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Yamaha FJR1300A(D) Service Manual

Summary of FJR1300A(D)

  • Page 1

    2013 service manual fjr1300a(d) 1mc-28197-e0

  • Page 2

    Eas20040 fjr1300a(d) 2013 service manual ©2012 by yamaha motor co., ltd. First edition, august 2012 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Important

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

  • Page 4: How to Use This Manual

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

  • Page 5: Symbols

    Eas20101 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...

  • Page 7: Table of Contents

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

  • Page 9: General Information

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

  • Page 10: Identification

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

  • Page 11: Features

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

  • Page 12: Features

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

  • Page 13: Features

    Features 1-4 eas1mc1081 ycc-t (yamaha chip controlled throttle) mechanism characteristics yamaha developed the ycc-t system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but yamaha has developed a fast- er, more compac...

  • Page 14: Features

    Features 1-5 ycc-t system outline 5 6 7 8 9 3 2 1 4 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. Ecu (engine control unit) 5. Sensor input 6. Gear position switch 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor.

  • Page 15: Features

    Features 1-6 eas1mc1087 outline of the cruise control system this model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the ycc-t system, the cruise control system can be controlled elec- tronically. Based on the signals that...

  • Page 16: Features

    Features 1-7 warning ewa1mc1006 • improper use of the cruise control system may result in loss of control, which could lead to an accident. Do not activate the cruise control system in heavy traffic, poor weather conditions, or among winding, slippery, hilly, rough or gravel roads. • when traveling ...

  • Page 17: Features

    Features 1-8 deactivating the cruise control system perform one of the following operations to cancel the set cruising speed. The cruise control setting in- dicator light “set” will go off. • turn the throttle grip past the closed position in the deceleration direction. • apply the front or rear bra...

  • Page 18: Features

    Features 1-9 operation chart automatic deactivation of the cruise control system the cruise control system for this model is electronically controlled and is linked with the other control systems. The cruise control system will automatically become deactivated under the following condi- tions: • the...

  • Page 19: Features

    Features 1-10 because the automatic deactivation of the cruise control system is stored in the memory of the ecu, the deactivation can be checked using the yamaha diagnostic tool. Tip in some cases, the cruise control system may not be able to maintain the set cruising speed when the vehicle is trav...

  • Page 20: Features

    Features 1-11 meter displays during cruise control system operation self-diagnosis device the cruise control system will also become deactivated when an irregularity with any of the vehicle sys- tems is detected. The cruise control setting indicator light “set” will go off and the cruise control sys...

  • Page 21: Features

    Features 1-12 tip • if the cruise control system turned off because a malfunction was detected by the fi self-diagnosis, the cruise control power switch “ ” must be pushed once before the system can return to the normal operating condition. • if a switch for the cruise control system is malfunctioni...

  • Page 22: Features

    Features 1-13 et3p61050 outline of the unified brake system the yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle usi...

  • Page 23: Features

    Features 1-14 brake pedal input force and braking force at each wheel metering valve this valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level. Only the rear brake caliper is operated when there is an ex...

  • Page 24: Features

    Features 1-15 et3p61019 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. However, one set of pistons in the right front brake caliper is operated together with the rear brake and this set of pi...

  • Page 25: Features

    Features 1-16 when the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • brake force: the force applied by braking to reduce the wheel speed. • wheel lock: a condition that occurs when the rota...

  • Page 26: Features

    Features 1-17 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed ...

  • Page 27: Features

    Features 1-18 warning ew3p61003 the braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of the tires. Even in vehicles equipped with abs, overturning of the vehicle c...

  • Page 28: Features

    Features 1-19 abs block diagram et3p61051 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor contains a hall ic. The wheel sensors are installed in the sensor housing...

  • Page 29: Features

    Features 1-20 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on during the abs self-diagnosis to check the electrical circuit of the light. If there are no problems detecte...

  • Page 30: Features

    Features 1-21 • hydraulic unit assembly the hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an abs motor, and abs ecu. The hydraulic unit adjusts the front and rear wheel brake fluid p...

  • Page 31: Features

    Features 1-22 3. When the abs ecu sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake mas...

  • Page 32: Features

    Features 1-23 • abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. The necessar...

  • Page 33: Features

    Features 1-24 abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when a malfunction is detected in the abs, a fault code is stored in the memory of the abs ecu for easy problem identification and trou...

  • Page 34: Features

    Features 1-25 et3p61052 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. Normal braking (abs not activated) when the abs is not activated, the inlet sol...

  • Page 35: Features

    Features 1-26 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line...

  • Page 36: Features

    Features 1-27 2. Pressurizing phase the outlet solenoid valve is closed by the “pressurization” signal transmitted from the abs ecu. At this time, the abs ecu controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, all...

  • Page 37: Features

    Features 1-28 et3p61053 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the multi-function meter center display. Instances when the abs warning light comes on 1. The abs warning light comes on...

  • Page 38: Features

    Features 1-29 2. The abs warning light comes on while the “ ” side of the start/engine stop switch is being pushed. When the engine is being started, the abs warning light comes on while the “ ” side of the start/en- gine stop switch is being pushed. (refer to “electric starting system” on page 8-7....

  • Page 39: Features

    Features 1-30 5. The abs warning light “1” flashes and a fault code “2” is indicated on the multi-function meter right display when the test coupler adapter “3” is connected to the abs test coupler “4” for troubleshooting the abs. The abs test coupler can be accessed by removing the right upper inne...

  • Page 40: Features

    Features 1-31 et3p61054 abs warning light and operation abs and ubs function warning ewa1mc1024 • when hydraulic control is performed by the abs, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake peda...

  • Page 41: Features

    Features 1-32 eas1mc1082 outline of the tcs (traction control system) the traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ecu monitors the front and rear wheel speeds using the signals from the...

  • Page 42: Features

    Features 1-33 tcs (traction control system) function the traction control system helps maintain traction when accelerating on slippery surfaces, such as un- paved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by r...

  • Page 43: Features

    Features 1-34 tip turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. Notice eca1mc1014 use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation ac...

  • Page 44: Features

    Features 1-35 eas1mc1030 multi-function meter unit warning ewa1mc1008 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. Tip the select switch “ / ” and the men...

  • Page 45: Features

    Features 1-36 fuel meter the fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “e” (empty) as the fuel level decreases. When the last segment starts flash- ing, refuel as soon as possible. When the main switch is turned to “on”, all di...

  • Page 46: Features

    Features 1-37 function display push the menu switch “menu” to switch the dis- play between the windshield adjusting function, grip warmer adjusting function, and information display selection function. Adjusting the windshield position to move the windshield up, push the “ ” side of the select switc...

  • Page 47: Features

    Features 1-38 tripmeter displays: “trip-1” and “trip-2” show the distance trav- eled since they were last set to zero. When approximately 5.5 l (1.45 us gal, 1.21 imp.Gal) of fuel remains in the fuel tank, the last segment of the fuel meter starts flashing. In ad- dition, the information display wil...

  • Page 48: Features

    Features 1-39 this display shows the ambient temperature from –9 °c to 50 °c in 1 °c increments. The tem- perature displayed may vary from the ambient temperature. Tip • –9 °c will be displayed even if the ambient tem- perature falls below –9 °c. • 50 °c will be displayed even if the ambient tem- pe...

  • Page 49: Features

    Features 1-40 • the “l/100km” display shows the amount of fuel necessary to travel 100 km. • for the uk only: the “mpg” display shows the distance that can be traveled on 1.0 imp.Gal of fuel. Tip if traveling at speeds under 10 km/h, “_ _._” will be displayed. Setting mode tip • the transmission mus...

  • Page 50: Features

    Features 1-41 2. Push the menu switch “menu”. The grip warmer setting display will be shown and “high” will flash in the display. 3. Push the menu switch “menu”. The temper- ature level for the high setting will start flash- ing. Use the select switch to set the temperature level, and then push the ...

  • Page 51: Features

    Features 1-42 2. Push the menu switch “menu” to display “time-2” and “time-3”. To reset a time trip, push the “reset” button to select the item to reset. 3. While the selected item is flashing, push the “reset” button for at least 2 seconds. 4. Push the menu switch “menu” to return to the setting mo...

  • Page 52: Features

    Features 1-43 2. Push the menu switch “menu”, use the se- lect switch to highlight the display to change, and then push the menu switch “menu” again. 3. Use the select switch to highlight the item to change, and then push the menu switch “menu”. 4. Use the select switch to select the item to show, a...

  • Page 53: Features

    Features 1-44 setting the clock 1. Use the select switch to highlight “clock”. 2. Push the menu switch “menu”. 3. When the hour digits start flashing, use the select switch to set the hours. 4. Push the menu switch “menu”, and the minute digits start flashing. 5. Use the select switch to set the min...

  • Page 54: Features

    Features 1-45 1. Use the code re-registering key to start the engine. Tip make sure there are no other immobilizer keys close to the main switch, and do not keep more than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter- ference, which may prevent the engine ...

  • Page 55: Important Information

    Important information 1-46 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-53. 3. When disasse...

  • Page 56: Important Information

    Important information 1-47 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if...

  • Page 57: Basic Service Information

    Basic service information 1-48 eas30380 basic service information eas30390 quick fasteners rivet type 1. Remove: • quick fastener tip to remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • quick fastener tip to install the quick fastener, push its pi...

  • Page 58: Basic Service Information

    Basic service information 1-49 eas30402 electrical system electrical parts handling notice eca16600 never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. Notice eca16751 when disconnecting the battery leads from the battery, be sure to ...

  • Page 59: Basic Service Information

    Basic service information 1-50 notice eca16620 handle electrical components with special care, and do not subject them to strong shocks. Notice eca16630 electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the ...

  • Page 60: Basic Service Information

    Basic service information 1-51 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector notice eca16780 • when disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and t...

  • Page 61: Basic Service Information

    Basic service information 1-52 4. Check: • continuity (with the pocket tester) tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (3). • as a quick remedy, use a contact revitalizer available at most part stores. 5. Check: • resistance tip th...

  • Page 62: Special Tools

    Special tools 1-53 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 63: Special Tools

    Special tools 1-54 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-19, 4-96 oil filter wrench 90890-01426 yu-38411 3-24 oil pressure gauge set 90890-03120 3-26 oil pressure adapter b 90890-03124 3-26 hexagon wrench (41) 90890-01525 ym-01525 4-33, 4-35 damper rod holder 90890-014...

  • Page 64: Special Tools

    Special tools 1-55 final gear backlash band 90890-01511 middle drive gear lash tool ym-01230 4-113 coupling gear/middle shaft tool 90890-01229 gear holder ym-01229 4-115, 4-118 bearing retainer wrench 90890-04050 pinion bearing retainer & remover ym-04050 4-115, 4-118 fork seal driver weight 90890-0...

  • Page 65: Special Tools

    Special tools 1-56 pivot shaft wrench adapter 90890-01476 5-8, 5-9 rotor holding tool 90890-01235 universal magneto & rotor holder yu-01235 5-13, 5-16 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-18, 5-34, 5-37, 5-82, 6-13 valve spring compressor 90890-04019 ym-04019 5-24, 5-29 valve spr...

  • Page 66: Special Tools

    Special tools 1-57 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-33, 5-34, 5-37 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-33 universal clutch holder 90890-04086 ym-91042 5-49, 5-52 thickness gauge 90890-03180 feeler gauge set yu-26900-9 5-50 bearing retainer wrench 90...

  • Page 67: Special Tools

    Special tools 1-58 piston pin puller set 90890-01304 piston pin puller yu-01304 5-86 piston ring compressor 90890-05158 ym-08037 5-91 slide hammer bolt 90890-01083 slide hammer bolt 6 mm yu-01083-1 5-102 weight 90890-01084 yu-01083-3 5-102 radiator cap tester 90890-01325 mityvac cooling system teste...

  • Page 68: Special Tools

    Special tools 1-59 radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-13 pressure gauge 90890-...

  • Page 69: Special Tools

    Special tools 1-60 test harness-lean angle sensor (6p) 90890-03209 yu-03209 8-183 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 8-184, 8-190 test harness- speed sensor (3p) 90890-03208 yu-03208 8-189 test harness s- pressure sensor (3p) 90890-03207 yu-03207 8-190 to...

  • Page 70: Special Tools

    Special tools 1-61.

  • Page 71: Specifications

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

  • Page 72: General Specifications

    General specifications 2-1 eas20280 general specifications model model 1mc1 (europe except (f)) 1mc2 (b) (f) 1mc6 (aus) dimensions overall length 2230 mm (87.8 in) overall width 750 mm (29.5 in) overall height 1325/1455 mm (52.2/57.3 in) seat height 805/825 mm (31.7/32.5 in) wheelbase 1545 mm (60.8 ...

  • Page 73: Engine Specifications

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

  • Page 74: Engine Specifications

    Engine specifications 2-3 bypass valve opening pressure 78.4–117.6 kpa (0.78–1.18 kgf/cm², 11.4–17.1 psi) relief valve operating pressure 480.0–560.0 kpa (4.80–5.60 kgf/cm², 69.6–81.2 psi) cooling system radiator capacity (including all routes) 2.60 l (2.75 us qt, 2.29 imp.Qt) radiator capacity 0.65...

  • Page 75: Engine Specifications

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

  • Page 76: Engine Specifications

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

  • Page 77: Engine Specifications

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

  • Page 78: Engine Specifications

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

  • Page 79: Engine Specifications

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

  • Page 80: Engine Specifications

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

  • Page 81: Chassis Specifications

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

  • Page 82: Chassis Specifications

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

  • Page 83: Chassis Specifications

    Chassis specifications 2-12 spring stroke k1 0.0–67.5 mm (0.00–2.66 in) spring stroke k2 67.5–135.0 mm (2.66–5.31 in) inner tube outer diameter 48.0 mm (1.89 in) inner tube bending limit 0.2 mm (0.01 in) optional spring available no recommended oil suspension oil m1 or equivalent quantity 716.0 cm³ ...

  • Page 84: Electrical Specifications

    Electrical specifications 2-13 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 5.0°/1050 r/min engine control unit model/manufacturer tbdfe3/denso (europe except (f)) (aus) tbdfh3/denso (b) (f) ignition coil minimum igniti...

  • Page 85: Electrical Specifications

    Electrical specifications 2-14 engine trouble warning light led abs warning light led cruise control system indicator light led cruise control setting indicator light led immobilizer system indicator light led traction control system indicator/warning light led electric starting system system type c...

  • Page 86: Electrical Specifications

    Electrical specifications 2-15 fuses main fuse 50.0 a cooling system fuse 30.0 a headlight fuse 25.0 a brake light fuse 1.0 a signaling system fuse 10.0 a ignition fuse 20.0 a radiator fan fuse 10.0 a × 2 auxiliary dc jack fuse 3.0 a hazard lighting fuse 7.5 a fuel injection system fuse 15.0 a abs m...

