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Yamaha FZ09E 2014 Service Manual

Summary of FZ09E 2014

  • Page 1

    2014 service manual fz09e fz09ec lit-11616-27-39 1rc-28197-10

  • Page 3

    Eas20050 fz09e fz09ec service manual ©2013 by yamaha motor corporation, u.S.A. First edition, august 2013 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-27-39.

  • Page 4

    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 5

    Eas20091 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 6

    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: General Information

    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 eas20110 table of contents.

  • Page 9: General Information

    1 2 3 4 5 6 7 8 9 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 eas1rc1101 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 s...

  • Page 12: Features

    Features 1-3 eas1rc1102 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ecu energizes the fuel injector, the fu...

  • Page 13: Features

    Features 1-4 eas1rc1103 instrument functions multi-function meter unit warning ewa12423 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function me...

  • Page 14: Features

    Features 1-5 to set the clock 1. Turn the key to “on”. 2. Push the “select” button and “reset” but- ton together for at least two seconds. 3. When the hour digits start flashing, push the “reset” button to set the hours. 4. Push the “select” button, and the minute digits will start flashing. 5. Push...

  • Page 15: Features

    Features 1-6 multi-function display the multi-function display is equipped with the following: • an odometer • two tripmeters (which show the distance trav- eled since they were last set to zero) • a fuel reserve tripmeter (which shows the dis- tance traveled since the left segment of the fuel meter...

  • Page 16: Features

    Features 1-7 average fuel consumption mode the average fuel consumption display can be set to either “ave_ _._ km/l”, “ave_ _._ l/100 km” or “ave_ _._ mpg”. This display shows the average fuel consump- tion since it was last reset. • “ave_ _._ km/l”: the average distance that can be traveled on 1.0 ...

  • Page 17: Features

    Features 1-8 notice eca11591 if the display indicates an error code, the ve- hicle should be checked as soon as possible in order to avoid engine damage. Brightness control mode this function allows you to adjust the brightness of the multi-function meter unit panel to suit the outside lighting cond...

  • Page 18: Features

    Features 1-9 eas1rc1109 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 19: Features

    Features 1-10 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 sensor 7. Crankshaft position sensor 8. Speed sensor 9. Coolant temperature sensor.

  • Page 20: Important Information

    Important information 1-11 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 1-18. 3. When disasse...

  • Page 21: Important Information

    Important information 1-12 manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. Notice eca13300 do not spin the bearing with compressed air because thi...

  • Page 22: Basic Service Information

    Basic service information 1-13 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 23: Basic Service Information

    Basic service information 1-14 the battery, be sure to disconnect the nega- tive battery lead first, then the positive bat- tery lead. If a tool or similar item contacts the vehicle while only the negative battery lead is connected, a spark could be generated, which is extremely dangerous. Tip if a ...

  • Page 24: Basic Service Information

    Basic service information 1-15 tip when resetting the ecu by turning the main switch to “off”, be sure to wait approximately 5 seconds before turning the main switch back to “on”. Checking the electrical system tip before checking the electrical system, make sure that the battery voltage is at least...

  • Page 25: Basic Service Information

    Basic service information 1-16 notice eca16790 when disconnecting a connector, do not pull the leads. Hold both sections of the connec- tor securely, and then disconnect the con- nector. 2. Check: • lead • coupler • connector moisture  dry with an air blower. Rust/stains  connect and disconnect se...

  • Page 26: Basic Service Information

    Basic service information 1-17 5. Check: • resistance tip the resistance values shown were obtained at the standard measuring temperature of 20 c (68 f). If the measuring temperature is not 20 c (68 f), the specified measuring conditions will be shown. Pocket tester 90890-03112 analog pocket tes...

  • Page 27: Special Tools

    Special tools 1-18 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 28: Special Tools

    Special tools 1-19 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-32 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-18, 4-61 damper rod holder 90890-01423 damping rod holder ym-01423 4-52, 4-53 oil filter wrench 90890-01426 yu-38411 3-23 rod holder 90890-01434 dampe...

  • Page 29: Special Tools

    Special tools 1-20 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-55, 4-56, 4-57 fork spring compressor 90890-01441 ym-01441 4-51, 4-56, 4-57 fork seal driver 90890-01442 adjustable fork seal driver (36–46 mm) ym-01442 4-54, 4-55 pivot shaft wrench adapter 90890-01476 5-7,...

  • Page 30: Special Tools

    Special tools 1-21 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-32, 5-33 compression gauge 90890-03081 engine compression tester yu-33223 5-1 vacuum gauge 90890-03094 vacuummate yu-44456 3-8 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-16, 1-17, 8-91, 8-92, 8-93, 8-97,...

  • Page 31: Special Tools

    Special tools 1-22 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-37, 8-102, 8-103, 8-109 fuel pressure adapter 90890-03176 ym-03176 7-11 thickness gauge 90890-03180 feeler gauge set yu-26900-9 3-5, 5-20, 5-43 test harness s– pressure sensor (3p) 90890-03207 yu-032...

  • Page 32: Special Tools

    Special tools 1-23 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-11 universal clutch holder 90890-04086 ym-91042 5-42, 5-45 valve lapper 90890-04101 valve lapping tool ym-a8998 3-6 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym-...

  • Page 33: Special Tools

    Special tools 1-24 extension 90890-04136 5-1 piston installing tool 90890-04161 ym-04161 5-68 camshaft wrench 90890-04162 ym-04162 5-12, 5-14 ignition checker 90890-06754 oppama pet-4000 spark checker ym-34487 8-100 yamaha bond no.1215 (three bond no.1215®) 90890-85505 5-34, 5-57 tool name/tool no. ...

  • Page 34: Special Tools

    Special tools 1-25.

  • Page 35: Specifications

    1 2 3 4 5 6 7 8 9 specifications general specifications..........................................................................2-1 engine specifications .............................................................................2-2 chassis specifications ............................................

  • Page 36: General Specifications

    General specifications 2-1 eas20280 general specifications model model fz09e 1rc4 fz09ec 1rc5 dimensions overall length 2075 mm (81.7 in) overall width 815 mm (32.1 in) overall height 1135 mm (44.7 in) seat height 815 mm (32.1 in) wheelbase 1440 mm (56.7 in) ground clearance 135 mm (5.31 in) minimum...

  • Page 37: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 847 cm 3 cylinder arrangement inline 3-cylinder bore  stroke 78.0  59.1 mm (3.07  2.33 in) compression ratio 11.50 : 1 standard compression pressure (at sea level) 1530 kpa/680 r/...

  • Page 38: Engine Specifications

    Engine specifications 2-3 radiator cap opening pressure 93.3–122.7 kpa (0.93–1.23 kgf/cm 2 , 13.5–17.8 psi) radiator core width 340.0 mm (13.39 in) height 222.6 mm (8.76 in) depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 47/47  29/22 (1.318) impel...

  • Page 39: Engine Specifications

    Engine specifications 2-4 valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) limit 4.542 mm (0.1788 in) valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (ex- haust) 0.025–0.052 mm (0.001...

  • Page 40: Engine Specifications

    Engine specifications 2-5 end gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) limit 0.80 mm (0.0315 in) ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) limit 0.115 mm (0.0045 in) oil ring end gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) connecting rod oil clearance 0.027–0.051 mm (0.0011–0....

  • Page 41: Engine Specifications

    Engine specifications 2-6 shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.050 mm (0.0020 in) shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) air filter air filter element oil-coated paper element fuel pump pump type electrical maximum consum...

  • Page 42: Chassis Specifications

    Chassis specifications 2-7 eas20300 chassis specifications chassis frame type diamond caster angle 25.00 trail 103 mm (4.1 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum wheel travel 137.0 mm (5.39 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel runo...

  • Page 43: Chassis Specifications

    Chassis specifications 2-8 brake disc runout limit (as measured on wheel) 0.10 mm (0.0039 in) brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) master cylinder inside diameter 15.00 mm (0.59 in) calip...

  • Page 44: Chassis Specifications

    Chassis specifications 2-9 rebound damping adjusting positions minimum 3 turn(s) out* standard 1 3/4 turn(s) out* maximum adjusting screw fully turned in *with the adjusting screw fully turned in rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper re...

  • Page 45: Electrical Specifications

    Electrical specifications 2-10 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 5.0 1200 r/min engine control unit model/manufacturer tbdfk4/denso ignition coil minimum ignition spark gap 6.0 mm (0.24 in) primary coil res...

  • Page 46: Electrical Specifications

    Electrical specifications 2-11 electric starting system system type constant mesh starter motor power output 0.70 kw armature coil resistance 0.0050–0.0150  brush overall length 12.0 mm (0.47 in) limit 6.50 mm (0.26 in) brush spring force 6.03–6.52 n (615–665 gf, 21.71–23.47 oz) mica undercut (dept...

  • Page 47: Electrical Specifications

    Electrical specifications 2-12 spare fuse 2.0 a.

  • Page 48: Tightening Torques

    Tightening torques 2-13 eas20320 tightening torques eas20331 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 49: Tightening Torques

    Tightening torques 2-14 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 3 13 nm (1.3 m·kgf, 9.4 ft·lbf) cylinder head bolt m9 8 see tip. Cylinder head bolt m6 4 10 nm (1.0 m·kgf, 7.2 ft·lbf) intake camshaft cap bolt m6 4 10 nm (1.0 m·kgf, 7.2 ft·lbf)...

  • Page 50: Tightening Torques

    Tightening torques 2-15 throttle body joint clamp screw m5 6 3.0 nm (0.30 m·kgf, 2.2 ft·lbf) air filter case cover screw m5 10 1.6 nm (0.16 m·kgf, 1.2 ft·lbf) air filter case joint clamp screw m5 3 2.8 nm (0.28 m·kgf, 2.0 ft·lbf) fuel injector adapter bolt m6 2 12 nm (1.2 m·kgf, 8.7 ft·lbf) air filt...

  • Page 51: Tightening Torques

    Tightening torques 2-16 tip camshaft cap bolt tighten the bolts to 10 nm (1.0 m·kgf, 7.2 ft·lbf) following the tightening order. Intake air pressure sensor screw m5 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) stator coil bolt m6 3 14 nm (1.4 m·kgf, 10 ft·lbf) oil level switch bolt m6 2 10 nm (1.0 m·kgf, 7.2 ft·l...

