok? Replace the oil level w...

  • Page 541: Elec

    8 - 45 – + elec signaling system eas00804 6. The fuel level gauge fails to operate. Yes no yes no 1. Fuel sender • drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. • connect the pocket tester ( Ω × 10) to the fuel sender terminals as shown. Tester positive probe → green...

  • Page 542: Elec

    8 - 46 – + elec cooling system eas00807 cooling system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y b /y...

  • Page 543: Elec

    8 - 47 – + elec cooling system eas00808 troubleshooting check: 1. Main, ignition, and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Radiator fan motor relay 6. Coolant temperature sensor 7. Wiring connections (the entire cooling system) note: @ • before troubleshooting,...

  • Page 544: Elec

    8 - 48 – + elec cooling system eas00809 yes no eas00810 yes no yes no 4. Radiator fan motor (test 1) • disconnect the radiator fan motor coupler from the wire harness. • connect the battery (12 v) as shown. Battery positive lead → blue 1 battery negative lead → black 2 • does the radiator fan motor ...

  • Page 545: Elec

    8 - 49 – + elec cooling system eas00811 yes no 7. Coolant temperature sensor • remove the coolant temperature sensor from the thermostat assembly inlet pipe. • connect the pocket tester ( Ω × 1) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a container fil...

  • Page 546: Elec

    8 - 50 – + elec eas00813 yes no 8. Wiring • check the entire cooling system’s wiring. Refer to “circuit diagram”. • is the cooling system’s wiring properly con- nected and without defects? Replace the ecu. Properly connect or repair the cooling system’s wiring. Cooling system.

  • Page 547: Elec

    8 - 51 – + elec fuel injection system fuel injection system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y b /y...

  • Page 548: Elec

    8 - 52 – + elec fuel injection system eas00816 troubleshooting check: 1. Main, fuel injection system and ignition fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Fuel injection system relay 6. Fuel pump resistance 7. Crankshaft position sensor 8. Cylinder indication sensor 9. Speed sensor 1...

  • Page 549: Elec

    8 - 53 – + elec fuel injection system eas00759 yes no eas00817 yes no eas00748 5. Fuel injection system relay • disconnect the fuel injection system relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the fuel injection system relay terminals as shown. Battery p...

  • Page 550: Elec

    8 - 54 – + elec fuel injection system yes no yes no yes no crankshaft position sensor resis- tance 420 ~ 569 Ω at 20 °c (68 °f) (between gray and black) • is the crankshaft position sensor ok? Replace the crank- shaft position sensor. 8. Cylinder identification sensor output volt- age • connect the ...

  • Page 551: Elec

    8 - 55 – + elec fuel injection system eas00811 yes no 10.Coolant temperature sensor • remove the coolant temperature sensor from the thermostat assembly inlet pipe. • connect the pocket tester ( Ω × 1) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a contai...

  • Page 552: Elec

    8 - 56 – + elec fuel injection system yes no yes no 11.Intake air temperature sensor resistance • remove the intake air temperature sensor from the air filter case. • connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. Tester positive probe → brown/white 1 te...

  • Page 553: Elec

    8 - 57 – + elec fuel injection system yes no yes no eas00818 yes no 13.Atmospheric pressure sensor output volt- age • connect the pocket tester (dc 20 v) to the atmospheric pressure sensor coupler termi- nal as shown. Tester positive probe → blue 1 tester negative probe → black/blue 2 • set the main...

  • Page 554: Elec

    8 - 58 – + elec fuel injection system eas00819 checking the fuel pump warning @ gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • stop the engine before refueling. • do not smoke, and...

  • Page 555: Elec

    8 - 59 – + elec fuel injection system eas00502 checking and adjusting the throttle position sensor note: before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the throttle body) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 556: Elec

    8 - 60 – + elec fuel injection system ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ throttle position sensor resis- tance (520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ) at 20 °c (68 °f) (yellow — black/blue) 2. Check: • throttle position sensor (removed from the throttle body) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 557: Elec

    8 - 61 – + elec fuel injection system e. Connect the pocket tester ( Ω × 1k) to the throttle position sensor. F. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → replace the th...