  • Page 87: Tightening Torques

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

  • Page 88: Tightening Torques

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

  • Page 89: Tightening Torques

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

  • Page 90: Tightening Torques

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

  • Page 91: Tightening Torques

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

  • Page 92: Tightening Torques

    Tightening torques 2-21 crankcase tightening sequence: tip middle gear case cover bolt apply locking agent (loctite®) only to the threads of the 2 upper middle gear case cover bolts, and then tighten all of the bolts to 12 nm (1.2 m·kg, 8.7 ft·lb). 9 8 3 6 1 2 5 4 7 10 lt.

  • Page 93: Tightening Torques

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

  • Page 94: Tightening Torques

    Tightening torques 2-23 rear shock absorber spring pre- load adjusting lever nut m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) upper bracket pinch bolt m8 2 26 nm (2.6 m·kg, 19 ft·lb) lower bracket pinch bolt m8 4 23 nm (2.3 m·kg, 17 ft·lb) steering stem nut m28 1 115 nm (11.5 m·kg, 85 ft·lb) lower ring nut m30 1...

  • Page 95: Tightening Torques

    Tightening torques 2-24 rear upper fuel tank bracket and rear lower fuel tank bracket nut m8 1 16 nm (1.6 m·kg, 11 ft·lb) rear lower fuel tank bracket and frame bolt m6 4 8 nm (0.8 m·kg, 5.8 ft·lb) fuel tank cap bolt m5 3 6 nm (0.6 m·kg, 4.3 ft·lb) storage compartment bolt m6 2 7 nm (0.7 m·kg, 5.1 f...

  • Page 96: Tightening Torques

    Tightening torques 2-25 hydraulic unit assembly cap nut m8 3 16 nm (1.6 m·kg, 11 ft·lb) hydraulic unit assembly bracket and hydraulic unit assembly bolt m6 5 7 nm (0.7 m·kg, 5.1 ft·lb) metering valve bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) proportioning valve bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) sidest...

  • Page 97: Tightening Torques

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

  • Page 98: 2-27

    Lubrication points and lubricant types 2-27 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobes camshaft journals balanc...

  • Page 99: 2-28

    Lubrication points and lubricant types 2-28 cylinder head cover mating surface three bond 1541c® cylinder head cover gasket yamaha bond no.1215 (three bond no.1215®) crankcase mating surface yamaha bond no.1215 (three bond no.1215®) crankshaft position sensor lead grommet yamaha bond no.1215 (three ...

  • Page 100: 2-29

    Lubrication points and lubricant types 2-29 eas20380 chassis lubrication point lubricant steering bearings and upper bearing cover lip lower bearing dust seal lip front wheel oil seal lip rear wheel oil seal lip rear wheel drive hub mating surface rear brake pedal pivoting point footrest assembly pi...

  • Page 101: 2-30

    Lubrication points and lubricant types 2-30

  • Page 102: 2-31

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

  • Page 103: 2-32

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

  • Page 104: 2-33

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

  • Page 105: 2-34

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

  • Page 106: 2-35

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

  • Page 107: 2-36

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

  • Page 108: 2-37

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

  • Page 109: 2-38

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

  • Page 110: 2-39

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

  • Page 111: 2-40

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

  • Page 112: 2-41

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

  • Page 113: 2-42

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

  • Page 114: Cooling System Diagrams

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

  • Page 115: Cooling System Diagrams

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

  • Page 116: Cooling System Diagrams

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

  • Page 117: Cooling System Diagrams

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

  • Page 118: Cable Routing

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

  • Page 119: Cable Routing

    Cable routing 2-48 1. Right grip warmer lead 2. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 3. Right handlebar switch lead 4. Clutch hose 5. Left handlebar switch lead 6. Clutch switch lead 7. Main switch lead 8. Immobilizer unit lead 9. Front wheel sensor lead 10. Br...

  • Page 120: Cable Routing

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

  • Page 121: Cable Routing

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

  • Page 122: Cable Routing

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

  • Page 123: Cable Routing

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

  • Page 124: Cable Routing

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

  • Page 125: Cable Routing

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

  • Page 126: Cable Routing

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

  • Page 127: Cable Routing

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

  • Page 128: Cable Routing

    Cable routing 2-57 rear fender (left side view) 2 1 3 4 6 5 7 a c b 8 4 5 4 5 j i k 9 10 1 11 12 13 14 15 d f g h e 16.

  • Page 129: Cable Routing

    Cable routing 2-58 1. Wire harness 2. License plate light connectors 3. Tail/brake light assembly coupler 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Brake switch relay 10. Brake light relay 11. Abs ecu coupler 12....

  • Page 130: Cable Routing

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

  • Page 131: Cable Routing

    Cable routing 2-60 1. Ignition coil #1 coupler 2. Clutch hose 3. Front wheel sensor lead 4. Immobilizer unit lead 5. Main switch lead 6. Throttle cable (decelerator cable) 7. Throttle cable (accelerator cable) 8. Brake hose (brake pipe/upper joint assembly to front brake calipers) 9. Brake hose (met...

  • Page 132: Cable Routing

    Cable routing 2-61 rear fender (top view) 1 2 3 b c a b.

  • Page 133: Cable Routing

    Cable routing 2-62 1. License plate light lead 2. Tail/brake light assembly lead 3. Seat lock cable a. Route the tail/brake light assembly lead and license plate light lead between the rib and the u- lock holder on the rear fender, making sure that the leads are not routed on top of the holder. B. F...

  • Page 134: Cable Routing

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

  • Page 135: Cable Routing

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

  • Page 136: Cable Routing

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

  • Page 137: Cable Routing

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

  • Page 138: Cable Routing

    Cable routing 2-67.

  • Page 139

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

  • Page 140

    Changing the coolant................................................................... 3-27 checking the final gear oil level ............................................ 3-29 changing the final gear oil........................................................ 3-29 checking the brake light switches....

  • Page 142: Periodic Maintenance

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

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-2 5 * brake hoses • check for cracks or damage. • check for correct routing and clamping. √ √ √ √ √ • replace. Every 4 years 6 * brake fluid • replace. Every 2 years 7 * wheels • check runout and for damage. √ √ √ √ 8 * tires • check tread depth and for damage. • replace if ne...

  • Page 144: Periodic Maintenance

    Periodic maintenance 3-3 eau17670 tip • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake and clutch service • regularly check and, if necessary, correct the brake and clutch fluid levels. • every two years replace the internal components...

  • Page 145: Periodic Maintenance

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

  • Page 146: Periodic Maintenance

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

  • Page 147: Periodic Maintenance

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

  • Page 148: Periodic Maintenance

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

  • Page 149: Periodic Maintenance

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

  • Page 150: Periodic Maintenance

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

  • Page 151: Periodic Maintenance

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

  • Page 152: Periodic Maintenance

    Periodic maintenance 3-11 6. After selecting the cylinder number, simulta- neously press the “tcs” button “1” and “re- set” button “2” for 2 seconds or more to execute the selection. 7. Change the co adjustment volume “3” by pressing the “tcs” button or “reset” but- ton. Tip the co adjustment volume...

  • Page 153: Periodic Maintenance

    Periodic maintenance 3-12 air filter element will also affect throttle body synchronization, leading to poor engine per- formance and possible overheating. 4. Install: • air filter element • air filter case cover • left side cover refer to “general chassis” on page 4-1. Tip when installing the air f...

  • Page 154: Periodic Maintenance

    Periodic maintenance 3-13 tip • 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. Ignoring this precaution could allow air ...

  • Page 155: Periodic Maintenance

    Periodic maintenance 3-14 notice eca13490 after adjusting the brake lever position, make sure there is no brake drag. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21240 checking the brake fluid level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make ...

  • Page 156: Periodic Maintenance

    Periodic maintenance 3-15 tip • be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • when bleeding the abs, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to...

  • Page 157: Periodic Maintenance

    Periodic maintenance 3-16 warning ewa14020 after bleeding the abs, check the brake op- eration. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • right side cover refer to “general chassis” on page 4-1. Eas21250 checking the front brake pads the following procedure applies to all of th...

  • Page 158: Periodic Maintenance

    Periodic maintenance 3-17 notice eca13510 after adjusting the brake pedal position, make sure there is no brake drag. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch” on page 3-30. Eas21260 checking the rear brake...

  • Page 159: Periodic Maintenance

    Periodic maintenance 3-18 warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for ...

  • Page 160: Periodic Maintenance

    Periodic maintenance 3-19 warning ewa13210 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. Tip for tires with a direction of rotation mark “1”: instal...

  • Page 161: Periodic Maintenance

    Periodic maintenance 3-20 tip set a torque wrench at a right angle to the steer- ing nut wrench. C. Loosen the lower ring nut completely and then tighten it to specification with the steer- ing nut wrench. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for loosene...

  • Page 162: Periodic Maintenance

    Periodic maintenance 3-21 eas1mc1043 checking the centerstand 1. Check: • centerstand operation check that the centerstand moves smoothly. Rough movement → repair or replace. Eas21730 lubricating the centerstand lubricate the pivoting point, metal-to-metal mov- ing parts, and spring contact points o...

  • Page 163: Periodic Maintenance

    Periodic maintenance 3-22 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping (right side only) notice eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting knob “1” in ...

  • Page 164: Periodic Maintenance

    Periodic maintenance 3-23 eas1mc1045 checking the rear suspension 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Check: • rear shock absorber assembly gas leaks/oil leaks → replace the rear shock absorber assem...

  • Page 165: Periodic Maintenance

    Periodic maintenance 3-24 eas21740 lubricating the rear suspension lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Eas20730 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle ...

  • Page 166: Periodic Maintenance

    Periodic maintenance 3-25 b. Lubricate the o-ring “3” of a new oil filter car- tridge with a thin coat of engine oil. Notice eca13390 make sure the o-ring “3” is positioned cor- rectly in the groove of the oil filter cartridge. C. Tighten the new oil filter cartridge to specifi- cation with the oil ...

  • Page 167: Periodic Maintenance

    Periodic maintenance 3-26 eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark → add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several min- utes, and then turn it off. Notice eca13410 when the engine is cold, t...

  • Page 168: Periodic Maintenance

    Periodic maintenance 3-27 notice eca13470 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • use only distilled water. However, if dis- tilled water is...

  • Page 169: Periodic Maintenance

    Periodic maintenance 3-28 2. Remove: • radiator cap “1” warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radia...

  • Page 170: Periodic Maintenance

    Periodic maintenance 3-29 • if coolant is swallowed, induce vomiting and get immediate medical attention. Notice eca13480 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- t...

  • Page 171: Periodic Maintenance

    Periodic maintenance 3-30 3. Check: • final gear oil filler bolt gasket damage → replace. 4. Install: • final gear oil drain bolt (along with the gasket ) 5. Fill: • final gear case (with the specified amount of the recom- mended final gear oil) refer to “checking the final gear oil level” on page 3...

  • Page 172: Periodic Maintenance

    Periodic maintenance 3-31 1. Check: • outer cable damage → replace. 2. Check: • cable operation rough movement → lubricate. Tip hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. Eas1mc1034 checking the throttle grip operation 1...

  • Page 173: Periodic Maintenance

    Periodic maintenance 3-32 eas1mc1047 checking the switches, lights and signals 1. Check that all switches operate and that all lights come on. Refer to “instrument and control functions” in owner’s manual. Faulty → refer to “checking the switches” on page 8-169 and “check- ing the bulbs and bulb soc...

  • Page 174: Periodic Maintenance

    Periodic maintenance 3-33 warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • headlight bulb secure the new headlight bulb with the head- light bulb holder. Notice eca13690 avoid touching the ...

  • Page 175: Chassis

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

  • Page 176

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

  • Page 177

    Steering head.......................................................................................... 4-94 removing the lower bracket..................................................... 4-96 checking the steering head ....................................................... 4-96 installing the ste...

  • Page 178: General Chassis

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

  • Page 179: General Chassis

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

  • Page 180: General Chassis

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

  • Page 181: General Chassis

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

  • Page 182: General Chassis

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

  • Page 183: General Chassis

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

  • Page 184: General Chassis

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

  • Page 185: General Chassis

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

  • Page 186: General Chassis

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

  • Page 187: General Chassis

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

  • Page 188: General Chassis

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

  • Page 189: General Chassis

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

  • Page 190: General Chassis

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

  • Page 191: General Chassis

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

  • Page 192: General Chassis

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

  • Page 193: General Chassis

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

  • Page 194: General Chassis

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

  • Page 195: General Chassis

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

  • Page 196: General Chassis

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

  • Page 197: General Chassis

    General chassis 4-20 removing the air filter case order job/parts to remove q’ty remarks left side cover refer to “removing the seats and covers”. Fuel tank refer to “fuel tank” on page 7-1. T-bar refer to “removing the t-bar”. 1 air shroud 1 2 air duct 1 3 air filter case cover 1 4 air filter eleme...

  • Page 198: General Chassis

    General chassis 4-21 13 filter assembly 1 14 air filter case joint assembly 1 15 air filter case 1 for installation, reverse the removal proce- dure. Removing the air filter case order job/parts to remove q’ty remarks t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r ...

  • Page 199: Front Wheel

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

  • Page 200: Front Wheel

    Front wheel 4-23 12 front brake disc 2 for installation, reverse the removal proce- dure. Removing the front wheel, brake discs, wheel sensor, and sensor housing order job/parts to remove q’ty remarks t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 91 nm (9.1 m ...

  • Page 201: Front Wheel

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

  • Page 202: Front Wheel

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

  • Page 203: Front Wheel

    Front wheel 4-26 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-17 and “checking the wheels” on page 3-17. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns...

  • Page 204: Front Wheel

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

  • Page 205: Front Wheel

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

  • Page 206: Front Wheel

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

  • Page 207: Front Wheel

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

  • Page 208: Rear Wheel

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

  • Page 209: Rear Wheel

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

  • Page 210: Rear Wheel

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

  • Page 211: Rear Wheel

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

  • Page 212: Rear Wheel

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

  • Page 213: Rear Wheel

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

  • Page 214: Rear Wheel

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

  • Page 215: Front Brake

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

  • Page 216: Front Brake

    Front brake 4-39 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm hold- er 1 3 brake master cylinde...

  • Page 217: Front Brake

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

  • Page 218: Front Brake

    Front brake 4-41 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake hose holder 1 2 brake hose union bolt 1 3 coppe...

  • Page 219: Front Brake

    Front brake 4-42 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad bolt 2 2 brake pad spring 2 3 front brake pad 4 4 brake caliper piston 4 5 brake caliper piston dust seal 4 6 brake caliper ...

  • Page 220: Front Brake

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

  • Page 221: Front Brake

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

  • Page 222: Front Brake

    Front brake 4-45 3. Install: • brake pad bolts • brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-14. 5. Check: • brake lever and brake pedal operation soft or spongy ...