  • Page 52: Tightening Torques

    Tightening torques 2-17 tip cylinder head bolt 1. Tighten the bolts to 25 nm (2.5 m·kgf, 18 ft·lbf) with a torque wrench following the tightening order. 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration. A. Loosen the bolt. B. Tigh...

  • Page 53: Tightening Torques

    Tightening torques 2-18 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (front upper and front lower) m10 4 45 nm (4.5 m·kgf, 33 ft·lbf) engine mounting nut (rear upper) m10 1 45 nm (4.5 m·kgf, 33 ft·lbf) engine mounting nut (rear lower) m10 1...

  • Page 54: Tightening Torques

    Tightening torques 2-19 front brake master cylinder res- ervoir cap screw m4 2 1.5 nm (0.15 m·kgf, 1.1 ft·lbf) clutch lever holder pinch bolt m6 1 11 nm (1.1 m·kgf, 8.0 ft·lbf) horn bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) front fender bolt m6 4 10 nm (1.0 m·kgf, 7.2 ft·lbf) meter bracket bolt m6 2 7 ...

  • Page 55: Tightening Torques

    Tightening torques 2-20 passenger footrest and rear frame bolt m8 4 28 nm (2.8 m·kgf, 20 ft·lbf) rear brake fluid reservoir nut m5 1 3.8 nm (0.38 m·kgf, 2.8 ft·lbf) sidestand bracket bolt m10 1 48 nm (4.8 m·kgf, 35 ft·lbf) sidestand switch bolt m5 2 4.3 nm (0.43 m·kgf, 3.1 ft·lbf) adapter bracket an...

  • Page 56: Tightening Torques

    Tightening torques 2-21 tip lower ring nut 1. Tighten the ring nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 18 nm (1.8 m·kgf, 13 ft·lbf). Thermostat assembly bolt m6 2 10 nm (1.0 m·kgf, 7.2 ft·lbf)...

  • Page 57

    Lubrication points and lubricant types 2-22 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or bearings cylinder head cover bolt gasket and timing chain bolt gasket camshaft lobes and journals (intake...

  • Page 58

    Lubrication points and lubricant types 2-23 eas20380 chassis primary driven gear end crankcase cover and clutch pull rod clutch housing spacer clutch boss conical washer transmission gears inner surface transmission collar transmission gears outer surface (shift fork contact parts) drive sprocket wa...

  • Page 59

    Lubrication points and lubricant types 2-24 shift pedal pivoting parts rear footrest ball and metal-to-metal moving parts shift shaft joint rod moving parts front wheel oil seal (left and right) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surface brake caliper pisto...

  • Page 60

    Lubrication system chart and diagrams 2-25 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 1 3 4 5 11 12 13 13 14 15 16 17 13 7 8 9 10 10 10 10 6 2.

  • Page 61

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

  • Page 62

    Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams 1 2 3 4.

  • Page 63

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

  • Page 64

    Lubrication system chart and diagrams 2-29 4 7 7 8 9 5 6 2 3 1.

  • Page 65

    Lubrication system chart and diagrams 2-30 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket.

  • Page 66

    Lubrication system chart and diagrams 2-31 4 5 6 2 3 1.

  • Page 67

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

  • Page 68

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

  • Page 69

    Lubrication system chart and diagrams 2-34 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-c side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork.

  • Page 70

    Lubrication system chart and diagrams 2-35 9 8 7 6 3 3 2 5 4 1.

  • Page 71

    Lubrication system chart and diagrams 2-36 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil passage to the timing chain tensioner 5. Oil passage to the cylinder head 6. Oil passage to the clutch chamber 7. Oil return passage from the cylinder head 8. Crankshaft 9. Main gallery.

  • Page 72: Cooling System Diagrams

    Cooling system diagrams 2-37 eas20420 cooling system diagrams 1 1 2 3.

  • Page 73: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Water pump 2. Thermostat 3. Radiator.

  • Page 74: Cooling System Diagrams

    Cooling system diagrams 2-39 1 2 3 4 5 6.

  • Page 75: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir.

  • Page 76: Cable Routing

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

  • Page 77: Cable Routing

    Cable routing 2-42 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake hose a. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover. B. Detailed drawing of around the front brake master cylinder c. S...

  • Page 78: Cable Routing

    Cable routing 2-43 handlebar (front view).

  • Page 79: Cable Routing

    Cable routing 2-44 1. Throttle cable 2. Meter lead 3. Meter assembly 4. Left handlebar switch lead 5. Horn lead 6. Wire harness 7. Right handlebar switch lead 8. Main switch lead 9. Horn lead 10. Handlebar switch coupler 11. Headlight 12. Front brake hose 13. Turn signal/position light assembly (lef...

  • Page 80: Cable Routing

    Cable routing 2-45 radiator (front side view and right side view).

  • Page 81: Cable Routing

    Cable routing 2-46 1. Radiator cap 2. Radiator 3. Radiator fan 4. Radiator outlet hose 5. Thermostat assembly 6. Water jacket joint 7. Coolant reservoir 8. Radiator inlet hose a. Install the radiator outlet hose with its white paint mark facing inward. B. Install the radiator outlet hose up to the b...

  • Page 82: Cable Routing

    Cable routing 2-47 fuel tank (left and bottom view).

  • Page 83: Cable Routing

    Cable routing 2-48 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Clip 7. Fuel hose assembly a. Insert the fuel tank drain hose up to the section where the fuel tank pipe increases in diameter. Install it so that the white paint mark faces the rearward. B. I...

  • Page 84: Cable Routing

    Cable routing 2-49 canister (for california only).

  • Page 85: Cable Routing

    Cable routing 2-50 1. Canister 2. Bracket 3. Canister purge hose (hose joint to canister) 4. Clip 5. Frame 6. Fuel tank drain hose 7. Fuel tank breather hose (rollover valve to canister) 8. Clamp 9. Rollover valve 10. Fuel tank breather hose (fuel tank to rollover valve) 11. Fuel tank 12. Rear shock...

  • Page 86: Cable Routing

    Cable routing 2-51 air filter case and throttle body (top view and left side view).

  • Page 87: Cable Routing

    Cable routing 2-52 1. Air filter case joint clamp 2. Ecu (engine control unit) 3. Air filter case 4. Throttle body 5. Clip 6. Cylinder head breather hose 7. Throttle cable (decelerator cable) (white plating) 8. Throttle cable (accelerator cable) (black plating) 9. Injector lead 10. Injector coupler ...

  • Page 88: Cable Routing

    Cable routing 2-53 air cut-off valve (left side view).

  • Page 89: Cable Routing

    Cable routing 2-54 1. Radiator fan cover 2. Air filter case 3. Clip 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover #1) 6. Air induction system hose (air cut-off valve to reed valve cover #2/#3) 7. Air cut-off va...

  • Page 90: Cable Routing

    Cable routing 2-55 frame and engine (right side view).

  • Page 91: Cable Routing

    Cable routing 2-56 1. Clamp 2. Rear brake light switch lead 3. Positioning tape 4. O 2 sensor coupler 5. Radiator fan motor coupler 6. Auxiliary dc jack 7. Headlight relay 8. Radiator fan motor lead 9. O 2 sensor lead 10. Frame 11. Engine 12. Adapter bracket 13. Bracket a. Insert the clamp into the ...

  • Page 92: Cable Routing

    Cable routing 2-57 frame and engine (left side view).

  • Page 93: Cable Routing

    Cable routing 2-58 1. Air induction system hose (air filter case to air cut-off valve) 2. Air filter case 3. Throttle cables 4. Stator coil assembly lead 5. Speed sensor lead 6. Clamp 7. Positive battery lead 8. Starter motor lead 9. Stator coil lead 10. Wire harness (to rectifier/regulator) 11. Gea...

  • Page 94: Cable Routing

    Cable routing 2-59 frame (top view).

  • Page 95: Cable Routing

    Cable routing 2-60 1. Injector coupler #1 2. Injector coupler #2 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Fuel injector coupler #3 9. Throttle position sensor coupler 10. Throttle servo motor coupler 11. Cross tube 1...

  • Page 96: Cable Routing

    Cable routing 2-61 frame (top view).

  • Page 97: Cable Routing

    Cable routing 2-62 1. Stator coil assembly lead 2. Oil level switch coupler 3. Rear brake light switch coupler 4. Sidestand switch coupler 5. Gear position sensor coupler 1 6. Gear position sensor coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9. Starter motor lead 10. Cover 11. Can...

  • Page 98: Cable Routing

    Cable routing 2-63 frame (top view).

  • Page 99: Cable Routing

    Cable routing 2-64 1. Positive battery lead 2. Starter relay 3. Fuse box 4. Positive battery terminal 5. Battery 6. Radiator fan motor relay 7. Negative battery lead 8. Negative battery terminal 9. Turn signal/hazard relay 10. Relay unit 11. Clamp 12. Tail/brake light coupler 13. Yamaha diagnostic t...

  • Page 100: Cable Routing

    Cable routing 2-65 front brake (right side view and left side view).

  • Page 101: Cable Routing

    Cable routing 2-66 1. Headlight assembly 2. Right brake caliper 3. Front brake hose 4. Clamp 5. Left brake caliper 6. Left reflector 7. Right reflector a. To left brake caliper b. To front brake master cylinder c. Install the front brake hose with its blue paint mark facing outward. D. Install the b...

  • Page 102: Cable Routing

    Cable routing 2-67 rear brake.

  • Page 103: Cable Routing

    Cable routing 2-68 1. Rear frame 2. Clamp 3. Rear brake caliper 4. Rear brake hose 5. Swingarm assembly a. Install the clamp facing the direction in the illustra- tion. B. Make sure to install the clamp all the way in the rear frame. C. Fasten the protector of the brake hose with the clamp. Install ...

  • Page 104: Cable Routing

    Cable routing 2-69.

  • Page 105

    1 2 3 4 5 6 7 8 9 periodic checks and adjustments periodic maintenance .............................................................................3-1 introduction ........................................................................................3-1 periodic maintenance chart for the emission...