  • Page 558: Elec

    8 - 62 – + elec fuel injection system example: if the maximum resistance = 5 k Ω, then the throttle position sensor’s maximum resistance when the throttle is fully closed should be: 5 k Ω × (0.13 ~ 0.15) = 650 ~ 750 Ω lift the throttle body assembly slightly out of the intake manifolds. Loosen the t...

  • Page 559: Elec

    8 - 63 – + elec windshield drive system windshield drive system circuit diagram on off 1 5 r r r br /l w /l l /y y br bl y ch dg y dg b l ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r br y b b b b (red) (red) br r /w r /b l /w y b r /w b /w b /r b r /w l /w (black) (black) l /y ...

  • Page 560: Elec

    8 - 64 – + elec windshield drive system troubleshooting check: 1. Main, windshield motor and backup fuses 2. Battery 3. Main switch 4. Windshield position switch 5. Wiring connections (of the windshield drive system) note: @ • before troubleshooting, remove the following part(s): 1) fuel tank 2) fro...

  • Page 561: Elec

    8 - 65 – + elec windshield drive system eas00795 yes no note: • if the windshield is up, it will go down when the gear is in the neutral position and the main switch is set to “off”. • the neutral indicator light will blink until the windshield has stopped and is all the way down. If the neutral ind...

  • Page 562: Trbl

    9 - 1 trbl shtg starting problems eas00844 troubleshooting note: @ the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, ...

  • Page 563: Trbl

    9 - 2 trbl shtg starting problems/ incorrect engine idling speed electrical systems battery • discharged battery • faulty battery fuse(s) • blown, damaged or incorrect fuse • improperly installed fuse spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • wo...

  • Page 564: Trbl

    9 - 3 trbl shtg poor medium-and-high-speed performance/ faulty gear shifting eas00848 poor medium-and-high-speed performance refer to “starting problems”. Engine air filter • clogged air filter element fuel system fuel pump • faulty fuel pump eas00850 faulty gear shifting shifting is difficult refer...

  • Page 565: Trbl

    9 - 4 trbl shtg faulty clutch/overheating eas00852 faulty clutch clutch slips clutch • improperly assembled clutch • improperly assembled clutch master cylin- der • improperly assembled clutch release cylin- der • incorrect clutch fluid level • damaged clutch hose • loose or fatigued clutch spring •...

  • Page 566: Trbl

    9 - 5 trbl shtg poor braking performance/ faulty front fork legs eas00857 poor braking performance • worn brake pad • worn brake disc • air in hydraulic brake system • leaking brake fluid • faulty brake caliper seal • loose union bolt • damaged brake hose • oil or grease on the brake disc • oil or g...

  • Page 567: Trbl

    9 - 6 trbl shtg unstable handling/ faulty lighting or signaling system eas00863 unstable handling handlebars • bent or improperly installed right handlebar • bent or improperly installed left handlebar steering head components • improperly installed upper bracket • improperly installed lower bracket...

  • Page 568: Trbl

    9 - 7 trbl shtg faulty lighting or signaling system turn signal blinks quickly • incorrect turn signal bulb • faulty turn signal relay • burnt-out turn signal bulb horn does not sound • improperly adjusted horn • damaged or faulty horn • faulty main switch • faulty horn switch • faulty battery • blo...

  • Page 569

    Fjr1300r/fjr1300rc wiring diagram (for usa) 1 main switch 2 rectifier/regulator 3 generator 4 backup fuse (odometer, clock and windshield) 5 main fuse 6 battery 7 fuel injection system fuse 8 starter relay 9 starter motor 0 diode a starting circuit cut-off relay b neutral switch c sidestand switch d...

  • Page 571

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A..

  • Page 572

    Fjr1300r/fjr1300rc wiring diagram (for usa) blue color code black/white black/yellow blue/black blue/green blue/white blue/yellow brown/blue brown/red brown/black black brown chocolate dark green green gray light green orange pink red sky blue white yellow black/blue black/red brown/white green/blue...