  • Page 223: Front Brake

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

  • Page 224: Front Brake

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

  • Page 225: Front Brake

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

  • Page 226: Front Brake

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

  • Page 227: Rear Brake

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

  • Page 228: Rear Brake

    Rear brake 4-51 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. Right side cover refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphrag...

  • Page 229: Rear Brake

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

  • Page 230: Rear Brake

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

  • Page 231: Rear Brake

    Rear brake 4-54 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake hose union bolt 1 2 copper washer 2 3 brake hose (proportioning valve to rear brake caliper) 1 4 rear brake caliper bol...

  • Page 232: Rear Brake

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

  • Page 233: Rear Brake

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

  • Page 234: Rear Brake

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

  • Page 235: Rear Brake

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

  • Page 236: Rear Brake

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

  • Page 237: Rear Brake

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

  • Page 238: Rear Brake

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

  • Page 239: Rear Brake

    Rear brake 4-62 4. Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 5. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-14. 6. Check: • brake pe...

  • Page 240: Abs (Anti-Lock Brake System)

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

  • Page 241: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-64 removing the rear fender assembly order job/parts to remove q’ty remarks rear cowlings/side covers/air shroud refer to “general chassis” on page 4-1. 1 brake fluid reservoir 1 2 tail/brake light assembly coupler 1 disconnect. 3 license plate light connector 2 discon...

  • Page 242: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-65 removing the metering valve, proportioning valve, and brake pipes order job/parts to remove q’ty remarks right side cover refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. 1 brake pipe union...

  • Page 243: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-66 12 brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 1 disconnect. 13 brake pipe (front brake master cylinder to brake pipe/lower joint assembly) 1 disconnect. 14 brake pipe/upper joint assembly 1 15 brake pipe/joint assembly stay 1 16 brak...

  • Page 244: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-67 removing the hydraulic unit assembly order job/parts to remove q’ty remarks rear cowlings/side covers/air shroud refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-14. Rear fender/metering valve/...

  • Page 245: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-68 et3p6d003 removing the hydraulic unit assembly notice eca3p6d018 unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids ...

  • Page 246: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-69 • metering valve cracks/damage → replace the metering valve et3p6d020 checking the brake pipes the following procedure applies to all of the brake pipes. 1. Check: • brake pipe end (flare nut) damage → replace the hydraulic unit, brake pipes, and related parts as a ...

  • Page 247: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-70 • brake pipe (brake pipe/upper joint assembly to front brake calipers) “3” • gaskets • brake pipe union bolts • brake hose union bolt tip when installing the brake hose and brake pipes onto the brake pipe joint assembly or brake hose joint assembly, make sure that t...

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

    Abs (anti-lock brake system) 4-71 11.Install: • metering valve “1” • brake pipe (metering valve to right front brake caliper) “2” • brake pipe (hydraulic unit to metering valve) “3” • gaskets • brake pipe union bolts tip temporarily install the metering valve and brake pipes. 12.Tighten: • brake pip...

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

    Abs (anti-lock brake system) 4-72 16.Delete the fault codes. (refer to “[c-1] de- leting the fault codes” on page 8-158.) 17.Perform a trial run. (refer to “checking the abs warning light” on page 4-75.) eas22800 hydraulic unit operation tests the reaction-force pulsating action generated in the bra...

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

    Abs (anti-lock brake system) 4-73 when the main switch is turned to “on”, a single pulse will be generated in the brake le- ver “1”. After the pulse is generated in the brake lever, it is generated in the brake pedal “2” twice. Tip a single pulse will be felt in the brake lever once, then in the bra...

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

    Abs (anti-lock brake system) 4-74 5. Connect the test coupler adapter “1” to the abs test coupler “2”. 6. Extend the sidestand. 7. Turn the main switch to “on”. 8. Push the “ ” side of the start/engine stop switch “1” for at least 4 seconds. Notice eca14790 do not operate the brake lever or the brak...

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

    Abs (anti-lock brake system) 4-75 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- mately 1.5 seconds. Tip the reaction-force pulsating action consists of quick pulses. Notice eca3p6d020 • check that the puls...

  • Page 253: Handlebars

    Handlebars 4-76 eas22850 handlebars removing the left handlebar order job/parts to remove q’ty remarks 1 clutch master cylinder holder 1 2 clutch master cylinder assembly 1 3 left handlebar 1 4 left handlebar switch holder 2 5 left handlebar switch 1 6 grip end 1 7 handlebar grip 1 8 lead holder 1 9...

  • Page 254: Handlebars

    Handlebars 4-77 removing the right handlebar order job/parts to remove q’ty remarks 1 front brake master cylinder holder 1 2 front brake master cylinder assembly 1 3 grip end 1 4 throttle cable housing 2 5 throttle cable 2 disconnect. 6 throttle grip 1 7 right handlebar 1 8 lead holder 1 9 right gri...

  • Page 255: Handlebars

    Handlebars 4-78 eas1mc1065 adjusting the handlebar position 1. Check: • handlebar position tip the handlebar position can be adjusted to one of three positions to suit the rider’s preference. 2. Adjust: • handlebar position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the plates “1”. ...

  • Page 256: Handlebars

    Handlebars 4-79 eas22890 checking the handlebars 1. Check: • left handlebar • right handlebar bends/cracks/damage → replace. Warning ewa13690 do not attempt to straighten a bent handle- bar as this may dangerously weaken it. Eas22900 installing the handlebars 1. Stand the vehicle on a level surface....

  • Page 257: Handlebars

    Handlebars 4-80 6. Install: • handlebar bolts “1” (temporarily) • handlebar nuts “2” (temporarily) 7. Tighten: • handlebar bolts • handlebar nuts tip first tighten the bolts, then tighten the nuts. 8. Install: • throttle grip • throttle cables • throttle cable housings “1” • grip end “2” tip • route...

  • Page 258: Handlebars

    Handlebars 4-81 10.Install: • clutch master cylinder assembly • clutch master cylinder holder “1” tip • install the clutch master cylinder holder with the “up” mark facing up. • align the mating surfaces of the clutch master cylinder holder with the punch mark “a” on the left handlebar. • first, tig...

  • Page 259: Front Fork

    Front fork 4-82 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Lower inner panels refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-22. 1 upper bracket pinch bo...

  • Page 260: Front Fork

    Front fork 4-83 disassembling the left front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 washer 2 4 spacer 1 5 fork spring 1 6 dust seal 1 7 oil seal clip 1 8 oil seal 1 9 washer 1 10 damper rod assembly bolt 1 11 copper washer 1 12 damper rod assembly 1 13 inner tube 1...

  • Page 261: Front Fork

    Front fork 4-84 17 outer tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the left front fork leg order job/parts to remove q’ty remarks new ls 17 16 15 14 13 12 10 11 9 8 7 6 5 4 3 3 2 1 35 nm (3.5 m • kg, 25 ft • ib) t.R ..

  • Page 262: Front Fork

    Front fork 4-85 disassembling the right front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 nut 1 4 spacer 1 5 washer 1 6 damper adjusting rod 1 7 damper adjusting valve 1 8 damper adjusting valve spring 1 9 fork spring 1 10 dust seal 1 11 oil seal clip 1 12 oil seal 1 13...

  • Page 263: Front Fork

    Front fork 4-86 18 outer tube bushing 1 1 d = 52 mm (2.05 in), l = 12 mm (0.47 in) 19 outer tube bushing 2 1 d = 51 mm (2.01 in), l = 15 mm (0.59 in) 20 inner tube bushing 1 21 outer tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the right front fork leg order job/parts to r...

  • Page 264: Front Fork

    Front fork 4-87 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...

  • Page 265: Front Fork

    Front fork 4-88 • washer ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull up the inner tube completely, fill it with oil up to the top, and then install the cap bolt. Tip do not install the fork spring. B. Place the front fork leg in a press and gradu- ally apply pressure to remove the oil ...

  • Page 266: Front Fork

    Front fork 4-89 3. Check: • damper rod assembly damage/wear → replace. Obstruction → blow out all of the oil passag- es with compressed air. Notice eca1mc1017 • the front fork leg has a very sophisticated internal construction, which are particular- ly sensitive to foreign material. • when disassemb...

  • Page 267: Front Fork

    Front fork 4-90 5. Install: • outer tube bushing 1 (d = 52 mm (2.05 in), l = 12 mm (0.47 in)) “1” • washer “2” (with the slide metal installer “3” and fork seal driver (weight) “4”) 6. Install: • oil seal “1” • suitable washer “2” (ex: 4sv-23115-00) (with the slide metal installer “3” and fork seal ...

  • Page 268: Front Fork

    Front fork 4-91 9. Install: • dust seal “1” (with the fork seal driver “2”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) notice eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassemb...

  • Page 269: Front Fork

    Front fork 4-92 15.Install: • fork spring tip install the fork spring so that the end “a” shown in the illustration is facing up. 16.Install (right side): • washer “1” • spacer “2” • nut “3” • damper adjusting valve spring “4” • damper adjusting valve “5” • damper adjusting rod “6” • cap bolt “7” ▼▼...

  • Page 270: Front Fork

    Front fork 4-93 2. Tighten: • lower bracket pinch bolts “1” • cap bolt “2” • upper bracket pinch bolt “3” warning ewa13680 make sure the brake hoses are routed prop- erly. 3. Adjust: • spring preload • rebound damping (right side only) • compression damping (right side only) refer to “adjusting the ...

  • Page 271: Steering Head

    Steering head 4-94 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Handlebars refer to “handlebars” on page 4-76. Front wheel refer to “front wheel” on page 4...

  • Page 272: Steering Head

    Steering head 4-95 11 upper ring nut 1 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 upper bearing cover 1 16 upper bearing inner race 1 17 upper bearing 1 18 lower bearing 1 19 lower bearing inner race 1 20 dust seal 1 21 upper bearing outer race 1 22 lower bearing outer race 1 for i...

  • Page 273: Steering Head

    Steering head 4-96 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 274: Steering Head

    Steering head 4-97 • lock washer “4” refer to “checking and adjusting the steering head” on page 3-19. 3. Install: • upper bracket • steering stem nut tip temporarily tighten the steering stem nut. 4. Install: • front fork legs refer to “front fork” on page 4-82. Tip temporarily tighten the upper an...

  • Page 275: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-98 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks left side cover/air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-31. Mufflers/exhaust pipe assemb...

  • Page 276: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-99 11 spacer 1 12 spacer 1 13 oil seal 6 14 bearing 2 15 bearing 2 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order job/parts to remove q’ty remarks new new new new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 40 nm (...

  • Page 277: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-100 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respon...

  • Page 278: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-101 • rear shock absorber gas leaks/oil leaks → replace the rear shock absorber assembly. • spring damage/wear → replace the rear shock ab- sorber assembly. • bushing damage/wear → replace the rear shock ab- sorber assembly. • spacer damage/scratches → replace. • bolts...

  • Page 279: Swingarm

    Swingarm 4-102 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks left side cover/air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-31. Rear shock absorber assembly/connecting arms refer to “rear shock absorber as- sembly” ...

  • Page 280: Swingarm

    Swingarm 4-103 12 oil seal 1 13 spacer 1 14 oil seal 1 15 circlip 1 16 bearing 1 17 spacer 1 18 bearing 1 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks lt lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • i...

  • Page 281: Swingarm

    Swingarm 4-104 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingar...

  • Page 282: Swingarm

    Swingarm 4-105 3. Tighten: • pivot shaft • pivot shaft nut • pivot shaft self-lock nut 3. Swingarm 4. Connecting arm a. Left side b. Right side t r . . Pivot shaft 23 nm (2.3 m·kg, 17 ft·lb) t r . . Pivot shaft nut 115 nm (11.5 m·kg, 85 ft·lb) t r . . Pivot shaft self-lock nut 125 nm (12.5 m·kg, 90 ...

  • Page 283: Shaft Drive

    Shaft drive 4-106 eas23550 shaft drive removing the final drive assembly order job/parts to remove q’ty remarks final gear oil drain. Refer to “changing the final gear oil” on page 3-29. Rear wheel refer to “rear wheel” on page 4-31. 1 final drive assembly 1 for installation, reverse the removal pro...

  • Page 284: Shaft Drive

    Shaft drive 4-107 removing the universal joint order job/parts to remove q’ty remarks left side cowling refer to “general chassis” on page 4-1. Final gear oil drain. Refer to “changing the final gear oil” on page 3-29. Final drive assembly refer to “shaft drive” on page 4-106. 1 shift arm 1 2 sidest...

  • Page 285: Shaft Drive

    Shaft drive 4-108 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 circlip 2 2 oil seal 1 3 drive shaft 1 4 spring 1 5 ring gear bearing housing 1 6 dust cover 1 7 oil seal 1 8 stopper bolt 1 left-hand threads 9 stopper bolt shim refer to “adjusting the ring-gear- to-s...

  • Page 286: Shaft Drive

    Shaft drive 4-109 * apply shaft drive gear oil (part no.: 9079e-sh002-00) 14 coupling gear nut 1 15 coupling gear 1 16 bearing retainer 1 left-hand threads 17 oil seal 1 18 final drive pinion gear 1 19 bearing 1 20 final drive pinion gear shim refer to “aligning the final drive pinion gear and ring ...

  • Page 287: Shaft Drive

    Shaft drive 4-110 eas23560 troubleshooting tip causes a, b and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual. In...

  • Page 288: Shaft Drive

    Shaft drive 4-111 troubleshooting chart when causes (a) or (b) shown in the table at the beginning of the “troubleshooting” section ex- ist, check the following points. Yes → no ↓ no → yes ↓ yes → no ↓ 1. Place the vehicle on a suitable stand so that the front wheel is ele- vated and then spin the f...

  • Page 289: Shaft Drive

    Shaft drive 4-112 eas23570 checking the final drive oil for contamination and checking the shaft drive for leaks 1. Drain: • final gear oil (from the final gear case) refer to “changing the final gear oil” on page 3-29. 2. Check: • final gear oil large amount of metal particles → check for bearing s...

  • Page 290: Shaft Drive

    Shaft drive 4-113 b. Finger tighten the ring gear fix bolt (m14) until it stops the ring gear from moving. Tip do not overtighten the ring gear fix bolt (m14). C. Install the final gear backlash band “2” and dial gauge “3”. Tip make sure that the dial gauge plunger contacts the groove “a” in the fin...

  • Page 291: Shaft Drive

    Shaft drive 4-114 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23600 measuring the ring-gear-to- stopper-bolt clearance 1. Remove: • ring gear bearing housing (along with the ring gear) refer to “adjusting the final gear backlash” on page 4-113. 2. Measure: • ring-gear-to-stopper-bolt cleara...