  • Page 106

    Checking the coolant level ........................................................3-25 checking the cooling system .....................................................3-25 changing the coolant....................................................................3-26 checking the front brake light sw...

  • Page 107: 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 lon- ger service life and re...

  • Page 108: Periodic Maintenance

    Periodic maintenance 3-2 eas1rc1302 general maintenance and lubrication chart no. Item routine initial odometer readings 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or ...

  • Page 109: Periodic Maintenance

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

  • Page 110: Periodic Maintenance

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

  • Page 111: Periodic Maintenance

    Periodic maintenance 3-5 page 7-15. • air filter case 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 clea...

  • Page 112: Periodic Maintenance

    Periodic maintenance 3-6 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • camshaft tip • refer to “camshafts” on page 5-9. • when removi...

  • Page 113: Periodic Maintenance

    Periodic maintenance 3-7 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: 1.58 mm (0.062 in) + 0.05 mm (0.002 in) = 1.63 mm (0.064 in) the valve pad number is 163. E. Round off the valve pad number acc...

  • Page 114: 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 7-8. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the yamaha diagnostic tool. Use the dia...

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-9 adjusting the throttle body synchronization 1. Adjust: • throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. B. Using the throttle body that has the ...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-10 cracks/damage  replace. 3. Install: • fuel tank refer to “fuel tank” on page 7-1. • rider seat refer to “general chassis” on page 4-1. Eas1rc1306 checking the air induction system refer to “checking the air induction system” on page 7-18. Eas21050 checking the cylinder hea...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-11 eas20870 adjusting the clutch lever free play 1. Check: • clutch lever free play “a” out of specification  adjust. 2. Adjust: • clutch lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-12 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a ha...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-13 eas21190 adjusting the rear disc brake 1. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Turn the adjusting bolt “2” in direction “a” or “b” until the specified brake pedal position is obtained. Warning ewa13070 after adjusting...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-14 before applying the brake. Ignoring this pre- caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. • if bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding pro...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-15 eas21670 checking the wheels the following procedure applies to both of the wheels. 1. Check: • wheel damage/out-of-round  replace. Warning ewa13260 never attempt to make any repairs to the wheel. Tip after a tire or wheel has been changed or re- placed, always balance the...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-16 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be g...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-17 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. Shift the transmission into the neutral posi- tion. 3. Check: • drive chain slack “a” out of specifi...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-18 eas21510 checking and adjusting the steering head 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 front wheel is elevated. 2. Check: •...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-19 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • upper bracket refer to “handlebar” on page 4-44. Eas1rc1321 lubricating the steering head 1. Lubricate: • upper bearing • lower bearing • bearing races eas1rc1322 checking the chassis fasteners make sure that all nuts, bolts, a...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-20 rough movement  repair or replace. Eas21721 lubricating the sidestand lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the sides- tand. Eas1rc1310 checking the sidestand switch refer to “electrical components” on page 8-85. Eas21531 c...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rebound damping (right side only) notice eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Tip althoug...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-22 the owner’s tool kit. B. Turn the adjusting ring “3” in direction “a” or “b”. C. Align the desired position on the adjusting ring with the stopper “4”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rebound damping notice eca13590 never go beyond the maximum or minimum adjustment positio...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-23 notice eca13361 • engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “cd” or higher and do not use oils labeled “energy conserving ii” or hig...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-24 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 an oil filter wrench. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • engine oil drain bolt (along wi...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-25 5. Measure: • engine oil pressure (at the following conditions) out of specification  check. 6. Install: • main gallery bolt notice eca1rc1301 be careful not to tighten too much. Eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip • place the v...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-26 eas21131 changing the coolant 1. Remove: • radiator cap bolt “1” • radiator cap “2” • radiator cap stopper “3” 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 ou...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-27 • coolant reservoir • coolant reservoir cover • coolant reservoir bolts 9. Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning ewa13040 • i...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-28 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adjusting nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21690 chec...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-29 d. Tighten the locknut. E. Slide the rubber cover to its original position. Tip make sure that the adjusting nut is covered com- pletely by the rubber cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21760 checking and charging the battery refer to “checking and charging the batt...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-30 6. Install: • headlight bulb secure the new headlight bulb with the head- light bulb holder. Notice eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux w...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 b c.

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-32.

  • Page 139: Chassis

    1 2 3 4 5 6 7 8 9 chassis general chassis........................................................................................4-1 removing the air scoops.................................................................4-5 installing the air scoops ....................................................

  • Page 140

    Assembling the rear brake master cylinder.......................4-43 installing the rear brake master cylinder .........................4-43 handlebar..................................................................................................4-44 removing the handlebar ...........................

  • Page 141: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 rider seat 1 2 battery band 1 3 negative battery lead 1 disconnect. 4 positive battery lead 1 disconnect. 5 battery 1 6 spacer 1 1 2 3 3 4 5 6 2.2 nm (0.22 m • kgf, 1.6 ft • ibf).

  • Page 142: General Chassis

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

  • Page 143: General Chassis

    General chassis 4-3 removing the headlight and meter assembly order job/parts to remove q’ty remarks 1 headlight unit side cover (left) 1 2 turn signal/position light coupler (left) 1 disconnect. 3 headlight unit side cover (right) 1 4 turn signal/position light coupler (right) 1 disconnect. 5 auxil...

  • Page 144: General Chassis

    General chassis 4-4 removing the air scoop and fuel tank cover order job/parts to remove q’ty remarks 1 air scoop (left) 1 2 air scoop (right) 1 3 fuel tank cover 1 4 fuel tank mole (left) 1 5 fuel tank mole (right) 1 1 2 3 4 5 5 1.5 nm (0.15 m • kgf, 1.1 ft • ibf) 1.5 nm (0.15 m • kgf, 1.1 ft • ibf...

  • Page 145: General Chassis

    General chassis 4-5 eas1rc1401 removing the air scoops 1. Remove: • air scoop (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air scoop bolt “2” and quick fas- teners “3”. B. Pull the air scoop off at the areas “a” shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove: • air scoop (right) “1” ...

  • Page 146: General Chassis

    General chassis 4-6 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • fuel tank mole (right) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the hole “a” in the fuel tank mole onto the projection “b” on the air scoop stay. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 a b 1 a b.

  • Page 147: General Chassis

    General chassis 4-7 removing the air filter case order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 ecu (engine control unit) 1 2 ecu coupler 2 disco...

  • Page 148: Front Wheel

    Front wheel 4-8 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 reflector 2 2 front brake caliper 2 3 wheel axle pinch bolt 1 loosen. 4 wheel axle 1 5 front wheel 1 6 collar 2 7 front brake disc 2 2 4 5 6 7 6 7 3 2 (5) (5) 18 nm (1.8 m • kgf, 13...

  • Page 149: Front Wheel

    Front wheel 4-9 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 1 2 3 1 2.

  • Page 150: Front Wheel

    Front wheel 4-10 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • left brake caliper • right brake caliper notice eca1rc1439 do not apply the brake lever when removing ...

  • Page 151: Front Wheel

    Front wheel 4-11 4. Check: • wheel bearings front wheel turns roughly or is loose  re- place the wheel bearings. • oil seal damage/wear  replace. Eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the new wheel bearing (right si...

  • Page 152: Front Wheel

    Front wheel 4-12 d. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. G. The spot where all the marks come to rest is the front wheel’s heavy spot “x”. ▲▲▲▲...

  • Page 153: Front Wheel

    Front wheel 4-13 3. Lubricate: • oil seal lips 4. Install: • collars • front wheel • wheel axle 5. Tighten: • wheel axle • wheel axle pinch bolt notice eca1rc1401 before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. Tip check ...

  • Page 154: Rear Wheel

    Rear wheel 4-14 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-32. 1 locknut 2 loosen. 2 adjusting bolt 2 loosen. 3 wheel axle nut 1 4 washer 1 5 wheel axle 1 6 adjusting block (left) 1 7 adjusting block (right) 1...

  • Page 155: Rear Wheel

    Rear wheel 4-15 removing the brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 bracket 1 3 rear wheel sprocket 1 4 collar 1 5 collar 1 6 oil seal 1 7 bearing 1 8 rear wheel drive hub 1 9 collar 1 10 rear wheel drive hub damper 6 11 rear wheel 1 1 2 3 3 4...

  • Page 156: Rear Wheel

    Rear wheel 4-16 disassembling the rear wheel order job/parts to remove q’ty remarks 1 oil seal 1 2 wheel bearing 1 3 spacer 1 4 wheel bearing 1 2 3 1 4.

  • Page 157: Rear Wheel

    Rear wheel 4-17 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear brake caliper “1” not...

  • Page 158: Rear Wheel

    Rear wheel 4-18 eas1rc1411 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear  replace the drive sprocket, the rear wheel sprocket and the drive chain as a set. Bent teeth  replace the drive sprocket, the rear wheel sprocket and the drive ch...

  • Page 159: Rear Wheel

    Rear wheel 4-19 2. Check: • rear brake disc refer to “checking the rear brake disc” on page 4-38. 3. Lubricate: • oil seal lips 4. Install: • collars • brake caliper bracket • rear wheel • adjusting blocks • wheel axle • washer • wheel axle nut tip • do not install the brake caliper. • align the pro...

  • Page 160: Front Brake

    Front brake 4-20 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 pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 reflector 1 6 front brake caliper 1 7 bleed screw ...

  • Page 161: Front Brake

    Front brake 4-21 removing the front brake master cylinder order job/parts to remove q’ty remarks right rear view mirror refer to “handlebar” on page 4-44. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-13. 1 brake master cylinder reservoir cap 1 2 brake master cylinder r...

  • Page 162: Front Brake

    Front brake 4-22 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 2 1 s bf bf.

  • Page 163: Front Brake

    Front brake 4-23 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-13. 1 brake hose union bolt 1 2 brake hose gasket 1 3 brake hose ...

  • Page 164: Front Brake

    Front brake 4-24 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal 4 7 br...