  • Page 292: Shaft Drive

    Shaft drive 4-115 tip if the ring-gear-to-stopper-bolt clearance is out of specification, repeat the above procedure. Eas23620 disassembling the final drive assembly 1. Remove: • ring gear bearing housing bolts “1” • ring gear bearing housing nuts “2” tip working in a crisscross pattern, loosen each...

  • Page 293: Shaft Drive

    Shaft drive 4-116 3. Remove: • bearing “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final gear case to approximately 150 °c (302 °f). B. Remove the bearing outer races with an ap- propriately shaped punch “2”. C. Remove the inner race from the final drive pinion gear. Tip the re...

  • Page 294: Shaft Drive

    Shaft drive 4-117 b. To find final drive pinion gear shim thickness “a”, use the following formula: where: a = 87 b = a numeral on the final gear case, to be di- vided by 100 and added to “86”. Example: if the final gear case is marked “49”: therefore, the calculated final drive pinion gear shim thi...

  • Page 295: Shaft Drive

    Shaft drive 4-118 example: if the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “+ 05”, and “f” is 13.00: therefore, the calculated ring gear shim thickness is 0.41 mm. Shim sizes are supplied in the following thick- nesses. Since the ring gear...

  • Page 296: Shaft Drive

    Shaft drive 4-119 6. Adjust: • final gear backlash refer to “measuring the final gear backlash” on page 4-112 and “adjust- ing the final gear backlash” on page 4-113. 7. Measure: • ring-gear-to-thrust-washer clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the ring gear bearing ...

  • Page 297: Shaft Drive

    Shaft drive 4-120 4. Install: • circlip 5. Install: • drive shaft “1” (to the final drive pinion gear) • oil seal “2” (to the final gear case with the fork seal driver weight “3” and oil seal installing tool “4”) 6. Install: • universal joint • final drive assembly tip align the drive shaft splines ...

  • Page 298: Shaft Drive

    Shaft drive 4-121 9. Install: • shift arm “1” tip align the punch mark “a” in the shift shaft with the slot in the shift arm. 10.Install: • rear wheel refer to “rear wheel” on page 4-31. 11.Fill: • final gear case refer to “checking the final gear oil level” on page 3-29. 12.Check: • shift pedal pos...

  • Page 299: Engine

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

  • Page 300

    Clutch ........................................................................................................ 5-43 removing the clutch ..................................................................... 5-49 checking the friction plates..................................................... 5-50 c...

  • Page 301

    Crankcase ................................................................................................ 5-77 disassembling the crankcase.................................................... 5-81 checking the crankcase .............................................................. 5-81 checking the...

  • Page 302: Engine Inspection

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

  • Page 303: Engine Inspection

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

  • Page 304: Engine Removal

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

  • Page 305: Engine Removal

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

  • Page 306: Engine Removal

    Engine removal 5-5 5 oil level switch coupler 1 disconnect. 6 crankshaft position sensor coupler 1 disconnect. 7 gear position switch coupler 1 disconnect. 8 cylinder identification sensor coupler 1 9 ignition coil coupler 4 10 wire harness holder 1 11 ground lead 1 disconnect. For installation, rev...

  • Page 307: Engine Removal

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

  • Page 308: Engine Removal

    Engine removal 5-7 16 spacer bolt 1 loosen. 17 engine mounting bolt (rear lower side) 1 18 spacer 1 19 engine mounting bolt (rear upper side) 1 20 engine 1 for installation, reverse the removal proce- dure. Removing the engine order job/parts to remove q’ty remarks t r . . 32 nm (3.2 m • kg, 23 ft •...

  • Page 309: Engine Removal

    Engine removal 5-8 eas1mc1066 removing the engine 1. Loosen: • spacer bolt tip loosen the spacer bolt with the pivot shaft wrench “1” and pivot shaft wrench adapter “2”. Eas23720 installing the engine 1. Install: • engine tip when mounting the engine to the frame, be sure to align the splines on the...

  • Page 310: Engine Removal

    Engine removal 5-9 6. Tighten: • engine mounting nut (rear upper side) “12” tip lubricate the engine mounting nut (rear upper side) threads with engine oil. 7. Tighten: • engine mounting bolt (left front lower side) “6” • engine mounting bolt (right front upper side) “8” • engine mounting bolt (righ...

  • Page 311: Engine Removal

    Engine removal 5-10 13.Install: • engine bracket (left rear side) “1” • engine bracket and frame bolt (left rear side) “2” • engine bracket and engine bolts (left rear side) “3” tip do not fully tighten the bolts. 14.Tighten: • engine bracket and frame bolt (left rear side) “2” 15.Tighten: • engine ...

  • Page 312: Camshafts

    Camshafts 5-11 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks t-bar refer to “general chassis” on page 4-1. Thermostat inlet pipe 1 refer to “thermostat” on page 6-6. Air cut-off valve/reed valves refer to “air induction system” on page 7-13. 1 ignition co...

  • Page 313: Camshafts

    Camshafts 5-12 removing the camshafts order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-36. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft cap 4 4 exhaust camshaft cap 4 ...

  • Page 314: Camshafts

    Camshafts 5-13 eas23810 removing the camshafts 1. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick-...

  • Page 315: Camshafts

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

  • Page 316: Camshafts

    Camshafts 5-15 tip • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the plastigauge®. D. Remove the camshaft caps and then mea- sure the width of the ...

  • Page 317: Camshafts

    Camshafts 5-16 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24010 installing the camshafts 1. Install: • exhaust camshaft sprocket • intake camshaft sprocket tip • while holding the camshaft sprockets with the rotor holding tool “1”, tighten the camshaft sprocket bolts. • make sure that the ...

  • Page 318: Camshafts

    Camshafts 5-17 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • exhaust camshaft caps • intake camshaft caps tip • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “e”, “e1”, “e2”, “e3”: exhaust “i”, “i1”, “i2”, “i3”: intake...

  • Page 319: Camshafts

    Camshafts 5-18 d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Turn: • crankshaft (several turns clockwise) 8. Check: • “t” mark make sure the “t” mark “a” on t...

  • Page 320: Camshafts

    Camshafts 5-19 11.Install: • cylinder head cover plate “1” tip be sure the “up” mark “a” is facing up. New 2 2 a 1 3 a a 1.

  • Page 321: Cylinder Head

    Cylinder head 5-20 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Camshafts refer to “camshafts” on page 5-11. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the removal proce-...

  • Page 322: Cylinder Head

    Cylinder head 5-21 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: • comb...

  • Page 323: Cylinder Head

    Cylinder head 5-22 e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Warning ew3p61014 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a...

  • Page 324: Valves and Valve Springs

    Valves and valve springs 5-23 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-20. 1 valve lifter 16 2 valve pad 16 3 valve cotter 32 4 upper spring seat 16 5 intake valve spring 8 6 exhaus...

  • Page 325: Valves and Valve Springs

    Valves and valve springs 5-24 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifte...

  • Page 326: Valves and Valve Springs

    Valves and valve springs 5-25 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼...

  • Page 327: Valves and Valve Springs

    Valves and valve springs 5-26 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replac...

  • Page 328: Valves and Valve Springs

    Valves and valve springs 5-27 b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Tip where the valve seat and valve face contacted one another, the blueing will have been re- m...

  • Page 329: Valves and Valve Springs

    Valves and valve springs 5-28 eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 2. Measure: • compressed valve spring force “a” out of specification → replace th...

  • Page 330: Valves and Valve Springs

    Valves and valve springs 5-29 2. Lubricate: • valve stem “1” • valve stem end • valve stem seal “2” (with the recommended lubricant) 3. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • upper spring seat “5” (into the cylinder head) tip • make sure each valve is...

  • Page 331: Valves and Valve Springs

    Valves and valve springs 5-30 6. Lubricate: • valve lifter (with the recommended lubricant) 7. Install: • valve pad • valve lifter tip • the valve lifter must move smoothly when ro- tated with a finger. • each valve lifter and valve pad must be rein- stalled in its original position. Recommended lub...

  • Page 332: Generator and Starter Clutch

    Generator and starter clutch 5-31 eas24480 generator and starter clutch removing the generator rotor and starter clutch order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Engine oil drain. Refer to “changing the engine oil” on page 3-24. 1 stator coil coupler 1 discon...

  • Page 333: Generator and Starter Clutch

    Generator and starter clutch 5-32 removing the stator coil assembly order job/parts to remove q’ty remarks 1 stator coil assembly lead holder 1 2 stator coil assembly 1 for installation, reverse the removal proce- dure..

  • Page 334: Generator and Starter Clutch

    Generator and starter clutch 5-33 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer tip while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff key notic...

  • Page 335: Generator and Starter Clutch

    Generator and starter clutch 5-34 b. When turning the starter clutch gear clock- wise “a”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch gear counter- clockwise “b”, it should turn freely,...

  • Page 336: Generator and Starter Clutch

    Generator and starter clutch 5-35 4. Install: • generator cover gasket • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. T r . . Generator cover bolt 12 nm (1.2 m·kg, 8.7 ft·lb) new.

  • Page 337: Pickup Rotor

    Pickup rotor 5-36 eas24520 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks side cowlings/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Generator cover refer to “generator and starter clutch” on page 5-31. 1 pickup ro...

  • Page 338: Pickup Rotor

    Pickup rotor 5-37 eas24530 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3” tip while holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. Eas24540 installing the pickup rotor 1. Install: • pickup rotor “1” • washer • p...

  • Page 339: Pickup Rotor

    Pickup rotor 5-38 4. Measure: • gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” out of specification → reinstall or replace. 5. Install: • pickup rotor cover gasket • pickup rotor cover tip tighten the pickup rotor cover bolts in stages and in a crisscross pattern. Gap (bet...

  • Page 340: Electric Starter

    Electric starter 5-39 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure..

  • Page 341: Electric Starter

    Electric starter 5-40 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 brush 2 4 brush seat (along with brushes) 1 5 washer 1 6 lock washer 1 7 oil seal 1 8 bearing 1 9 starter motor rear cover 1 10 collar 1 11 o-ring 2 12 starter moto...

  • Page 342: Electric Starter

    Electric starter 5-41 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “1” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 343: Electric Starter

    Electric starter 5-42 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” tip align the slot “a” on the brush seat with the tab “b” in the starter motor f...

  • Page 344: Clutch

    Clutch 5-43 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-24. 1 clutch cover 1 2 clutch cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 345: Clutch

    Clutch 5-44 removing the clutch order job/parts to remove q’ty remarks rear balancer refer to “balancers” on page 5-106. 1 oil guide plate 1 2 clutch spring plate retainer 1 3 clutch spring plate 1 4 clutch spring plate seat 1 5 pressure plate 1 6 short clutch push rod 1 7 ball 1 8 long clutch push ...

  • Page 346: Clutch

    Clutch 5-45 17 clutch damper spring seat 1 18 clutch boss 1 19 thrust washer 1 20 spacer 1 21 clutch housing 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 (6) new new new lt t r . ...

  • Page 347: Clutch

    Clutch 5-46 removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-12. 1 clutch master cylinder reservoir cap 1 2 clutch master cylinder reservoir diaphragm holder 1 3 clutch master cylinder reservoir d...

  • Page 348: Clutch

    Clutch 5-47 disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 washer 1 5 clutch master cylinder kit 1 6 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 349: Clutch

    Clutch 5-48 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-12. 1 clutch hose union bolt 1 2 copper washer 2 3 clutch hose 1 disconnect. 4 clutch release cylinder 1 5 dowel pin 2 6 plate 1 for i...

  • Page 350: Clutch

    Clutch 5-49 eas25080 removing the clutch 1. Remove: • clutch cover “1” tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • rear balancer weight refer to “balancers” on page 5-106. 3. Remove: • clu...

  • Page 351: Clutch

    Clutch 5-50 eas25100 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the friction plates as a set. Tip me...

  • Page 352: Clutch

    Clutch 5-51 eas25150 checking the clutch housing 1. Check: • clutch housing dogs damage/pitting/wear → deburr the clutch housing dogs or replace the clutch housing. Tip pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: • bearing damage/wear → replace the bearing and...

  • Page 353: Clutch

    Clutch 5-52 eas25250 installing the clutch 1. Install: • clutch housing “1” tip • make sure that the projections “a” in the clutch housing align with the slots “b” in the oil pump drive sprocket. • make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • insert a c...

  • Page 354: Clutch

    Clutch 5-53 • clutch plates (with the recommended lubricant) 7. Install: • friction plates • clutch plates tip first, install a friction plate and then alternate be- tween a clutch plate and a friction plate. 8. Install: • clutch spring bolts tip tighten the clutch spring bolts in stages and in a cr...

  • Page 355: Clutch

    Clutch 5-54 eas25290 checking the clutch master cylinder 1. Check: • clutch master cylinder body cracks/damage → replace the clutch mas- ter cylinder. • clutch fluid delivery passage (clutch master cylinder body) obstruction → blow out with compressed air. 2. Check: • clutch master cylinder • clutch...

  • Page 356: Clutch

    Clutch 5-55 3. Fill: • clutch master cylinder reservoir (with the specified amount of the specified brake and clutch fluid) warning ewa1mc1009 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill ...

  • Page 357: Clutch

    Clutch 5-56 eas25350 installing the clutch release cylinder 1. Check: • copper washers “1” • clutch hose “2” • clutch hose union bolt “3” warning ewa1mc1027 proper clutch hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-47. Notice ec3p61035 when instal...

  • Page 358: Shift Shaft

    Shift shaft 5-57 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-43. 1 oil baffle plate 1 1 2 shift arm 1 3 circlip 1 4 shift shaft 1 5 shift shaft spring 1 6 spacer 1 7 stopper lever spring 1 8 stopper...

  • Page 359: Shift Shaft

    Shift shaft 5-58 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • shift lever sp...

  • Page 360: Shift Shaft

    Shift shaft 5-59 c. Tighten both locknuts to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Shift rod locknut 7 nm (0.7 m·kg, 5.1 ft·lb) 1 2 c d a b.

  • Page 361: Oil Pump

    Oil pump 5-60 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-24. Throttle bodies refer to “throttle bodies” on page 7-4. Exhaust pipe assembly refer to “engine removal” on page 5-3. Sidestand r...

  • Page 362: Oil Pump

    Oil pump 5-61 11 relief valve assembly 1 12 o 2 sensor lead bracket 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks 12.

  • Page 363: Oil Pump

    Oil pump 5-62 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump driven sprocket 1 8 oil pump housing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 364: Oil Pump

    Oil pump 5-63 eas24960 checking the oil pump 1. Check: • oil pump driven sprocket • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-ho...

  • Page 365: Oil Pump

    Oil pump 5-64 1. Check: • oil delivery pipes damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer ...

  • Page 366: Middle Gear

    Middle gear 5-65 eas25710 middle gear removing the middle gear order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Oil pan/oil pump refer to “oil pump” on page 5-60. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper ...

  • Page 367: Middle Gear

    Middle gear 5-66 14 middle drive shaft assembly 1 15 spacer 1 16 middle driven gear 1 17 bearing retainer 1 18 bearing 1 19 middle drive pinion gear shim refer to “aligning the middle gear” on page 5-74. 20 bearing 1 for installation, reverse the removal proce- dure. Removing the middle gear order j...

  • Page 368: Middle Gear

    Middle gear 5-67 disassembling the middle drive shaft assembly order job/parts to remove q’ty remarks 1 spring retainer 2 2 spring seat 1 3 damper spring 1 4 damper driven cam 1 5 damper drive cam 1 6 middle drive shaft 1 for assembly, reverse the disassembly pro- cedure..

  • Page 369: Middle Gear

    Middle gear 5-68 disassembling the middle driven shaft assembly order job/parts to remove q’ty remarks 1 oil seal 1 2 middle driven pinion gear nut 1 3 middle driven shaft 1 4 middle driven pinion gear 1 5 bearing retainer 1 6 bearing 1 7 middle driven shaft bearing housing 1 for assembly, reverse t...

  • Page 370: Middle Gear

    Middle gear 5-69 eas25730 removing the middle drive shaft assembly 1. Remove: • middle drive pinion gear nut “1” • lock washer “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Straighten the lock washer tab. B. Loosen the middle drive pinion gear nut. Tip while holding the middle drive shaft...

  • Page 371: Middle Gear

    Middle gear 5-70 c. Remove the middle driven pinion gear nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Remove: • bearing retainer ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the middle driven shaft bearing housing onto the lower crankcase. B. Straighten the t...

  • Page 372: Middle Gear

    Middle gear 5-71 c. Tighten the bearing retainer to specification. D. Lock the threads with a drift punch. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Tighten: • middle driven pinion gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle driven pinion gear nut to s...

  • Page 373: Middle Gear

    Middle gear 5-72 • middle drive pinion gear nut “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle drive pinion gear nut to specification. Tip • lubricate the nut threads with engine oil. • install the middle drive pinion gear nut with its large inner diameter side facing in...

  • Page 374: Middle Gear

    Middle gear 5-73 eas25880 measuring the middle gear backlash 1. Measure: • middle gear backlash out of specification → refer to “adjusting the middle gear backlash” on page 5-73. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the middle drive shaft “1”. B. Install the gear lash measuremen...

  • Page 375: Middle Gear

    Middle gear 5-74 tip while carefully tightening the middle driven shaft bearing housing bolts in stages and in a criss- cross pattern, turn the middle driven shaft back and forth until the dial gauge reads 0.10–0.20 mm (0.0039–0.0079 in). 6. Measure: • crankcase-to-middle-driven-shaft-bearing- housi...

  • Page 376: Middle Gear

    Middle gear 5-75 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the middle gears with the appropri- ate shim(s) that has had its respective thick- ness calculated from information marked on the crankcase and middle driven pinion gear. B. To find middle drive pinion gear shim thick- ne...

  • Page 377: Middle Gear

    Middle gear 5-76 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ middle driven pinion gear shim thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50

  • Page 378: Crankcase

    Crankcase 5-77 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Cylinder head refer to “cylinder head” on page 5-20. Starter clutch refer to “generator and starter clutch” on page 5-31. Pickup rotor refer to “pickup roto...

  • Page 379: Crankcase

    Crankcase 5-78 9 lower crankcase 1 10 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 1st 20 n...

  • Page 380: Crankcase

    Crankcase 5-79 removing the oil baffle plate and bearings order job/parts to remove q’ty remarks connecting rod refer to “connecting rods and pis- tons” on page 5-85. Crankshaft/crankshaft journal bearings refer to “crankshaft” on page 5-93. Transmission refer to “transmission” on page 5-97. 1 oil b...

  • Page 381: Crankcase

    Crankcase 5-80 13 lower crankcase 1 for installation, reverse the removal proce- dure. Removing the oil baffle plate and bearings order job/parts to remove q’ty remarks 10 ls ls 2 lt lt lt lt lt lt lt lt 4 8 3 lt 5 7 6 12 1 9 13 t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ...

  • Page 382: Crankcase

    Crankcase 5-81 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts tip • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerica...

  • Page 383: Crankcase

    Crankcase 5-82 eas25680 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) 2. Apply: • sealant (onto the crankcase mating surfaces and oil baffle plate 2) tip do not allow any sealant to come into contact with the oil gallery or crankshaft journal b...

  • Page 384: Crankcase

    Crankcase 5-83 tip • lubricate the bolts “1”–“10” thread and wash- ers with engine oil. • lubricate the bolts “11”–“31” thread part and mating surface with engine oil. • apply locking agent (loctite®) to the threads of the bolt “16”. • finger tighten the crankcase bolts. • m9 × 115 mm bolts: “1”–“10...

  • Page 385: Crankcase

    Crankcase 5-84 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Tighten: • crankcase bolts “11”–“31” tip tighten the crankcase bolts in the proper tight- ening sequence as shown. T r . . Crankcase bolt “11”, “12” 24 nm (2.4 m·kg, 17 ft·lb) crankcase bolt “13”, “14” 12 nm (1.2 m·kg, 8.7 ft·lb) cr...

  • Page 386: Connecting Rods and Pistons

    Connecting rods and pistons 5-85 et3p61027 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-77. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston 4...

  • Page 387: Connecting Rods and Pistons

    Connecting rods and pistons 5-86 eas26030 removing the connecting rods and pistons the following procedure applies to all of the con- necting rods and pistons. 1. Remove: • connecting rod cap “1” tip identify the position of each connecting rod so that it can be reinstalled in its original place. 2....

  • Page 388: Connecting Rods and Pistons

    Connecting rods and pistons 5-87 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “c” with the cylinder bore gauge. Tip measure cylinder bore “c” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. B. If out of ...

  • Page 389: Connecting Rods and Pistons

    Connecting rods and pistons 5-88 2. Install: • piston ring (into the cylinder) tip level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oi...

  • Page 390: Connecting Rods and Pistons

    Connecting rods and pistons 5-89 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Et3p61028 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bear...

  • Page 391: Connecting Rods and Pistons

    Connecting rods and pistons 5-90 e. Tighten the connecting rod nuts. Refer to “installing the connecting rods and pistons” on page 5-90. F. Remove the connecting rod and big end bearings. Refer to “removing the connecting rods and pistons” on page 5-86. G. Measure the compressed plastigauge® width “...

  • Page 392: Connecting Rods and Pistons

    Connecting rods and pistons 5-91 tip • apply engine oil onto the piston pin. • make sure that the “y” mark “a” on the connect- ing rod is facing to the left when the punch mark “b” on the piston is pointing up. Refer to the illustration. • when installing a piston pin clips so that the clip ends are...

  • Page 393: Connecting Rods and Pistons

    Connecting rods and pistons 5-92 8. Tighten: • connecting rod nuts “1” warning ew3p61019 replace the connecting rod bolts and nuts with new ones. Tip tighten the connecting rod nuts using the follow- ing procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the connecting rod nuts ...

  • Page 394: Crankshaft

    Crankshaft 5-93 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-77. Front balancer weight refer to “balancers” on page 5-106. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-85. 1 crankshaft ...

  • Page 395: Crankshaft

    Crankshaft 5-94 eas26040 removing the crankshaft journal bearings 1. Remove: • crankshaft journal upper bearings (from the upper crankcase) • crankshaft journal lower bearings (from the lower crankcase) tip identify the position of each crankshaft journal bearing so that it can be reinstalled in its...

  • Page 396: Crankshaft

    Crankshaft 5-95 e. Install the crankshaft journal lower bearings “3” into the lower crankcase and assemble the crankcase halves. Tip • align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d” in the lower crankcase. • do not move the crankshaft until the clearance me...

  • Page 397: Crankshaft

    Crankshaft 5-96 tip • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • be sure to install each crankshaft journal bear- ing in its original place..

  • Page 398: Transmission

    Transmission 5-97 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-77. Stopper lever refer to “shift shaft” on page 5-57. 1 drive axle assembly 1 2 bearing 1 3 washer 1 4 be...

  • Page 399: Transmission

    Transmission 5-98 13 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 400: Transmission

    Transmission 5-99 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 5th pinion gear 1 5 toothed spacer 1 6 toothed washer 2 7 circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 collar 1 11 main...

  • Page 401: Transmission

    Transmission 5-100 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 middle drive gear 1 2 washer 1 3 2nd wheel gear 1 4 collar 1 5 washer 1 6 5th wheel gear 1 7 circlip 2 8 toothed washer 2 9 3rd wheel gear 1 10 toothed spacer 1 11 toothed lock washer 1 12 toothed lock ...

  • Page 402: Transmission

    Transmission 5-101 18 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 e m m m m m m 5 new new.

  • Page 403: Transmission

    Transmission 5-102 eas26250 removing the transmission 1. Remove: • main axle assembly tip remove the main axle assembly with the slide hammer bolts “1” and weight. Eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • s...

  • Page 404: Transmission

    Transmission 5-103 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replac...

  • Page 405: Transmission

    Transmission 5-104 • be sure to align the projection on the toothed lock washer that is between the alignment marks “b” with the alignment mark “c” on the re- tainer. 3. Install: • 2nd pinion gear “1” tip make sure that the side of the 2nd pinion gear with the groove “d” is facing inward as shown in...

  • Page 406: Transmission

    Transmission 5-105 4. Install: • drive axle assembly tip • the bearing pin “1” must face towards the rear of the upper crankcase. • make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • transmission rough movement → repair. Tip oil each gear, shaft, and be...

  • Page 407: Balancers

    Balancers 5-106 et3p61031 balancers removing the front balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-77. 1 front balancer lever 1 2 front balancer shaft 1 3 washer 2 4 bearing 2 5 front balancer gear 1 6 damper 4 7 front balancer weight 1 for inst...

  • Page 408: Balancers

    Balancers 5-107 removing the rear balancer order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup rotor” on page 5-36. Clutch cover refer to “clutch” on page 5-43. 1 rear balancer cover 1 2 rear balancer cover gasket 1 3 rea...

  • Page 409: Balancers

    Balancers 5-108 eas26120 checking the balancers 1. Check: • front balancer gear damage/wear → replace the front balancer gear and crankshaft. • rear balancer gear damage/wear → replace the rear balancer gear and clutch housing. 2. Check: • balancer shafts cracks/damage/wear → replace the balanc- er ...

  • Page 410: Balancers

    Balancers 5-109 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • front balancer lever “1” • front balancer lever bolt “2” tip • apply locking agent (loctite®) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • front balancer shaft “...

  • Page 411: Balancers

    Balancers 5-110 2. Align: • “t” mark on the pickup rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark “a” on the pick- up rotor with the crankcase ma...

  • Page 412: Balancers

    Balancers 5-111 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • rear balancer lever “1” • rear balancer lever bolt “2” tip • apply locking agent (loctite®) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • rear balancer shaft “1” ...

  • Page 413: Cooling System

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

  • Page 414: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-27. Side cowlings/battery refer to “general chassis” on page 4-1. 1 coolant reservoir breather hose 1 2 coolant reservoir cap 1 3 coolant reservoir 1 4...

  • Page 415: Radiator

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

  • Page 416: Radiator

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

  • Page 417: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-24. Coolant drain. Refer to “changing the coolant” on page 3-27. Radiator refer to “radiator” on page 6-1. Exhaust pipe assembly refer to “...

  • Page 418: Oil Cooler

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

  • Page 419: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-27. Left side cowling/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 radiator cap 1 2 coola...

  • Page 420: Thermostat

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

  • Page 421: Thermostat

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

  • Page 422: Thermostat

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

  • Page 423: Water Pump

    Water pump 6-10 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-27. 1 water pump breather hose 1 disconnect. 2 radiator outlet hose 1 disconnect. 3 w...

  • Page 424: Water Pump

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

  • Page 425: Water Pump

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

  • Page 426: Water Pump

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

  • Page 427: Water Pump

    Water pump 6-14 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-27. 3. Check: • cooling system leaks → repair or replace any faulty part. 4. Measure: • radiator cap opening pressure below the specified pressure → replace th...

  • Page 428: Water Pump

    Water pump 6-15.

  • Page 429: Fuel System

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

  • Page 430: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. 1 fuel tank panel 1 2 fuel sender coupler 1 disconnect. 3 fuel pump coupler 1 disconnect. 4 fuel tank breather hose 1 5 fuel tank overflow hose 1 6 fuel h...

  • Page 431: Fuel Tank

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

  • Page 432: Fuel Tank

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

  • Page 433: Throttle Bodies

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

  • Page 434: Throttle Bodies

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

  • Page 435: Throttle Bodies

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

  • Page 436: Throttle Bodies

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

  • Page 437: Throttle Bodies

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

  • Page 438: Throttle Bodies

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

  • Page 439: Throttle Bodies

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

  • Page 440: Throttle Bodies

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

  • Page 441: Throttle Bodies

    Throttle bodies 7-12 2. Adjust: • accelerator position sensor angle tip before adjusting the accelerator position sensor, the throttle bodies must be removed. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporary tighten the accelerator position sensor bolts. B. Check that the throttle valv...

  • Page 442: Air Induction System

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

  • Page 443: Air Induction System

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

  • Page 444: Air Induction System

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

  • Page 445: Air Induction System

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

  • Page 446: Air Induction System

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

  • Page 447: Electrical System

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

  • Page 448

    [a] checking the cruise control system indicator light ..................................................................................................... 8-91 [b-1] diagnosis using the fault codes ..................................... 8-91 [b-2] diagnosis using the malfunction history codes.... 8...

  • Page 449

    Grip warmer system ........................................................................... 8-161 circuit diagram .............................................................................. 8-161 troubleshooting .......................................................................... 8-163 e...

  • Page 450: Ignition System

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

  • Page 451: Ignition System

    Ignition system 8-2 2. Main switch 5. Joint coupler 9. Ignition fuse 16.Fuel injection system fuse 25.Main fuse 26.Battery 27.Engine ground 32.Relay unit 35.Sidestand switch 41.Right handlebar switch 43.Start/engine stop switch 45.Gear position switch 90.Crankshaft position sensor 94.Lean angle sens...

  • Page 452: Ignition System

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

  • Page 453: Ignition System

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

  • Page 454: Ignition System

    Ignition system 8-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the start/engine stop switch. Refer to “checking the switches” on page 8-169. • the start/engine stop switch is faulty. • replace the right handlebar switch. 9. Check the gear position switch. Refer to “checking...

  • Page 455: Ignition System

    Ignition system 8-6.

  • Page 456: Electric Starting System

    Electric starting system 8-7 eas27160 electric starting system eas27170 circuit diagram pull p on off a br /l r r /w r /w b r /w r /bw /l b /y g /y g /w w /l b /y b /y w /l l /gb b b /w l /w l /w r /b w /l b /y sb b /r b /r g /w l /g l /w r /w b b b b b b b r r b /wb /w b /w b /w sb br /l r /w rr r ...