  • Page 165: Front Brake

    Front brake 4-25 eas22220 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 166: Front Brake

    Front brake 4-26 d. Measure the brake disc runout. E. If out of specification, repeat the adjustment steps until the brake disc runout is within specification. F. If the brake disc runout cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • f...

  • Page 167: Front Brake

    Front brake 4-27 c. Tighten the bleed screw. D. Install the brake pads and brake pad spring. Tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • brake pad pin • brake pad clips • front brake caliper 7. Check: • b...

  • Page 168: Front Brake

    Front brake 4-28 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the right side brake caliper pistons with a piece of wood “a”. B. Blow compressed air into the brake hose joint opening “b” to force out the left side pistons from the brake caliper. Warning ewa1rc1401 • never try to pry out the brake calip...

  • Page 169: Front Brake

    Front brake 4-29 replace the brake caliper piston dust seals and brake caliper piston seals. Eas22440 installing the front brake calipers the following procedure applies to both of the brake calipers. 1. Install: • front brake caliper “1” (temporarily) • brake hose gaskets • brake hose “2” • brake h...

  • Page 170: Front Brake

    Front brake 4-30 7. Check: • brake lever operation soft or spongy feeling  bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-13. Eas22490 removing the front brake master cylinder tip before removing the front brake master cylinder, drain the brake fluid from the ent...

  • Page 171: Front Brake

    Front brake 4-31 holder with the punch mark “b” on the handle- bar. • first, tighten the upper bolt, then the lower bolt. • there should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the front brake master cylinder holder. Al- so, the punch mark should be seen. 2....

  • Page 172: Rear Brake

    Rear brake 4-32 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 rear brake caliper 1 4 brake pad 2 5 brake pad shim 2 6 brake pad insulator 2 7 brake pad spring 1 8 bleed screw 1 lt s s s s.

  • Page 173: Rear Brake

    Rear brake 4-33 removing the rear brake master cylinder order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Brake fluid drain. Refer to “bleeding the hy...

  • Page 174: Rear Brake

    Rear brake 4-34 removing the rear brake master cylinder order job/parts to remove q’ty remarks 13 brake pedal 1 14 rear brake master cylinder assembly 1 15 rear brake light switch 1 55 nm (5.5 m • kgf, 40 ft • ibf) 3.8 nm (0.38 m • kgf, 2.8 ft • ibf) 30 nm (3.0 m • kgf, 22 ft • ibf) 13 14 15 lt 30 n...

  • Page 175: Rear Brake

    Rear brake 4-35 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 brake master cylinder kit 1 3 hose joint 1 4 bushing 1 5 brake master cylinder body 1 s bf bf.

  • Page 176: Rear Brake

    Rear brake 4-36 removing the rear brake caliper order job/parts to remove q’ty remarks 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose 1 4 rear brake caliper 1 lt s s.

  • Page 177: Rear Brake

    Rear brake 4-37 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 brake pad 2 4 brake pad shim 2 5 brake pad insulator 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston dust seal 1 9 brake caliper piston sea...

  • Page 178: Rear Brake

    Rear brake 4-38 eas22561 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 179: Rear Brake

    Rear brake 4-39 lators, brake pad shims, and brake pad spring 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 and push the brake caliper piston into the brak...

  • Page 180: Rear Brake

    Rear brake 4-40 1. Remove: • brake hose union bolt “1” • brake hose gaskets “2” • brake hose “3” tip put the end of the brake hose into a container and pump out the brake fluid carefully. Eas22601 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston dust ...

  • Page 181: Rear Brake

    Rear brake 4-41 2. Check: • rear brake caliper bracket “1” cracks/damage  replace. Refer to “rear wheel” on page 4-14. Eas22651 assembling the rear brake caliper warning ewa1rc1403 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid....

  • Page 182: Rear Brake

    Rear brake 4-42 4. Fill: • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of b...

  • Page 183: Rear Brake

    Rear brake 4-43 eas22730 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents. 1. Install: • brake master cylinder kit eas2...

  • Page 184: Handlebar

    Handlebar 4-44 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks meter bracket refer to “general chassis” on page 4-1. 1 rearview mirror 2 2 front brake light switch connector 2 disconnect. 3 front master cylinder holder 1 4 front brake master cylinder assembly 1 5 rig...

  • Page 185: Handlebar

    Handlebar 4-45 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” tip blow compressed air between the left handlebar and the handlebar grip, and graduall...

  • Page 186: Handlebar

    Handlebar 4-46 4. Install: • throttle grip “1” • throttle cables • throttle cable housings “2” • grip end tip • align the projection “a” on the throttle cable housing with the hole “b” in the handlebar. • there should be 1–3 mm (0.04–0.12 in) of clearance “c” between the throttle grip and the grip e...

  • Page 187: Handlebar

    Handlebar 4-47 9. Install: • left handlebar switch tip align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 10.Adjust: • throttle grip free play refer to “checking the throttle grip” on page 3-28. 11.Adjust: • clutch lever free play refer to “adjusting the clutch...

  • Page 188: Front Fork

    Front fork 4-48 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-8. 1 front fender 1 2 upper bracket pinch bolt 1 loosen. 3 cap bolt 1 loosen. 4 lower b...

  • Page 189: Front Fork

    Front fork 4-49 disassembling the left front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 washer 1 4 spacer 1 5 fork spring 1 6 locknut 1 7 dust seal 1 8 oil seal clip 1 9 outer tube 1 10 oil seal 1 11 washer 1 12 outer tube bushing 1 13 inner tube bushing 1 14 damper ro...

  • Page 190: Front Fork

    Front fork 4-50 disassembling the right front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 washer 1 4 spacer 1 5 fork spring 1 6 locknut 1 7 damper adjusting rod 1 8 dust seal 1 9 oil seal clip 1 10 outer tube 1 11 oil seal 1 12 washer 1 13 outer tube bushing 1 14 inner ...

  • Page 191: Front Fork

    Front fork 4-51 eas1rc1412 removing the front fork legs the following procedure applies to both of the front fork legs. Tip each front fork leg is equipped with a spring pre- load adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screw and compression damping forc...

  • Page 192: Front Fork

    Front fork 4-52 notice eca1rc1404 do not scratch the outer tube. 4. Remove: • outer tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. B. Securely clamp the brake caliper bracket in a vise with soft jaws. C. Separate the outer tube from the inner tube by pulling the outer...

  • Page 193: Front Fork

    Front fork 4-53 3. Check: • damper rod “1” damage/wear  replace. Obstruction  blow out all of the oil passag- es with compressed air. Notice eca1rc1405 • the front fork leg has a very sophisticated internal construction, which are particular- ly sensitive to foreign material. • when disassembling ...

  • Page 194: Front Fork

    Front fork 4-54 3. Lubricate: • inner tube’s outer surface 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” • outer tube bushing “5” • inner tube bushing “6” notice eca1rc1411 make sure the numbered side of the oil seal faces bottom side. Tip • before installing the oil se...

  • Page 195: Front Fork

    Front fork 4-55 8. Install: • oil seal clip “1” tip adjust the oil seal clip so that it fits into the outer tube’s groove. 9. Install: • dust seal “1” (with the fork seal driver “2”) 10.Install: • rod puller “1” • rod puller attachment (m10) “2” (onto the damper rod “3”) 11.Fill: • front fork leg (w...

  • Page 196: Front Fork

    Front fork 4-56 air. 14.Measure: • front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) out of specification  correct. 15.Install: • fork spring (left side) “1” • spacer (left side) “2” • locknut (left side) “3” • washer (le...

  • Page 197: Front Fork

    Front fork 4-57 j. Install the washer and cap bolt, and then fin- ger tighten the cap bolt. Warning ewa13670 always use a new cap bolt o-ring. K. Hold the cap bolt “5” and tighten the locknut “3” to specification. L. Remove the rod holder and fork spring com- pressor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 198: Front Fork

    Front fork 4-58 j. Position the locknut “3” as specified “b”. K. Set the cap bolt distance “c” to specification. L. Install the damper adjusting rod, washer and cap bolt, and then finger tighten the cap bolt. Warning ewa13670 always use a new cap bolt o-ring. M. Hold the cap bolt “5” and tighten the...

  • Page 199: Steering Head

    Steering head 4-59 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Headlight assembly refer to “general chassis” on page 4-1. Meter assembly refer to “general ...

  • Page 200: Steering Head

    Steering head 4-60 removing the lower bracket order job/parts to remove q’ty remarks 12 lower bracket cap 1 13 steering stem nut 1 14 upper bracket 1 15 lock washer 1 16 upper ring nut 1 17 rubber washer 1 18 lower ring nut 1 19 lower bracket 1 20 bearing cover 1 21 lower bearing dust seal 1 22 uppe...

  • Page 201: Steering Head

    Steering head 4-61 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 202: Steering Head

    Steering head 4-62 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • upper bracket • lower bracket (along with the steering stem) bends/cracks/damage  replace. Eas23140 installing the steering head 1. Lubricate: • upper bearing • lower bearing 2. Install: • lower ring nut “1” • rubber washer “2” • upper...

  • Page 203: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank”...

  • Page 204: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-64 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 respons...

  • Page 205: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-65 2. Check: • bearings • oil seals damage/pitting  replace. 3. Check: • collars damage/scratches  replace. Eas23272 installing the relay arm 1. Lubricate: • collars • oil seals 2. Install: • bearings “1” (to the relay arm) • oil seals “2” (to the relay arm) tip • wh...

  • Page 206: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-66 rear shock absorber assembly upper nut 44 nm (4.4 m·kgf, 32 ft·lbf) relay arm nut 61 nm (6.1 m·kgf, 44 ft·lbf) connecting arm lower nut 55 nm (5.5 m·kgf, 40 ft·lbf) t r . ..

  • Page 207: Swingarm

    Swingarm 4-67 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-32. Rear wheel refer to “rear wheel” on page 4-14. Muffler assembly refer to “engine removal” on page 5-3. Chain refer to “chain drive” on page 4-70. 1 conn...

  • Page 208: Swingarm

    Swingarm 4-68 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • connecting arm lower nut “1” •...

  • Page 209: Swingarm

    Swingarm 4-69 • collars “3” damage/scratches  replace. • bearings “4” damage/pitting  replace. Eas23380 installing the swingarm 1. Lubricate: • dust covers • pivot shaft • oil seals • collars 2. Install: • bearings “1” (to the swingarm) • oil seals “2” (to the swingarm) tip when installing the oil...

  • Page 210: Chain Drive

    Chain drive 4-70 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks 1 locknut 2 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive chain guide 1 6 drive sprocket nut 1 7 washer 1 8 drive sprocket 1 9 drive chain 1 1 2 3 4 5 6 14 nm (1.4 m • kgf, 10 ft • ib...

  • Page 211: Chain Drive

    Chain drive 4-71 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Straighten the drive sprocket nut ...

  • Page 212: Chain Drive

    Chain drive 4-72 notice eca1rc1403 • this vehicle has a drive chain with small rubber o-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.G., benzine), or a coarse brush to clean the drive chain. High-pressure methods could forc...

  • Page 213: Chain Drive

    Chain drive 4-73 eas1rc1403 installing the drive chain 1. Install: • drive chain notice eca17410 be sure to put on safety goggles when work- ing. Tip install the drive chain joint with the drive chain cut & rivet tool. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. When press fitting the connecting plate “1”, ...

  • Page 214: Chain Drive

    Chain drive 4-74 refer to “adjusting the drive chain slack” on page 3-16. Notice eca13550 a drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within th...

  • Page 215: Engine

    1 2 3 4 5 6 7 8 9 engine engine inspection......................................................................................5-1 measuring the compression pressure .....................................5-1 engine removal.................................................................................

  • Page 216

    Checking the clutch housing .....................................................5-44 checking the clutch boss ............................................................5-44 checking the pressure plate .....................................................5-44 checking the primary drive gear .........

  • Page 217

    Checking the shift drum assembly ...........................................5-81 checking the transmission ..........................................................5-81 assembling the main axle and drive axle ...............................5-81 installing the transmission .............................

  • Page 218: Engine Inspection

    Engine inspection 5-1 eas1rc1506 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 219: Engine Inspection

    Engine inspection 5-2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • spark plugs 7. Install: • ignition coils refer to “camshafts” on page 5-9. • air cut-off valve refer to “air induction system” on page 7-15. • air filter case refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank”...

  • Page 220: Engine Removal

    Engine removal 5-3 eas23711 engine removal removing the muffler and exhaust pipe order job/parts to remove q’ty remarks 1 o 2 sensor coupler bracket 1 2 o 2 sensor coupler 1 disconnect. 3 muffler assembly 1 4 exhaust gasket 3 5 muffler protector 1 1 2 3 4 5 (6) 10 nm (1.0 m • kgf, 7.2 ft • ibf) 10 n...

  • Page 221: Engine Removal

    Engine removal 5-4 disconnecting the leads and hoses order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover/rear side cover (left) refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to...

  • Page 222: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks 8 gear position sensor coupler 2 disconnect. 9 crankshaft position sensor coupler 1 disconnect. 10 stator coil coupler 1 disconnect. 8 9 7 nm (0.7 m • kgf, 5.1 ft • ibf) 12 nm (1.2 m • kgf, 8.7 ft • ibf) 10

  • Page 223: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks 1 engine mounting bolt (right front upper side) 1 2 adapter bolt (right) 1 3 engine mounting bolt (right front lower side)/engine mounting bolt (left front lower side)/engine mounting bolt (left front upper side) 1/1/1 4 a...

  • Page 224: Engine Removal

    Engine removal 5-7 eas1rc1501 removing the engine 1. Loosen: • engine mounting adjust bolt (front) tip loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. 2. Loosen: • engine mounting adjust bolts (rear) tip loosen the engine mounting adjust bolts with the pivot shaft wrench “1” ...

  • Page 225: Engine Removal

    Engine removal 5-8 tip • tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • make sure that the flange on the engine mounting adjust bolt contacts the engine. 8. Install: • adapter bolt (right) “9” (temporarily tighten) 9. Install: ...

  • Page 226: Camshafts

    Camshafts 5-9 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general ...

  • Page 227: Camshafts

    Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks crankshaft end cover/timing mark accessing bolt refer to “generator and starter clutch” on page 5-30. 1 timing chain cover 1 2 timing chain cover gasket 1 3 timing chain tensioner 1 4 timing chain tensioner gasket 1 5 intak...

  • Page 228: Camshafts

    Camshafts 5-11 eas23810 removing the camshafts 1. Remove: • timing mark accessing bolt “1” • crankshaft end cover “2” 2. Align: • mark “a” on the generator rotor (with the generator rotor cover mark “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is a...

  • Page 229: Camshafts

    Camshafts 5-12 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 230: Camshafts

    Camshafts 5-13 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 231: Camshafts

    Camshafts 5-14 b. Keep pressing the timing chain tensioner rod by hand, remove the hexagon wrench and slowly release the timing chain tensioner rod. C. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner hous- ing smoothly. If there is rough movement, re- place the ...

  • Page 232: Camshafts

    Camshafts 5-15 4. Install: • exhaust camshaft “1” • intake camshaft “2” tip • make sure the punch mark “a” on each cam- shaft faces up. • when installing the camshaft, no need to align the mark “b” on the camshaft sprocket. 5. Install: • camshaft cap • intake camshaft cap • exhaust camshaft cap tip ...

  • Page 233: Camshafts

    Camshafts 5-16 8. Check: • camshaft punch mark “a” make sure the punch mark “a” on the cam- shaft is aligned with the camshaft cap align- ment mark “b”. 9. Install: • timing chain tensioner • timing chain tensioner gasket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a few drops of engine oil to the ins...

  • Page 234: Camshafts

    Camshafts 5-17 turning the hexagon wrench clockwise. G. Remove the hexagon wrench, and check the timing chain tension. H. Install the timing chain tensioner cap bolt and gasket, and then tighten the timing chain ten- sioner cap bolt to the specified torque. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Turn: ...

  • Page 235: Camshafts

    Camshafts 5-18 tip after installing the cylinder head gasket “1” to the cylinder head cover, cut off the “a” section. 15.Install: • spark plugs • ignition coils “1” tip install the ignition coils “1” in the direction shown in the illustration. Spark plug 13 nm (1.3 m·kgf, 9.4 ft·lbf) 1 a t r . . 1.

  • Page 236: Cylinder Head

    Cylinder head 5-19 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Intake camshaft refer to “camshafts” on page 5-9. Exhaust camshaft refer to “camshafts” on page 5-9. 1 coolant temperature sensor 1 2 cylinder hea...

  • Page 237: Cylinder Head

    Cylinder head 5-20 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the camshafts” on page 5-11. 2. 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...

  • Page 238: Cylinder Head

    Cylinder head 5-21 eas24240 installing the cylinder head 1. Install: • timing chain guide (exhaust side) “1” • cylinder head gasket “2” • dowel pins “3” 2. Install: • cylinder head • cylinder head bolts (m6) • cylinder head bolts (m9) tip • pass the timing chain through the timing chain cavity. • lu...

  • Page 239: Valves and Valve Springs

    Valves and valve springs 5-22 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 5-19. 1 intake valve lifter 6 2 intake valve pad 6 3 intake valve cotter 12 4 intake valve spring retainer 6 5 i...

  • Page 240: Valves and Valve Springs

    Valves and valve springs 5-23 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 241: Valves and Valve Springs

    Valves and valve springs 5-24 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”. B. Inst...

  • Page 242: Valves and Valve Springs

    Valves and valve springs 5-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear  grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem  replace the valve. 5. M...

  • Page 243: Valves and Valve Springs

    Valves and valve springs 5-26 • valve seat tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice eca13790 do not let the lapping c...

  • Page 244: Valves and Valve Springs

    Valves and valve springs 5-27 2. Measure: • compressed valve spring force “a” out of specification  replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification  replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve ...

  • Page 245: Valves and Valve Springs

    Valves and valve springs 5-28 3. Install: • valve spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • valve spring retainer “5” (into the cylinder head) tip • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. ...

  • Page 246: Valves and Valve Springs

    Valves and valve springs 5-29 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..

  • Page 247: Generator and Starter Clutch

    Generator and starter clutch 5-30 eas24480 generator and starter clutch removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank r...

  • Page 248: Generator and Starter Clutch

    Generator and starter clutch 5-31 removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks 9 generator rotor 1 10 starter clutch 1 11 starter clutch gear 1 12 woodruff key 1 13 starter clutch idle gear shaft 1 14 starter clutch idle gear 1 15 crankshaft end...

  • Page 249: Generator and Starter Clutch

    Generator and starter clutch 5-32 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 250: Generator and Starter Clutch

    Generator and starter clutch 5-33 erator rotor “2” and hold the generator rotor. 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...

  • Page 251: Generator and Starter Clutch

    Generator and starter clutch 5-34 3. Apply: • sealant (onto the stator coil assembly lead grommet) 4. Install: • generator cover gasket • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. 5. Connect: • stator coil coupler • crankshaft position sensor couple...

  • Page 252: Electric Starter

    Electric starter 5-35 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to ...

  • Page 253: Electric Starter

    Electric starter 5-36 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 starter motor yoke 1 4 armature assembly 1 5 gasket 2 6 brush holder set 1 7 rear cover 1.

  • Page 254: Electric Starter

    Electric starter 5-37 eas24791 checking the starter motor 1. Check: • commutator dirt  clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification  scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of t...

  • Page 255: Electric Starter

    Electric starter 5-38 7. Check: • bearing • oil seal damage/wear  replace the starter motor. Eas24800 assembling the starter motor 1. Install: • brush holder set • insulator “1” tip install the insulator as shown in the illustration. 2. Install: • rear cover “1” • starter motor yoke “2” • front cov...

  • Page 256: Clutch

    Clutch 5-39 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-23. 1 clutch cable 1 disconnect. 2 cover 1 3 o 2 sensor coupler bracket 1 4 clutch cover 1 5 clutch cover gasket 1 6 dowel pin 2 7 oil filler ca...