  • Page 457: Electric Starting System

    Electric starting system 8-8 2. Main switch 5. Joint coupler 9. Ignition fuse 25.Main fuse 26.Battery 27.Engine ground 29.Starter relay 30.Starter motor 32.Relay unit 33.Starting circuit cut-off relay 35.Sidestand switch 36.Clutch switch 41.Right handlebar switch 43.Start/engine stop switch 45.Gear ...

  • Page 458: Electric Starting System

    Electric starting system 8-9 eas27180 starting circuit cut-off system operation if the main switch is turned to “on” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutral (th...

  • Page 459: Electric Starting System

    Electric starting system 8-10 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar 5. Throttle bodies ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ...

  • Page 460: Electric Starting System

    Electric starting system 8-11 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-169. Replace the main switch/immobilizer unit. 9. Check the gear position switch. Refer to “checking the switches” on page 8-169. Replace the...

  • Page 461: Electric Starting System

    Electric starting system 8-12.

  • Page 462: Charging System

    Charging system 8-13 eas27200 charging system eas27210 circuit diagram a r b ww w b b b b b r r rr r a b a b b /g b /g b r r w ww b r (b) (gy) 3 4 25 26 27.

  • Page 463: Charging System

    Charging system 8-14 3. Ac magneto 4. Rectifier/regulator 25.Main fuse 26.Battery 27.Engine ground a. Wire harness b. Negative battery sub-wire harness.

  • Page 464: Charging System

    Charging system 8-15 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page ...

  • Page 465: Charging System

    Charging system 8-16.

  • Page 466: Lighting System

    Lighting system 8-17 eas27240 lighting system eas27250 circuit diagram pass p on off a br /l r l /r r r r /y r /w g /l y /w b l l /r y b l /r l b bb g b b b b b r r l /r l /r l /r l /r rr l /r g y g y b /w b /w b /w b /lb b b b /wb /l b /w b /w r /w br /w r /w y g /l r /y l /by b /w b /w y /w g /l l...

  • Page 467: Lighting System

    Lighting system 8-18 2. Main switch 5. Joint coupler 7. Hazard lighting fuse 9. Ignition fuse 16.Fuel injection system fuse 17.Backup fuse 19.Headlight fuse 21.Headlight relay (on/off) 25.Main fuse 26.Battery 27.Engine ground 48.Left handlebar switch 51.Dimmer/pass switch 56.Headlight relay (dimmer)...

  • Page 468: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tan...

  • Page 469: Lighting System

    Lighting system 8-20 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-17. Properly connect or replace the wire har- ness. Replace the ecu, meter assembly, or headlight assembly. Refer to “re- placing the ecu (engine control unit)” on page 8-174..

  • Page 470: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram pull press p on off a (b) (b) br /r br /l r l /r r br /r p br b y l ch dg y br lg /b g /w g /y lg /b b g /w g /y br b g /y g /w g /w g /y l /rb r/ y br /g sb /w sb b b b b b r r br l /r l /r l /r b /w br /wb r/ w br /bb r/ b b ...

  • Page 471: Signaling System

    Signaling system 8-22 2. Main switch 5. Joint coupler 7. Hazard lighting fuse 8. Abs ecu fuse 9. Ignition fuse 11.Signaling system fuse 16.Fuel injection system fuse 17.Backup fuse 20.Horn 25.Main fuse 26.Battery 27.Engine ground 32.Relay unit 37.Brake light fuse 38.Rear brake light switch 40.Front ...

  • Page 472: Signaling System

    Signaling system 8-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. • the fuel meter fails to come on. • the speedometer fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Sid...

  • Page 473: Signaling System

    Signaling system 8-24 checking the signaling system the horn fails to sound. Ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the horn switch. Refer to “checking the switches” on page 8-169. • the horn switch is faulty. •...

  • Page 474: Signaling System

    Signaling system 8-25 the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the rear turn signal light bulbs and sockets. Refer to “checking the bulbs and ...

  • Page 475: Signaling System

    Signaling system 8-26 ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ 3. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-21. Properly connect or...

  • Page 476: Signaling System

    Signaling system 8-27 ng → ok ↓ tip replace the wire harness if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white–white) (gray–gray) • between abs ecu coupler and ecu coupler. (blue/yellow–blue/yellow) (white/yellow–white/yellow) • between ecu coupler...

  • Page 477: Signaling System

    Signaling system 8-28.

  • Page 478: Cooling System

    Cooling system 8-29 eas27300 cooling system eas27310 circuit diagram p on off a br /l r l r r br /b y /l l b b b b b r r b /w b /w b /w b /lg /w r /w b /l g /w br /w b /lb /l b /w b /w l b b br /b br /l y /l br /w r /w rr r r g /y r /w g /y r /w r br /l r r b l (b) b l (b) r br /l (b) b l (b) b y /l...

  • Page 479: Cooling System

    Cooling system 8-30 2. Main switch 5. Joint coupler 9. Ignition fuse 12.Right radiator fan motor fuse 13.Left radiator fan motor fuse 16.Fuel injection system fuse 22.Radiator fan motor relay 23.Left radiator fan motor 24.Right radiator fan motor 25.Main fuse 26.Battery 27.Engine ground 28.Cooling s...

  • Page 480: Cooling System

    Cooling system 8-31 eas27320 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, cooling system, fuel ...

  • Page 481: Cooling System

    Cooling system 8-32 ng → ok ↓ 7. Check the entire cooling system wiring. Refer to “circuit diagram” on page 8-29. Properly connect or replace the wire har- ness. Replace the ecu. Refer to “replac- ing the ecu (engine control unit)” on page 8-174..

  • Page 482: Fuel Injection System

    Fuel injection system 8-33 eas27330 fuel injection system eas27340 circuit diagram p on off a pull br /l r r b r r /w y /w g /y r /w r /w r /b b /r bb br /w sb b /r b /r b /w l /g l /g r /ll /y r /b b b b b b r r b /wb /w b /w b /w b /w b /w b /wb b b /w b /lb b b /wb /l b /w b b /w l /b l /r r /l b...

  • Page 483: Fuel Injection System

    Fuel injection system 8-34 2. Main switch 4. Rectifier/regulator 5. Joint coupler 8. Abs ecu fuse 9. Ignition fuse 16.Fuel injection system fuse 17.Backup fuse 21.Headlight relay (on/off) 22.Radiator fan motor relay 25.Main fuse 26.Battery 27.Engine ground 32.Relay unit 33.Starting circuit cut-off r...

  • Page 484: Fuel Injection System

    Fuel injection system 8-35 eas27351 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 485: Fuel Injection System

    Fuel injection system 8-36 eas30580 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on the multi-function meter right disp...

  • Page 486: Fuel Injection System

    Fuel injection system 8-37 eas30610 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “tcs” button “1” and “reset” button “2”, turn the main switch to “on”, and continue to pre...

  • Page 487: Fuel Injection System

    Fuel injection system 8-38 • actuator operation to operate the actuator, set the start/engine stop switch from“ ” to “ ”. 8. Turn the main switch to “off” to cancel the diagnostic mode. Tip information about each diagnostic code number is organized in this manual as follows: • if a diagnostic code n...

  • Page 488: Fuel Injection System

    Fuel injection system 8-39 connecting the yamaha diagnostic tool remove the protective cap, and then connect the yamaha diagnostic tool to the coupler “1”. Tip when the yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from...

  • Page 489: Fuel Injection System

    Fuel injection system 8-40 eas27462 troubleshooting details this section describes the measures per fault code number displayed on the multi-function meter right display. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the c...

  • Page 490: Fuel Injection System

    Fuel injection system 8-41 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between cylinder identifica- tion sensor coupler and ecu coupler. White/black–white/black blue–blue between cylinder identifica- tion sensor coupler and joint coupler. Black/blue–black/blue betw...

  • Page 491: Fuel Injection System

    Fuel injection system 8-42 1 connection of crankshaft po- sition sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the ...

  • Page 492: Fuel Injection System

    Fuel injection system 8-43 fault code no. 13 item intake air pressure sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 03 meter display displays the intake air pressure. Procedure shift the transmission into gear, extend the side...

  • Page 493: Fuel Injection System

    Fuel injection system 8-44 tip if fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. 5 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the current altitude ...

  • Page 494: Fuel Injection System

    Fuel injection system 8-45 1 condition of intake air pres- sure sensor hose. Check the intake air pressure sensor hose condition. Clogged or detached hose → repair or replace the sen- sor hose. Start the engine and let it idle for approximately 5 seconds. Fault code number is not dis- played → servi...

  • Page 495: Fuel Injection System

    Fuel injection system 8-46 13 meter display throttle position sensor signal 2 • 9–23 (fully closed position) • 94–108 (fully open position) procedure • check with throttle valves fully closed. • check with throttle valves fully open. Item probable cause of mal- function and check maintenance job con...

  • Page 496: Fuel Injection System

    Fuel injection system 8-47 6 defective throttle position sensor. Check throttle position sen- sor signal 1. Execute the diagnostic mode. (code no. 01) when the throttle valves are fully closed: a value of 12–21 is indicat- ed. When throttle valves are fully open: a value of 97–106 is indicat- ed. Ch...

  • Page 497: Fuel Injection System

    Fuel injection system 8-48 1 connection of sidestand switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 498: Fuel Injection System

    Fuel injection system 8-49 fault code no. 20 item intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “on”, the intake air pres- sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Fail-safe system able to start engine able to drive ve...

  • Page 499: Fuel Injection System

    Fuel injection system 8-50 2 defective atmospheric pres- sure sensor. Execute the diagnostic mode. (code no. 02) when engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa (757.6 mmhg, 29.8 inhg) 3000 m (9800 ft) abo...

  • Page 500: Fuel Injection System

    Fuel injection system 8-51 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 501: Fuel Injection System

    Fuel injection system 8-52 fault code no. 22 item air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 05 meter display displays the air temperature. Procedure compare the actually measured air temperature with the me...

  • Page 502: Fuel Injection System

    Fuel injection system 8-53 5 defective air temperature sensor. Execute the diagnostic mode. (code no. 05) when engine is cold: displayed temperature is close to the ambient temper- ature. The displayed temperature is not close to the ambient tem- perature. → check the air temperature sensor. Replace...

  • Page 503: Fuel Injection System

    Fuel injection system 8-54 3 wire harness continuity. Open or short circuit → re- place the wire harness. Between atmospheric pres- sure sensor coupler and ecu coupler. Pink–pink between atmospheric pres- sure sensor coupler and joint coupler. Blue–blue black/blue–black/blue between joint coupler an...

  • Page 504: Fuel Injection System

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

  • Page 505: Fuel Injection System

    Fuel injection system 8-56 5 check fuel pressure. Refer to “checking the fuel pressure” on page 7-10. Start the engine, warm it up, and then race it, or execute the diagnostic mode. (code no. 63) fault code number is not dis- played → service is finished. Fault code number is dis- played → go to ite...

  • Page 506: Fuel Injection System

    Fuel injection system 8-57 3 defective lean angle sensor. Execute the diagnostic mode. (code no. 08) replace if defective. Refer to “checking the lean angle sensor” on page 8-183. Turn the main switch to “on”, then to “off”, and then back to “on”. Fault code number is not dis- played → service is fi...

  • Page 507: Fuel Injection System

    Fuel injection system 8-58 4 installed condition of cylin- der-#1 ignition coil. Check for looseness or pinching. Improperly installed ignition coil → reinstall or replace the ignition coil. Start the engine and let it idle for approximately 5 seconds. Fault code number is not dis- played → service ...

  • Page 508: Fuel Injection System

    Fuel injection system 8-59 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 509: Fuel Injection System

    Fuel injection system 8-60 item probable cause of mal- function and check maintenance job confirmation of service completion 1 connection of cylinder-#3 ig- nition coil coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and lock...

  • Page 510: Fuel Injection System

    Fuel injection system 8-61 fault code no. 36 item cylinder-#4 ignition coil: open or short circuit detected in the primary lead of the cylinder-#4 ignition coil. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faul...

  • Page 511: Fuel Injection System

    Fuel injection system 8-62 6 malfunction in ecu. Execute the diagnostic mode. (code no. 33) no spark → replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-174. Fault code no. 39 item injector: open or short circuit detected. Fail-safe system able to start engine (depending ...

  • Page 512: Fuel Injection System

    Fuel injection system 8-63 2 connection of injector #1, #2, #3, and/or injector #4 coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or r...

  • Page 513: Fuel Injection System

    Fuel injection system 8-64 fault code no. 41 item lean angle sensor: open or short circuit detected. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 08 meter display lean angle sensor output voltage • 0.4–1.4 (upright) • 3.7–4.4 (overturned) procedure remove the l...

  • Page 514: Fuel Injection System

    Fuel injection system 8-65 5 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-174. Fault code no. 42 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B neutral switch: open or short circuit is detected. C clutch swi...

  • Page 515: Fuel Injection System

    Fuel injection system 8-66 3 connection of abs ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. Execu...

  • Page 516: Fuel Injection System

    Fuel injection system 8-67 8 delete the fault code. Turn the main switch to “on”, and then rotate the rear wheel by hand. Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (19 mph). The fault code can also be deleted by activating the di- agnostic mode a...

  • Page 517: Fuel Injection System

    Fuel injection system 8-68 2 connection of neutral switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness...

  • Page 518: Fuel Injection System

    Fuel injection system 8-69 6 defective gear position switch (neutral circuit). Check the gear position switch. Refer to “checking the switches” on page 8-169. Execute the diagnostic mode. (code no. 21) when the clutch lever is re- leased: “off” when the clutch lever is squeezed: “on” correct indicat...

  • Page 519: Fuel Injection System

    Fuel injection system 8-70 meter display clutch switch • “on” (when the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted) • “off” (when the clutch lever is squeezed with the transmission in gear and when the sidestand is extended) procedure operate the trans...

  • Page 520: Fuel Injection System

    Fuel injection system 8-71 4 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 521: Fuel Injection System

    Fuel injection system 8-72 9 delete the fault code. Turn the main switch to “on”, and then rotate the rear wheel by hand. Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (19 mph). The fault code can also be delete by activating the diag- nostic mode an...

  • Page 522: Fuel Injection System

    Fuel injection system 8-73 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ne...

  • Page 523: Fuel Injection System

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

  • Page 524: Fuel Injection System

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

  • Page 525: Fuel Injection System

    Fuel injection system 8-76 7 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-174. Fault code no. 46 item charging voltage is abnormal. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item ...

  • Page 526: Fuel Injection System

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

  • Page 527: Fuel Injection System

    Fuel injection system 8-78 5 accelerator position sensor resistance. Measure the accelerator po- sition sensor resistance. Black/blue–blue refer to “checking the accelerator position sensor” on page 8-188. Turn the main switch to “on”. Fault code number is not dis- played → service is finished. Faul...

  • Page 528: Fuel Injection System

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

  • Page 529: Fuel Injection System

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

  • Page 530: Fuel Injection System

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

  • Page 531: Fuel Injection System

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

  • Page 532: Fuel Injection System

    Fuel injection system 8-83 4 defective meter assembly. Replace the meter assembly. Turn the main switch to “on”. Fault code number is not dis- played → service is finished. Fault code number is dis- played → go to item 5. 5 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine con...

  • Page 533: Fuel Injection System

    Fuel injection system 8-84.

  • Page 534: Cruise Control System

    Cruise control system 8-85 eas1mc1010 cruise control system eas1mc1011 circuit diagram pull pull res set p on off a press (b) (b) br /l r r /w r lg /l y /w g b y /w y /b y /w y /b y /w y /b br y /w y /b y /b y /b b b b b b r r b /w b /w b /w b /lb b /wb /l b /w b /w r /w br /w y /b o /wg /lb r/ l b ...

  • Page 535: Cruise Control System

    Cruise control system 8-86 2. Main switch 5. Joint coupler 9. Ignition fuse 11.Signaling system fuse 16.Fuel injection system fuse 17.Backup fuse 25.Main fuse 26.Battery 27.Engine ground 31.Cruise control system fuse 36.Clutch switch 37.Brake light fuse 38.Rear brake light switch 39.Grip cancel swit...

  • Page 536: Cruise Control System

    Cruise control system 8-87 eas1mc1012 cruise control circuit operation 21 20 19 18 17 16 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4.

  • Page 537: Cruise Control System

    Cruise control system 8-88 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10.Cruise control power switch 11.Cruise control setting switch 12.Clutch switch 13.Front brake l...

  • Page 538: Cruise Control System

    Cruise control system 8-89 eas1mc1014 basic instructions for troubleshooting warning ewa1mc1001 • perform the troubleshooting [a] → [b] → [c] in order. Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted. • use sufficiently charg...

  • Page 539: Cruise Control System

    Cruise control system 8-90 eas1mc1015 basic process for troubleshooting [a] [c-2] [b-4] [b-2] [b-1] [b-3] • • • [c-1] • comes on fails to come on flashes no no push the cruise control power switch, and check the cruise control system indicator light. Fault code number is not displayed. Explain the c...

  • Page 540: Cruise Control System

    Cruise control system 8-91 warning ewa1mc1005 when maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[c-2] final check” on page 8-101.) eas1mc1016 [a] checking the c...

  • Page 541: Cruise Control System

    Cruise control system 8-92 item probable cause of mal- function and check maintenance job confirmation of service completion 1 locate the malfunction. Execute the diagnostic mode. (code 82, 83) when the front brake is ap- plied: “on” when the front brake is not applied: “off” malfunction → go to ite...

  • Page 542: Cruise Control System

    Cruise control system 8-93 6 check the fuse. (signaling system fuse, brake light fuse) abnormality → replace the fuse. (signaling system fuse, brake light fuse) turn the main switch to “on”. Operate the brake lever. Fault code number is not dis- played → service is finished. Fault code number is dis...

  • Page 543: Cruise Control System

    Cruise control system 8-94 meter display “on” (when the brakes are applied) “off” (when the brakes are not applied) procedure operate the brake pedal. Item probable cause of mal- function and check maintenance job confirmation of service completion 1 locate the malfunction. Execute the diagnostic mo...

  • Page 544: Cruise Control System

    Cruise control system 8-95 6 check the fuse. (signaling system fuse, brake light fuse) abnormality → replace the fuse. (signaling system fuse, brake light fuse) turn the main switch to “on”. Operate the brake pedal. Fault code number is not dis- played → service is finished. Fault code number is dis...

  • Page 545: Cruise Control System

    Cruise control system 8-96 fault code no. 91 item a cruise control setting switch “res+”: open or short circuit is detected. B cruise control setting switch “set–”: open or short circuit is de- tected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 80, 81 meter displ...

  • Page 546: Cruise Control System

    Cruise control system 8-97 4 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. Turn the ...

  • Page 547: Cruise Control System

    Cruise control system 8-98 8 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-174. Fault code no. 91 item a cruise control setting switch “res+”: open or short circuit is de- tected. B cruise control setting switch “set–”: open or short circuit is det...

  • Page 548: Cruise Control System

    Cruise control system 8-99 3 connection of main switch coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected → connect the coupler secure- ly or replace the wire har- ness. T...

  • Page 549: Cruise Control System

    Cruise control system 8-100 eas1mc1018 [b-2] diagnosis using the malfunction history codes execute the diagnostic mode (code no. 61) to check the malfunction history. • refer to “diagnostic mode” on page 8-37. • malfunction history is displayed in the multi-function meter unit right display. [b-3] •...

  • Page 550: Cruise Control System

    Cruise control system 8-101 eas1mc1020 [b-4] malfunction history is not displayed use the yamaha diagnostic tool to check whether automatic deactivation history for the cruise control system exists. 1. There is automatic deactivation history for the cruise control system. • explain the conditions fo...

  • Page 551: Cruise Control System

    Cruise control system 8-102.

  • Page 552: Fuel Pump System

    Fuel pump system 8-103 eas27550 fuel pump system eas27560 circuit diagram p on off a br /l r r r /w r /b r /b br /w r /l l /y b b b b b r r b /w b /w b /w bb b r /l r /w l /y br /w b /w b /w br /l br /w br /w r /w r /w rr r r br /l r r r /b b r /w w /l a b a r br /l (b) o /gg /y l/ yl /b gy /ry /w b...

  • Page 553: Fuel Pump System

    Fuel pump system 8-104 2. Main switch 5. Joint coupler 9. Ignition fuse 16.Fuel injection system fuse 25.Main fuse 26.Battery 27.Engine ground 32.Relay unit 34.Fuel pump relay 41.Right handlebar switch 43.Start/engine stop switch 88.Fuel pump 102.Ecu (engine control unit) a. Wire harness b. Negative...

  • Page 554: Fuel Pump System

    Fuel pump system 8-105 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (m...

  • Page 555: Fuel Pump System

    Fuel pump system 8-106.

  • Page 556: Windshield Drive System

    Windshield drive system 8-107 eas27610 windshield drive system eas27620 circuit diagram menu c c p on off a br /g br r br /l b p /w br br br /g br br r r b /w b /lb b /wb /l b /w b /w bp /b br /g br r r /g r /g r /g p /b p /w w /g w /r w /l w /lb /w w /rw /g br /l r /g br /l r b b b b b r r rr r r /...

  • Page 557: Windshield Drive System

    Windshield drive system 8-108 2. Main switch 5. Joint coupler 6. Windshield drive system fuse 9. Ignition fuse 11.Signaling system fuse 17.Backup fuse 25.Main fuse 26.Battery 27.Engine ground 48.Left handlebar switch 53.Menu switch 54.Select switch 69.Windshield drive unit 70.Windshield drive unit r...

  • Page 558: Windshield Drive System

    Windshield drive system 8-109 eas27630 troubleshooting the windshield fails to move. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check that there are no rocks or o...

  • Page 559: Windshield Drive System

    Windshield drive system 8-110 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the windshield drive unit re- lay (up). Refer to “checking the re- lays” on page 8-177. Replace the windshield drive unit relay (up). 9. Check the windshield drive unit re- lay (down). Refer to “checking the re- lays” on ...

  • Page 560: Accessory Box System

    Accessory box system 8-111 et3p61009 accessory box system et3p61010 circuit diagram p on off b b a br /l r br b b b b b r r b b b br br br bb br /l rr a b c a a b b b /g b /g b bb r b br r br /l r r r br /l br b (b) bb b b b /l b 2 11 25 26 27 67 5.

  • Page 561: Accessory Box System

    Accessory box system 8-112 2. Main switch 5. Joint coupler 11.Signaling system fuse 25.Main fuse 26.Battery 27.Engine ground 67.Accessory box solenoid a. Wire harness b. Negative battery sub-wire harness c. Accessory box solenoid sub-lead.

  • Page 562: Accessory Box System

    Accessory box system 8-113 et3p61012 troubleshooting the accessory box fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Left side cowling 3. Fuel tank 4. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and s...

  • Page 563: Accessory Box System

    Accessory box system 8-114.

  • Page 564: Immobilizer System

    Immobilizer system 8-115 eas27640 immobilizer system eas27650 circuit diagram p on off a (b) (b) br /l r b /w y /l r /w g /b b b lg r /g r b b b b b r /g r /w r r b /w b /w b /w b /w b /w b /w b /lb b /wb /l b /w b /w y /ly /l r /w y /l br /w r /g r /g r /g g /b b /w b /w br /l br /w r /g r /g r /w ...

  • Page 565: Immobilizer System

    Immobilizer system 8-116 1. Immobilizer unit 2. Main switch 5. Joint coupler 9. Ignition fuse 16.Fuel injection system fuse 17.Backup fuse 25.Main fuse 26.Battery 27.Engine ground 72.Meter assembly 73.Multi-function meter 74.Immobilizer system indicator light 96.Yamaha diagnostic tool connector 102....

  • Page 566: Immobilizer System

    Immobilizer system 8-117 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 567: Immobilizer System

    Immobilizer system 8-118 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with...

  • Page 568: Immobilizer System

    Immobilizer system 8-119 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Tip do not start the engine with a standar...

  • Page 569: Immobilizer System

    Immobilizer system 8-120 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost st...

  • Page 570: Immobilizer System

    Immobilizer system 8-121 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, fuel injection sys- tem, and backup) refer to “checking the fus-...

  • Page 571: Immobilizer System

    Immobilizer system 8-122 eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number is indicated in the multi-function meter right display and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code...

  • Page 572: Immobilizer System

    Immobilizer system 8-123 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 55 immobilizer unit key code registra- tion malfunction. Same stand...

  • Page 573: Immobilizer System

    Immobilizer system 8-124.

  • Page 574: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 eas28790 abs (anti-lock brake system) eas27730 circuit diagram pull p on off a a press (b) (b) br /l r r /w r /w br r r y br b lg /b g /w g /y lg /b b g /w g /y g /w g /y g /y g /w g /w g /y b r /wr /bw /l w /l b /y b /y w /l w /l l /w l /w r /b w /l b /y l /w l /w...

  • Page 575: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 2. Main switch 5. Joint coupler 8. Abs ecu fuse 9. Ignition fuse 11.Signaling system fuse 14.Abs motor fuse 15.Abs solenoid fuse 16.Fuel injection system fuse 17.Backup fuse 25.Main fuse 26.Battery 27.Engine ground 29.Starter relay 32.Relay unit 33.Starting circuit...

  • Page 576: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 eas27740 abs components chart 6 4,5 7 11 10 12,13 14 15 1 11 2 3 6 a a 7 8 9 1. Abs test coupler 2. Abs warning light 3. Abs ecu fuse 4. Abs solenoid fuse 5. Abs motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9. Rear wheel sensor ...

  • Page 577: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128.

  • Page 578: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 eas27750 abs coupler location chart b/w l/r l/b sb w b w gy gy w w gy r/w w/l w/g w/r g/w l/r l/b g/b g/r r/g r/g r/g ch br/b br/w br/b br/w b/r l/w y/w b/y p/w p/b br/y w/y w/b b/w b/w p dg sb/w y w w b g/w l/w w/y l/b b/w gy w g/r l/r y w/l g/y sb br/w b/w b/g r ...

  • Page 579: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 1. Meter assembly coupler 2. Abs test coupler 3. Rear wheel sensor coupler 4. Abs ecu coupler 5. Front wheel sensor coupler.

  • Page 580: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler connection...

  • Page 581: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 tip the abs performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned to “on”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even sligh...

  • Page 582: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 eas27810 basic process for troubleshooting [a] [a-4] [b-1] [c-3] [a-1] [a-2] [a-3] [b-3] [b-2] • • • • • • • • • • • • • • • • • • • [c-1] [c-2] comes on fails to come on yes yes yes no no flashes yes yes cannot delete ok no no turn the main switch to “on”, and che...

  • Page 583: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 warning ewa1mc1004 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[c-3] final check” on page 8-160.) eas27830 [a] checking the abs warning l...

  • Page 584: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 • if the t/c terminal is not short-circuited to the ground, check the internal circuit of the meter assem- bly. Turn the main switch to “off”. Disconnect the abs ecu coupler and check that the abs warning light comes on when the main switch is turned to “on”. If th...

  • Page 585: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 eas1mc1005 [b-1] a fault code number is not displayed in the multi-function meter right display 1. The abs warning light remains on. A malfunction is detected. [b-2] 2. The abs warning light flashes every 0.5 second for more than 6 seconds. A malfunction is not det...

  • Page 586: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 • if the abs warning light does not come on, the abs ecu is defective. Replace the hydraulic unit assembly. 7. The hydraulic unit assembly is defective. Eas1mc1029 [b-3] diagnosis using the fault codes connect the test coupler adapter to the abs test coupler, and t...

  • Page 587: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138 abs_22 start switch signal is not received prop- erly (start switch circuit or start switch monitor circuit). • wire harness • connection of the relay unit coupler and abs ecu coupler. Abs_23 brake light signal is not received prop- erly when main switch is turned ...

  • Page 588: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the centerstand). Tip fault code num...

  • Page 589: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 tip with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). Fault code no. Abs_11 abs_25 symptom front wheel sensor signal is not received prop- erly. Orde...

  • Page 590: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_13 abs_26 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job 1 installed condition of wheel sensor. Check for looseness....

  • Page 591: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 tip vehicle possibly ridden on uneven roads. 5 hydraulic unit assembly internal mal- function. Replace the hydraulic unit assembly. Fault code no. Abs_15 symptom no continuity in the front wheel sensor circuit. Order item/components and probable cause check or main...

  • Page 592: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-143 3 defective wheel sensor. If the above items were performed and no malfunc- tions were found, connect the abs ecu coupler and front wheel sensor coupler, and then delete the fault codes. If fault code number “abs_15” could not be deleted, the front wheel sensor is ...

  • Page 593: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-144 2 wire harness continuity. • check for continuity between the gray terminal “1” and the gray terminal “3” and between the white terminal “2” and the white terminal “4”. • if there is no continuity, the wire harness is defec- tive. Replace the wire harness. • check ...

  • Page 594: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-145 2 foreign material inside sensor hous- ing. Check the interior of the sensor housing and the surface of the sensor rotor for foreign material, such as metal particles. Clean the sensor housing and sensor rotor if necessary. Refer to “maintenance of the front wheel ...

  • Page 595: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-146 2 connections • starter relay coupler • abs ecu coupler • right handlebar switch coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, replace the wire harness and connect the cou...

  • Page 596: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-147 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and brake light relay coupler. (yellow–yellow) • between rear brake light switch coupler and brake switch relay coupler. (green/white–green/white) • b...