  • Page 257: Clutch

    Clutch 5-40 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 1 2 pull lever 1 3 pull lever spring 1 4 circlip 1 5 pull lever shaft 1 6 oil seal 1 7 bearing 1 8 bearing 1 1 2 3 4 5 6 7 8 e.

  • Page 258: Clutch

    Clutch 5-41 removing the clutch order job/parts to remove q’ty remarks oil pump driven sprocket refer to “oil pump” on page 5-50. 1 compression spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 7 6 clutch plate 8 7 friction plate 2 2 green paint mark. 8 clutch boss nut 1 9 coni...

  • Page 259: Clutch

    Clutch 5-42 eas30712 removing the clutch 1. Remove: • cover “1” • clutch cover “2” • gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • oil pump driven sprocket “1” refer to “oil pump” on ...

  • Page 260: Clutch

    Clutch 5-43 8. Remove: • clutch boss nut • conical spring washer • washer • clutch boss • thrust plate • clutch housing • oil pump drive chain eas25100 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate 1, 2 damage/wear  replace ...

  • Page 261: Clutch

    Clutch 5-44 2. Measure: • clutch spring free length “a” out of specification  replace the clutch springs as a set. 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 housi...

  • Page 262: Clutch

    Clutch 5-45 eas25210 checking the primary driven gear 1. Check: • primary driven gear “1” damage/wear  replace the clutch housing and crankshaft as a set. Excessive noise during operation  replace the clutch housing and crankshaft as a set. Eas25220 checking the pull lever shaft and pull rod 1. Ch...

  • Page 263: Clutch

    Clutch 5-46 3. Install: • friction plate 1 • clutch plate • friction plate 2 tip • first, install a friction plate and then alternate between a clutch plate and a friction plate. • install the last friction plate “1” offset from the other friction plates “2”, making sure to align a projection on the...

  • Page 264: Clutch

    Clutch 5-47 7. Adjust: • clutch lever free play refer to “adjusting the clutch lever free play” on page 3-11. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) a b.

  • Page 265: Shift Shaft

    Shift shaft 5-48 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-39. Shift arm refer to “chain drive” on page 4-70. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 circlip 1 6 washer 1 7 stopper le...

  • Page 266: Shift Shaft

    Shift shaft 5-49 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear  replace. • shift shaft spring “2” • collar damage/wear  replace. Eas25430 checking the stopper lever 1. Check: • stopper lever “1” bends/damage  replace. Roller turns roughly  replace the stopper le...

  • Page 267: Oil Pump

    Oil pump 5-50 eas24921 oil pump removing the oil pump order job/parts to remove q’ty remarks clutch cover refer to “clutch” on page 5-39. 1 oil pump driven sprocket 1 2 oil pump assembly 1 1 2 10 nm (1.0 m • kgf, 7.2 ft • ibf) 15 nm (1.5 m • kgf, 11 ft • ibf) 10 nm (1.0 m • kgf, 7.2 ft • ibf) lt.

  • Page 268: Oil Pump

    Oil pump 5-51 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump cover 1 2 oil pump shaft 1 3 pin 1 4 oil pump inner rotor 1 5 oil pump outer rotor 1 6 circlip 1 hold down the washer when removing the circlip. 7 washer 1 8 spring 1 9 relief valve 1 10 dowel pin 2 e 1 2 3 4 ...

  • Page 269: Oil Pump

    Oil pump 5-52 eas25620 checking the sprocket and chain 1. Check: • oil pump drive sprocket refer to “checking the clutch hous- ing” on page 5-44. 2. Check: • oil pump drive chain “1” damage/stiffness  replace the oil pump drive chain and oil pump drive sprocket (clutch housing) as a set. Eas24960 c...

  • Page 270: Oil Pump

    Oil pump 5-53 eas24971 checking the relief valve 1. Check: • relief valve “1” • spring “2” damage/wear  replace the oil pump as- sembly. Eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • outer rotor “1” • inner...

  • Page 271: Oil Pan

    Oil pan 5-54 eas1rc1502 oil pan removing the oil pan order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Muffler assembly refer to “engine removal” on p...

  • Page 272: Oil Pan

    Oil pan 5-55 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas24990 checking the oil strainer 1. Check: • oi...

  • Page 273: Crankcase

    Crankcase 5-56 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 5-19. Water pump refer to “water pump” on page 6-8. Starter clutch refer to “generator and starter clutch” on...

  • Page 274: Crankcase

    Crankcase 5-57 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 the proper sequence...

  • Page 275: Crankcase

    Crankcase 5-58 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) notice eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turne...

  • Page 276: Crankcase

    Crankcase 5-59 8. Tighten: • crankcase bolts “9”–“30” tip tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolts “9”–“14” 24 nm (2.4 m·kgf, 17 ft·lbf) crankcase bolts “15”–“30” 10 nm (1.0 m·kgf, 7.2 ft·lbf) 8 1 2 3 4 5 6 7 8 t r . . 22 9 10 11 12 13 14 15 16 17 18 19 20 ...

  • Page 277: Connecting Rods and Pistons

    Connecting rods and pistons 5-60 eas1rc1503 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-56. 1 connecting rod cap 3 2 big end lower bearing 3 3 piston pin clip 6 4 piston pin 3 5 piston 3 6 ...

  • Page 278: Connecting Rods and Pistons

    Connecting rods and pistons 5-61 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” • connecting rod • big end bearings tip • identify the position of each big end bearing so that it can b...

  • Page 279: Connecting Rods and Pistons

    Connecting rods and pistons 5-62 and front-to-back measurements of the cylinder. Then, find the average of the measurements. B. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter “p” with the mi- crometer. D. If out of sp...

  • Page 280: Connecting Rods and Pistons

    Connecting rods and pistons 5-63 tip use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest. 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 oil r...

  • Page 281: Connecting Rods and Pistons

    Connecting rods and pistons 5-64 out of specification  replace the big end bearings. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the following procedure applies to all of the connecting rods. Notice eca13930 do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-b...

  • Page 282: Connecting Rods and Pistons

    Connecting rods and pistons 5-65 big end bearing kept in the current condition. Tip • do not move the connecting rod or crankshaft until the clearance measurement has been completed. • make sure that the projection “a” on the con- necting rod cap faces the same direction as the “y” mark “b” on the c...

  • Page 283: Connecting Rods and Pistons

    Connecting rods and pistons 5-66 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • big end bearings (p 1 –p 3 ) tip • the numbers “a” stamped into the crankshaft web and the numbers “1” on the connecting rods are used to determine the replacement big end bearings sizes. • “p 1 ”–“p 3 ” refer to the bear...

  • Page 284: Connecting Rods and Pistons

    Connecting rods and pistons 5-67 the bolt threads and seats with molybdenum disulfide oil. C. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. D. Tighten the connecting rod bolt while check- ing that the sections sh...

  • Page 285: Connecting Rods and Pistons

    Connecting rods and pistons 5-68 6. Offset: • piston ring end gaps 7. Lubricate: • crankshaft pins • connecting rod big end bearing inner surface (with the recommended lubricant) 8. Install: • piston assemblies “1” (into the cylinder “2” and onto the crankshaft pin) notice eca1rc1502 if the projecti...

  • Page 286: Connecting Rods and Pistons

    Connecting rods and pistons 5-69 b. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap “3”. C. Tighten the connecting rod bolts further to reach the specified angle 175–185. Warning ewa13400 if the connecting rod bolt is tightened more than the specified angle, ...

  • Page 287

    Crankshaft and balancer shaft 5-70 eas25950 crankshaft and balancer shaft removing the crankshaft and balancer shaft order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-56. Connecting rod refer to “removing the connecting rods and pistons” on page 5-61. 1 balancer s...

  • Page 288

    Crankshaft and balancer shaft 5-71 eas25980 removing the crankshaft and balancer shaft 1. Remove: • balancer shaft “1” • balancer shaft journal bearings • crankshaft assembly “2” • crankshaft journal bearings tip identify the position of each balancer shaft jour- nal bearings and crankshaft journal ...

  • Page 289

    Crankshaft and balancer shaft 5-72 d. Put a piece of plastigauge® “1” on each crankshaft journal. Tip do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves. Tip • align ...

  • Page 290

    Crankshaft and balancer shaft 5-73 eas26130 checking the balancer shaft 1. Measure: • balancer shaft runout out of specification  replace the balancer shaft. 2. Check: • balancer shaft journal surfaces • bearing surfaces scratches/wear  replace the balancer shaft. 3. Measure: • balancer shaft jour...

  • Page 291

    Crankshaft and balancer shaft 5-74 e. Install the balancer shaft journal lower bear- ings “1” into the lower crankcase and assem- ble the crankcase halves. Tip • align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in the crankcase. • do not move the balancer s...

  • Page 292

    Crankshaft and balancer shaft 5-75 nal bearings “1” with the notches “b” in the crankcase. • be sure to install each crankshaft journal bear- ings in its original place. Eas26220 installing the balancer assembly 1. Install: • balancer journal upper bearings (into the upper crankcase) • balancer jour...

  • Page 293: Transmission

    Transmission 5-76 eas26241 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-56. 1 drive axle assembly 1 2 oil seal 1 3 bearing 1 4 washer 1 5 shift drum retainer 2 6 shift fork guide bar...

  • Page 294: Transmission

    Transmission 5-77 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 295: Transmission

    Transmission 5-78 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 bearing 1 2 washer 1 3 1st wheel gear 1 4 collar 1 5 5th wheel gear 1 6 circlip 1 7 washer 1 8 3rd wheel gear 1 9 collar 1 10 toothed lock washer 1 11 toothed lock washer retainer 1 12 4th wheel gear 1 1...

  • Page 296: Transmission

    Transmission 5-79 disassembling the drive axle assembly order job/parts to remove q’ty remarks 21 collar 1 22 bearing 1 23 circlip 1 24 drive axle 1 21 m m e m e 22 23 24 m m m m m m.

  • Page 297: Transmission

    Transmission 5-80 eas26250 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork-l • shift fork-r • shift drum assembly • shift fork-c 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a...

  • Page 298: Transmission

    Transmission 5-81 eas26270 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear  replace the shift drum assembly. • shift drum segment “1” damage/wear  replace the shift drum as- sembly. • shift drum bearing “2” damage/pitting  replace the shift drum as- sembly. Ea...

  • Page 299: Transmission

    Transmission 5-82 • align the opening between the ends “b” of the circlip with a groove “c” in the axle. • install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e” as shown. 2. Install: • toothed lock washer retainer “1” • toothed lock washer “2” tip • with t...

  • Page 300: Transmission

    Transmission 5-83 3. Install: • shift fork-c “1” • shift drum assembly “2” • shift fork guide bar “3” tip • the embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “r”, “c”, “l”. • carefully position the shift forks so that they are in...

  • Page 301: Cooling System

    1 2 3 4 5 6 7 8 9 cooling system radiator .......................................................................................................6-1 checking the radiator .....................................................................6-2 installing the radiator ...................................

  • Page 302: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks air scoop (right) refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-26. 1 coolant reservoir hose 1 disconnect. 2 coolant reservoir cover 1 3 coolant reservoir 1 ...

  • Page 303: Radiator

    Radiator 6-2 eas26390 checking the radiator 1. Check: • radiator fins obstruction  clean. Apply compressed air to the rear of the radia- tor. Damage  repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage ...

  • Page 304: Radiator

    Radiator 6-3 pressure. C. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • radiator cap opening pressure below the specified pressure  replace the radiator cap. Refer to “checking the radiator” on page 6-2..

  • Page 305: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks coolant reservoir refer to “radiator” on page 6-1. Muffler assembly refer to “engine removal” on page 5-3. Coolant drain. Refer to “changing the coolant” on page 3-26. Engine oil drain. Refer to “changi...

  • Page 306: 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 cracks/damage/wear  replace. Eas26430 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth da...

  • Page 307: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks muffler assembly refer to “engine removal” on page 5-3. Coolant drain. Refer to “changing the coolant” on page 3-26. 1 radiator outlet hose 1 2 water pump inlet hose 1 3 oil cooler outlet hose ...

  • Page 308: Thermostat

    Thermostat 6-7 eas26450 checking the thermostat 1. Check: • thermostat assembly “1” cracks/damage  replace. Eas26480 installing the thermostat assembly 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-26. 2. Check: • coolin...

  • Page 309: Water Pump

    Water pump 6-8 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-26. 1 water pump inlet hose 1 disconnect. 2 water pump assembly 1 1 2 12 nm (1.2 m • kgf, 8.7 ft • ibf).

  • Page 310: Water Pump

    Water pump 6-9 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 water pump driven gear 1 5 pin 1 6 washer 1 7 impeller shaft 1 8 mechanical seal 1 9 bearing 1 10 oil seal 1 e e 1 2 3 4 5 6 7 8 9 10 10 nm (1.0 m • kgf, 7.2 ft • ...

  • Page 311: Water Pump

    Water pump 6-10 eas26520 disassembling the water pump 1. Remove: • mechanical seal (housing side) “1” tip remove the mechanical seal (housing side) from the inside of the water pump housing “2”. 2. Remove: • bearing “1” • oil seal “2” tip remove the oil seal and bearing from the out- side of the wat...

  • Page 312: Water Pump

    Water pump 6-11 with oil or grease. Tip use the special tools and a press to press the mechanical seal (housing side) straight in until it touches the water pump housing. 3. Install: • mechanical seal (impeller side) “1” tip • before installing the mechanical seal (impeller side), apply tap water or...

  • Page 313: Fuel System

    1 2 3 4 5 6 7 8 9 fuel system fuel tank ......................................................................................................7-1 removing the fuel tank ...................................................................7-3 removing the fuel pump ........................................

  • Page 314: 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. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. 1 fuel hose connector 1 disconnect. 2 fuel pump coupler 1 disconnect. 3 fuel tank breath...

  • Page 315: Fuel Tank

    Fuel tank 7-2 removing the rollover valve and canister (for california only) order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 canister purge hose (...

  • Page 316: Fuel Tank

    Fuel tank 7-3 eas1rc1701 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • rider seat • air scoop/fuel tank cover refer to “general chassis” on page 4-1. 3. Disconnect: • fuel hose (fuel tank side) • fuel pump coupler • fuel tank drain ho...

  • Page 317: Fuel Tank

    Fuel tank 7-4 tip • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • install the fuel pump gasket so that the lip side turns to the inside of the fuel tank. • install the fuel pump as shown in the illustra- tion. • align t...

  • Page 318: Throttle Bodies

    Throttle bodies 7-5 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Air scoop/fuel tank cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “...

  • Page 319: Throttle Bodies

    Throttle bodies 7-6 removing the sensors order job/parts to remove q’ty remarks 1 negative pressure hose 6 2 hose joint 2 3 canister purge hose 5 for california only. 4 hose joint 3 for california only. 5 intake air pressure sensor 2 1 6 intake air pressure sensor 1 1 7 throttle position sensor 1 8 ...

  • Page 320: Throttle Bodies

    Throttle bodies 7-7 removing the injectors order job/parts to remove q’ty remarks throttle bodies/throttle body joint refer to “throttle bodies” on page 7-5. 1 fuel rail 1 2 injector 3 3 injector coupler 2 disconnect. 4 injector lead 1 5 injector lead coupler 1 disconnect. 6 wire harness 1 7 adapter...

  • Page 321: Throttle Bodies

    Throttle bodies 7-8 eas1rc1706 checking the injectors (before removing) 1. Check: • injectors use the diagnostic code numbers “36”–“38”. Refer to “self-diagnostic function and diagnostic code table” on page 9-5. Eas1rc1710 removing the fuel hose (fuel rail side) 1. Remove: • fuel tank refer to “remo...

  • Page 322: Throttle Bodies

    Throttle bodies 7-9 warning ewa1rc1703 if the throttle bodies are subjected to strong shocks or dropped during cleaning, replace them as a set. 1. Check: • throttle bodies cracks/damage  replace the throttle bod- ies as a set. 2. Clean: • throttle bodies notice eca1rc1701 • observe the following pr...

  • Page 323: Throttle Bodies

    Throttle bodies 7-10 • do not allow carbon deposits or other for- eign materials to enter any of the passages in each throttle body or in the space be- tween the throttle valve shaft and the throt- tle body. F. After removing the carbon deposits, clean the inside of the throttle bodies with the reco...

  • Page 324: Throttle Bodies

    Throttle bodies 7-11 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” to the fuel rail joint “2”, and then connect an air compressor “3” to the adapter. B. Connect the pressure gauge “4” to the injec- tor pressure adapter “1”. C. Close the valve on the injector pressure ...

  • Page 325: Throttle Bodies

    Throttle bodies 7-12 faulty  replace the fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1rc1711 installing the fuel hose (fuel rail side) 1. Connect: • fuel hose (fuel rail side) notice eca1rc1708 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose connect...

  • Page 326: Throttle Bodies

    Throttle bodies 7-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1rc1717 adjusting the accelerator position sensor warning ewa1rc1706 • handle the accelerator position sensor with special care. • never subject the accelerator position sen- sor to strong shocks. If the accelerator po- sition sensor is droppe...

  • Page 327: Throttle Bodies

    Throttle bodies 7-14 m. Check the meter display value. If the meter display value is not 97–107, adjust the accel- erator position sensor angle. N. Select the diagnostic code number “15”. O. Turn the throttle grip to the fully closed posi- tion. P. Check the meter display value. If the meter display...

  • Page 328: Air Induction System

    Air induction system 7-15 eas27040 air induction system 1 2 3 2 3 4 4.

  • Page 329: Air Induction System

    Air induction system 7-16 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover).

  • Page 330: Air Induction System

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

  • Page 331: Air Induction System

    Air induction system 7-18 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 332: Air Induction System

    Air induction system 7-19 2. Install: • reed valve assembly 1 • reed valve assembly 2 tip • install the reed valve assembly 1 so that the open side turns to the exhaust side of the en- gine. • install the reed valve assembly 2 so that the open side turns to the intake side of the engine. 3. Install:...

  • Page 333: Electrical System

    1 2 3 4 5 6 7 8 9 electrical system ignition system...........................................................................................8-1 circuit diagram ...................................................................................8-1 engine stopping due to sidestand operation ...........

  • Page 334

    Checking the relay unit (diode)..................................................8-99 checking the ignition coils........................................................8-100 checking the ignition spark gap..............................................8-100 checking the crankshaft position sensor......

  • Page 336: Ignition System

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

  • Page 337: Ignition System

    Ignition system 8-2 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 18.Joint connector 19.Joint coupler 20.Relay unit 23.Ecu (engine control unit) 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Spark plug 33.Crankshaft position s...

  • Page 338: Ignition System

    Ignition system 8-3 eas1rc1804 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 339: Ignition System

    Ignition system 8-4 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 1. Check the fuses. (main, ignition and fuel i...

  • Page 340: Ignition System

    Ignition system 8-5 9. Check the gear position sensor. Refer to “checking the gear position sensor” on page 8-110. Ng replace the gear position sensor. Ok 10.Check the sidestand switch. Refer to “checking the switches” on page 8-89. Ng replace the sidestand switch. Ok 11.Check the relay unit (di...

  • Page 341: Ignition System

    Ignition system 8-6.

  • Page 342: Electric Starting System

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

  • Page 343: Electric Starting System

    Electric starting system 8-8 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 16.Starter relay 17.Starter motor 18.Joint connector 19.Joint coupler 20.Relay unit 21.Starting circuit cut-off relay 58.Gear position sensor 61.Sidestand switch 62.Rig...

  • Page 344: 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 345: Electric Starting System

    Electric starting system 8-10 a. When the transmission is in neu- tral b. When the sidestand is up and the clutch lever is pulled to the han- dlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Side...

  • Page 346: Electric Starting System

    Electric starting system 8-11 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (main, ignition and fuel injection ...

  • Page 347: Electric Starting System

    Electric starting system 8-12 9. Check the gear position sensor. Refer to “checking the gear position sensor” on page 8-110. Ng replace the gear position sensor. Ok 10.Check the sidestand switch. Refer to “checking the switches” on page 8-89. Ng replace the sidestand switch. Ok 11.Check the clut...