  • Page 597: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-148 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and brake light relay coupler. (yellow–yellow) • between rear brake light switch coupler and brake switch relay coupler. (green/white–green/white) • b...

  • Page 598: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-149 fault code no. Abs_32 symptom hydraulic unit solenoid relay is short-circuited. Order item/components and probable cause check or maintenance job 1 short circuit in solenoid relay. Replace the hydraulic unit assembly. 2 hydraulic unit assembly internal mal- functio...

  • Page 599: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-150 fault code no. Abs_41 symptom front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the abs ecu to release the hydraulic pressure (when the battery voltage is normal) order item/components and probable caus...

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

    Abs (anti-lock brake system) 8-151 warning ewa3p6d006 the front brakes will not function properly if the connections are reversed. • brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder • brake pipe/upper joint assembly “3” and brake pipe “4” outlet: t...

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

    Abs (anti-lock brake system) 8-152 warning ewa3p6d007 the rear brake will not function properly if the connections are reversed. • brake pipe/middle joint assembly “1” and brake hose “2” inlet: from the rear brake master cyl- inder • brake pipe “3” outlet: to the proportioning valve • brake pipe “4”...

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

    Abs (anti-lock brake system) 8-153 • if the brake pipes (to the proportioning valve and the metering valve) are switched during assembly, the brakes will continue to operate as normal. However, the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be rever...

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

    Abs (anti-lock brake system) 8-154 fault code no. Abs_51 abs_52 symptom power voltage is too high. Order item/components and probable cause check or maintenance job 1 battery voltage replace the battery. Refer to “checking and charging the bat- tery” on page 8-174. 2 disconnected battery terminal (f...

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

    Abs (anti-lock brake system) 8-155 3 open or short circuit in wire harness. • replace if there is an open or short circuit. • between abs ecu coupler and abs ecu fuse. (brown/white–brown/white) • between abs ecu coupler and abs solenoid fuse. (red/white–red/white) • between abs ecu coupler and joint...

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

    Abs (anti-lock brake system) 8-156 fault code no. Abs_63 symptom front wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job 1 short circuit in wire harness. • check that there is no short circuit between the white terminal “1” and the black terminal “2”. ...

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

    Abs (anti-lock brake system) 8-157 fault code no. Abs_64 symptom rear wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job 1 short circuit in wire harness. • check that there is no short circuit between the gray terminal “1” and the white terminal “2”. • ...

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

    Abs (anti-lock brake system) 8-158 eas1mc1007 [c-1] deleting the fault codes 1. Check: • engine stop due to sidestand operation warning ewa1mc1021 • make sure to elevate the rear wheel. • make sure that there are no persons or ob- jects in front of the vehicle. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

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

    Abs (anti-lock brake system) 8-159 5. Check: • abs ecu voltage lower than 12.8 v → charge or replace the battery. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the abs ecu coupler. B. Measure the abs ecu voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

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

    Abs (anti-lock brake system) 8-160 b. Shift the transmission into gear and extend the sidestand. C. Push the “ ” side of the start/engine stop switch. D. Measure the abs ecu voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. If the above-mentioned checks are within specification, replace ...

  • Page 610: Grip Warmer System

    Grip warmer system 8-161 et3p66016 grip warmer system et3p66017 circuit diagram menu p on off a (b) (b) br /l r r b b b b b r r b /w b /w b /w b /w b /lb b /wb /l b /w b /w l /b l /r l /r l /r l /b l /b r /w l /b l /r b br /w w /g w /r w /l w /lb /w w /rw /g b /w b /w y /ry /ry b by b br /l br /w r ...

  • Page 611: Grip Warmer System

    Grip warmer system 8-162 2. Main switch 5. Joint coupler 9. Ignition fuse 16.Fuel injection system fuse 17.Backup fuse 25.Main fuse 26.Battery 27.Engine ground 48.Left handlebar switch 53.Menu switch 54.Select switch 72.Meter assembly 73.Multi-function meter 102.Ecu (engine control unit) 114.Left gr...

  • Page 612: Grip Warmer System

    Grip warmer system 8-163 et3p66019 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Lower center cover 3. Fuel tank 4. T-bar the grip warmers do not become warm at all. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. C...

  • Page 613: Grip Warmer System

    Grip warmer system 8-164 the grip warmers are abnormally hot while the engine is idling. Ng → ok ↓ the grip warmers do not become very warm while the vehicle is traveling. Ng → ok ↓ ng → ok ↓ the temperature levels of the grip warmer settings cannot be changed. Ng → ok ↓ ng → ok ↓ 1. Check that the ...

  • Page 614: Electrical Components

    Electrical components 8-165 eas27970 electrical components 1 24 2 3 4 5 6 9 11 12 10 8 7 13 14 15 16 17 18 19 23 22 21 20

  • Page 615: Electrical Components

    Electrical components 8-166 1. Windshield drive unit 2. Battery 3. Starter relay 4. Cooling system fuse 5. Front brake light switch 6. Clutch switch 7. Windshield drive system fuse 8. Fuse box 1 9. Fuse box 2 10. Hazard lighting fuse 11. Cruise control system fuse 12. Brake light fuse 13. Right radi...

  • Page 616: Electrical Components

    Electrical components 8-167 7 1 3 2 18 21 20 19 9 11 12 13 14 15 16 17 6 8 4 5 10

  • Page 617: Electrical Components

    Electrical components 8-168 1. Coolant temperature sensor 2. Accelerator position sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Atmospheric pressure sensor 6. Brake light relay 7. Hydraulic unit assembly 8. Lean angle sensor 9. Brake switch relay 10. Cylinder identification sen...

  • Page 618: Electrical Components

    Electrical components 8-169 eas27980 checking the switches (b) (b) (b) 4 r br/l br/r br/l br/r r 5 6 16 w/b l/r w/y 14 p b 10 12 13 11 1 br/g l/r 2 3 9 8 7 g/w g/y y/w y/b g/w g/y y/b y/w pull br b y g press br g b y p sb y/w l/w b/r b/y b b br y/b g/y g/w br y/b g/y g/w pull b/w w/g mode r/b w/l b ...

  • Page 619: Electrical Components

    Electrical components 8-170 1. Start/engine stop switch 2. Hazard switch 3. Mode switch 4. Front brake light switch 5. Main switch 6. Rear brake light switch 7. Gear position switch 8. Sidestand switch 9. Clutch switch 10. Horn switch 11. Dimmer/pass switch 12. Cruise control power switch 13. Cruise...

  • Page 620: Electrical Components

    Electrical components 8-171 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes...

  • Page 621: Electrical Components

    Electrical components 8-172 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or b...

  • Page 622: Electrical Components

    Electrical components 8-173 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in t...

  • Page 623: Electrical Components

    Electrical components 8-174 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • right upper inner panel refer to “general chassis” on page 4-1. Eas1mc1024 replacing the ecu (engine control...

  • Page 624: Electrical Components

    Electrical components 8-175 4. Check: • battery charge ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals. Tip • the charge state of an vrla (valve regulated lead acid) battery can be checked by measur- ing its open-circuit voltage (i.E., the volt...

  • Page 625: Electrical Components

    Electrical components 8-176 • if the battery becomes hot to the touch at any time during the charging process, dis- connect the battery charger and let the bat- tery cool before reconnecting it. Hot batteries can explode! • as shown in the following illustration, the open-circuit voltage of an vrla ...

  • Page 626: Electrical Components

    Electrical components 8-177 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) notice eca13630 first, connect the positive battery lead “1”, and then the negative battery lead “2”. 8. Check: • battery terminals dirt → clean ...

  • Page 627: Electrical Components

    Electrical components 8-178 relay unit (fuel pump relay) headlight relay (on/off) headlight relay (dimmer) first step: second step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive battery ...

  • Page 628: Electrical Components

    Electrical components 8-179 brake switch relay brake light relay first step: second step: radiator fan motor relay windshield drive unit relay (down) first step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3”...

  • Page 629: Electrical Components

    Electrical components 8-180 second step: windshield drive unit relay (up) first step: second step: eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Tip the pocket tester and the analog pocket tester readings are shown in the following table. 1. ...

  • Page 630: Electrical Components

    Electrical components 8-181 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no ...

  • Page 631: Electrical Components

    Electrical components 8-182 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the ig- nition coil as shown. B. Measure the secondary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61015 checking the ignition spark gap 1. Check: • igni...

  • Page 632: Electrical Components

    Electrical components 8-183 b. Measure the crankshaft position sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28130 checking the lean angle sensor 1. Remove: • lean angle sensor (from the rear fender) 2. Check: • lean angle sensor output voltage out of specification → repl...

  • Page 633: Electrical Components

    Electrical components 8-184 eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the stator coil. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the digital circuit tester to the...

  • Page 634: Electrical Components

    Electrical components 8-185 b. Check the oil level switch for continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28220 checking the fuel sender 1. Remove: • fuel pump (from the fuel tank) 2. Check: • fuel sender resistance out of specification → replace the fuel pump assembly. ▼▼▼ ▼ ▼ ...

  • Page 635: Electrical Components

    Electrical components 8-186 eas1mc1086 checking the front turn signal light assemblies the following procedure applies to both of the front turn signal light assemblies. 1. Check: • front turn signal light assembly faulty → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the...

  • Page 636: Electrical Components

    Electrical components 8-187 2. Check: • coolant temperature sensor resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100/× 1 kΩ) to the coolant temperature sensor terminals as shown. B. Immerse the coolant temperature sens...

  • Page 637: Electrical Components

    Electrical components 8-188 eas29100 checking the accelerator position sensor 1. Remove: • accelerator position sensor (from the throttle bodies) warning ewa1mc1003 • handle the accelerator position sensor with special care. • never subject the accelerator position sen- sor to strong shocks. If the ...

  • Page 638: Electrical Components

    Electrical components 8-189 eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the air induction system solenoid coupler from the wire harness. B. Con...

  • Page 639: Electrical Components

    Electrical components 8-190 notice eca1mc1005 pay attention to the installing direction of the test harness s-pressure sensor (3p) coupler “a”. B. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor (3p). C. Turn the main switch to “on”. D. Measure the intake air pressure ...

  • Page 640: Electrical Components

    Electrical components 8-191 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100/× 1 kΩ) to the air temperature sensor terminals as shown. B. Immerse the air temperature sensor “1” in a container filled with water “2”. Tip make sure that the air temperature sensor...

  • Page 641: Electrical Components

    Electrical components 8-192 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the fuel injector coupler from wire harness. B. Connect the pocket tester ( Ω × 1) to the fuel injector terminals as shown. C. Measure the fuel injector resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 642: Electrical Components

    Electrical components 8-193 c. Measure the accessory box solenoid resis- tance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p66023 checking the grip warmers the following procedure applies to both of the grip warmers. 1. Check: • grip warmer resistance out of specification → replace the gri...

  • Page 643: Troubleshooting

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

  • Page 644: Troubleshooting

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

  • Page 645: Troubleshooting

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

  • Page 646: Troubleshooting

    Troubleshooting 9-3 eas28600 overheating engine 1. Clogged coolant passages • cylinder head and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiato...

  • Page 647: Troubleshooting

    Troubleshooting 9-4 • bent or damaged outer tube 3. Swingarm • worn bearing or bushing • bent or damaged swingarm rear shock absorber assembly • faulty rear shock absorber spring • leaking oil or gas tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear wheel(...

  • Page 648: 9-5

    Self-diagnostic function and diagnostic code table 9-5 eas1mc1048 self-diagnostic function and diagnostic code table self-diagnostic function table fault code no. Item reference pages 11 cylinder identification sensor: no normal signals are received from the cylinder identification sensor. 8-40 12 c...

  • Page 649: 9-6

    Self-diagnostic function and diagnostic code table 9-6 communication error with the meter diagnostic code: sensor operation table 51 immobilizer unit: code cannot be transmitted between the key and the immobilizer unit. 8-122 52 immobilizer unit: codes between the key and immobilizer unit do not mat...

  • Page 650: 9-7

    Self-diagnostic function and diagnostic code table 9-7 03 intake air pressure displays the intake air pressure. Shift the transmission into gear, extend the side- stand, and then operate the throttle while pushing the “ ” side of the start/engine stop switch. (if the display value changes, the perfo...

  • Page 651: 9-8

    Self-diagnostic function and diagnostic code table 9-8 15 accelerator position sen- sor signal 2 • fully closed position 10–24 check with throttle grip ful- ly closed position. • fully open position 95–109 check with throttle grip ful- ly open position. 16 front wheel vehicle speed pulses front whee...

  • Page 652: 9-9

    Self-diagnostic function and diagnostic code table 9-9 60 eeprom fault code dis- play — • no history 00 • no malfunctions detect- ed (if the self-diagnosis fault code 44 is indicat- ed, the ecu is defec- tive.) • history exists 01–04 (cylinder fault code) • (if more than one cylin- der is defective,...

  • Page 653: 9-10

    Self-diagnostic function and diagnostic code table 9-10 63 malfunction code rein- statement (for fault code no. 24, 42, 69 only) • no malfunction code 00 — • malfunction code exists fault code 24, 42, 69 • (if more than one code number is detected, the display alternates every two seconds to show al...

  • Page 654: 9-11

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

  • Page 655: 9-12

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

  • Page 656: Wiring Diagram

    Eas28740 wiring diagram fjr1300a(d) 2013 1. Immobilizer unit 2. Main switch 3. Ac magneto 4. Rectifier/regulator 5. Joint coupler 6. Windshield drive system fuse 7. Hazard lighting fuse 8. Abs ecu fuse 9. Ignition fuse 10. Auxiliary dc jack fuse 11. Signaling system fuse 12. Right radiator fan motor...

  • Page 657

    Eas28750 color code b black br brown ch chocolate dg dark green g green gy gray l blue lg light green o orange p pink r red sb sky blue w white y yellow b/g black/green b/l black/blue b/r black/red b/w black/white b/y black/yellow br/b brown/black br/g brown/green br/l brown/blue br/r brown/red br/w...

  • Page 661

    Fjr1300a(d) 2013 wiring diagram fjr1300a(d) 2013 schÉma de cblage fjr1300a(d) 2013 schaltplan fjr1300a(d) 2013 schema elettrico fjr1300a(d) 2013 diagrama elÉctrico pull press pull mode menu pass res set p on off c c b b a a (b) (b) br/r br/l r b/w y/l r/w g/b b b lg r/g r b w w w br/g l/r r/w r/w br...

  • Page 662

    Fjr1300a(d) 2013 wiring diagram fjr1300a(d) 2013 schÉma de cblage fjr1300a(d) 2013 schaltplan fjr1300a(d) 2013 schema elettrico fjr1300a(d) 2013 diagrama elÉctrico pull press pull mode menu pass res set p on off c c b b a a (b) (b) (b) (b) (b) (b) (b) (gy) (b) a b c d a a b a c (b) (b) (b) (b) (b) (...