  • Page 348: Charging System

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

  • Page 349: Charging System

    Charging system 8-14 1. Ac magneto 2. Rectifier/regulator 4. Main fuse 13.Battery 14.Engine ground.

  • Page 350: Charging System

    Charging system 8-15 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Rear side cover 1. Check the fuse. (main) refer to “checking the fuses” on page 8-93. Ng replace the fuse. Ok 2. Check the battery. Refer to ...

  • Page 351: Charging System

    Charging system 8-16.

  • Page 352: Lighting System

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

  • Page 353: Lighting System

    Lighting system 8-18 3. Main switch 4. Main fuse 9. Ignition fuse 10.Signal fuse 11.Headlight fuse 13.Battery 14.Engine ground 18.Joint connector 19.Joint coupler 23.Ecu (engine control unit) 45.Meter assembly 47.Meter light 54.High beam indicator light 69.Left handlebar switch 74.Pass switch 75.Dim...

  • Page 354: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Rear side cover 6...

  • Page 355: Lighting System

    Lighting system 8-20 8. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 8-17. Ng properly connect or repair the lighting sys- tem’s wiring. Ok replace the ecu or meter assembly. Refer to “replacing the ecu (en- gine control unit)” on page 8-93..

  • Page 356: Signaling System

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

  • Page 357: Signaling System

    Signaling system 8-22 3. Main switch 4. Main fuse 8. Parking lighting fuse 9. Ignition fuse 10.Signal fuse 13.Battery 14.Engine ground 18.Joint connector 19.Joint coupler 20.Relay unit 23.Ecu (engine control unit) 35.Coolant temperature sensor 39.Speed sensor 45.Meter assembly 46.Neutral indicator l...

  • Page 358: Signaling System

    Signaling system 8-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter c...

  • Page 359: Signaling System

    Signaling system 8-24 the tail/brake light fails to come on. The turn signal light, turn signal indicator light or both fail to blink. 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Ng properly connect or repair the signaling system’s wiring. Ok this circui...

  • Page 360: Signaling System

    Signaling system 8-25 the neutral indicator light fails to come on. The oil level warning light fails to come on. The fuel level warning light fails to come on. 5. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Ng properly connect or repair the signaling system...

  • Page 361: Signaling System

    Signaling system 8-26 the speedometer fails to operate. The coolant temperature warning light fails to come on. 2. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Ng properly connect or repair the signaling system’s wiring. Ok replace the ecu or meter assembly....

  • Page 362: Cooling System

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

  • Page 363: Cooling System

    Cooling system 8-28 3. Main switch 4. Main fuse 7. Radiator fan fuse 9. Ignition fuse 13.Battery 14.Engine ground 18.Joint connector 23.Ecu (engine control unit) 35.Coolant temperature sensor 85.Radiator fan motor relay 86.Radiator fan motor.

  • Page 364: Cooling System

    Cooling system 8-29 eas27320 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (main, ignition and radiator fan) refer to “checking the fuses” on page 8-93. ...

  • Page 365: Cooling System

    Cooling system 8-30

  • Page 366: Fuel Injection System

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

  • Page 367: Fuel Injection System

    Fuel injection system 8-32 3. Main switch 4. Main fuse 5. Electric throttle valve fuse 9. Ignition fuse 11.Headlight fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 16.Starter relay 18.Joint connector 19.Joint coupler 20.Relay unit 21.Starting circuit cut-off relay 22.Fuel pump relay ...

  • Page 368: Fuel Injection System

    Fuel injection system 8-33 eas27351 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 369: Fuel Injection System

    Fuel injection system 8-34 ecu detects an abnormal signal from a sensor if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for...

  • Page 370: Fuel Injection System

    Fuel injection system 8-35 eas30580 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the faulty system with the fa...

  • Page 371: Fuel Injection System

    Fuel injection system 8-36 eas27411 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 “select” button “1” and “reset” button “2” , turn the main switch to “on”, and continue to...

  • Page 372: Fuel Injection System

    Fuel injection system 8-37 tip information about each diagnostic code number is organized in this manual as follows: • if a diagnostic code number has a corresponding fault code number, the information is shown in “troubleshooting details”. (refer to “troubleshooting details” on page 8-38.) • if a d...

  • Page 373: Fuel Injection System

    Fuel injection system 8-38 tip when the yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation. Eas27462 troubleshooting details this section describes the measures per fault code number displayed on th...

  • Page 374: Fuel Injection System

    Fuel injection system 8-39 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 securely or replace the wire harness. ...

  • Page 375: Fuel Injection System

    Fuel injection system 8-40 procedure shift the transmission into gear, extend the sidestand, and then operate the throttle while pushing the “ ” side of the start/engine stop switch. (if the display value changes, the performance is ok.) item probable cause of malfunction and check maintenance job c...

  • Page 376: Fuel Injection System

    Fuel injection system 8-41 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 1. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the current altitud...

  • Page 377: Fuel Injection System

    Fuel injection system 8-42 item probable cause of malfunction and check maintenance job confirmation of service completion 1 condition of intake air pres- sure sensor 1 hose. Check the intake air pressure sensor hose condition. Clogged or detached hose  repair or replace the sensor hose. Start the ...

  • Page 378: Fuel Injection System

    Fuel injection system 8-43 01 meter display throttle position sensor signal 1 • 11–21 (fully closed position) • 96–106 (fully open position) procedure • check with throttle valves fully closed. • check with throttle valves fully open. 13 meter display throttle position sensor signal 2 • 9–23 (fully ...

  • Page 379: Fuel Injection System

    Fuel injection system 8-44 5 throttle position sensor resistance. Measure the throttle position sensor resistance. Black/blue–blue refer to “checking the throttle position sen- sor” on page 8-107. Turn the main switch to “on”. Fault code number is not dis- played  service is finished. Fault code nu...

  • Page 380: Fuel Injection System

    Fuel injection system 8-45 item probable cause of malfunction and check maintenance job confirmation of service completion 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...

  • Page 381: Fuel Injection System

    Fuel injection system 8-46 6 defective sidestand switch. Execute the diagnostic mode. (code no. 20) shift the transmission into gear. Sidestand retracted: “on” sidestand extended: “off” replace if defective. Turn the main switch to “on”, and then extend and retract the sidestand. Fault code number i...

  • Page 382: Fuel Injection System

    Fuel injection system 8-47 1 defective intake air pressure sensor 1. Execute the diagnostic mode. (code no. 03) 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) abov...

  • Page 383: Fuel Injection System

    Fuel injection system 8-48 fault code no. 21 item coolant temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 06 meter display displays the coolant temperature. Procedure compare the actually measured coolant temperature...

  • Page 384: Fuel Injection System

    Fuel injection system 8-49 5 defective coolant tempera- ture sensor. Execute the diagnostic mode. (code no. 06) 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 cool- ant temperature sens...

  • Page 385: Fuel Injection System

    Fuel injection system 8-50 3 wire harness continuity. Open or short circuit  replace the wire harness. Between intake air tempera- ture sensor coupler and ecu coupler. Brown/white–brown/white between intake air tempera- ture sensor coupler and joint connector. Black/blue–black/blue between joint co...

  • Page 386: Fuel Injection System

    Fuel injection system 8-51 item probable cause of malfunction and check maintenance job confirmation of service completion 1 installed condition of o 2 sen- sor. Improperly installed sensor  reinstall or replace the sensor. Start the engine, warm it up, and then race it, or execute the diagnostic m...

  • Page 387: Fuel Injection System

    Fuel injection system 8-52 5 check fuel pressure. Refer to “checking the fuel pressure” on page 7-11. 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 388: Fuel Injection System

    Fuel injection system 8-53 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 securely or replace the wire harness. ...

  • Page 389: Fuel Injection System

    Fuel injection system 8-54 tip • if fault code numbers “25” and “26” are both indicated, take the actions specified for fault code number “25” first. • if fault code numbers “25” and “14” are both indicated, take the actions specified for fault code number “25” first. 5 defective intake air pressure...

  • Page 390: Fuel Injection System

    Fuel injection system 8-55 tip • if fault code numbers “25” and “26” are both indicated, take the actions specified for fault code number “25” first. • if fault code numbers “26” and “37” are both indicated, take the actions specified for fault code number “26” first. Procedure shift the transmissio...

  • Page 391: Fuel Injection System

    Fuel injection system 8-56 fault code no. 30 item latch up 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 lean angle sensor and incline it ...

  • Page 392: Fuel Injection System

    Fuel injection system 8-57 actuation actuates the cylinder-#1 ignition coil five times at one-second intervals. Illuminates the engine trouble warning light. Procedure check that a spark is generated five times. • connect an ignition checker. Item probable cause of malfunction and check maintenance ...

  • Page 393: Fuel Injection System

    Fuel injection system 8-58 6 malfunction in ecu. Execute the diagnostic mode. (code no. 30) no spark  replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-93. Fault code no. 34 item cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinde...

  • Page 394: Fuel Injection System

    Fuel injection system 8-59 4 installed condition of cylin- der-#2 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 395: Fuel Injection System

    Fuel injection system 8-60 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 securely or replace the wire harness. ...

  • Page 396: Fuel Injection System

    Fuel injection system 8-61 37 actuation actuates injector #2 five times at one-second intervals. Illuminates the engine trouble warning light. Procedure check that injector #2 is actuated five times by listening for the operating sound. 38 actuation actuates injector #3 five times at one-second inte...

  • Page 397: Fuel Injection System

    Fuel injection system 8-62 5 wire harness continuity. Open or short circuit  replace the wire harness. Between injector coupler and ecu coupler. Injector #1 red/black–red/black injector #2 green/black–green/black injector #3 blue/black–blue/black between injector coupler and relay unit coupler. Red...

  • Page 398: Fuel Injection System

    Fuel injection system 8-63 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 securely or replace the wire harness. ...

  • Page 399: Fuel Injection System

    Fuel injection system 8-64 procedure check that the number increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped. Item probable cause of malfunction and check maintenance job confirmation of service completion 1 locate the malfunction. E...

  • Page 400: Fuel Injection System

    Fuel injection system 8-65 4 wire harness continuity. Open or short circuit  replace the wire harness. Between speed sensor cou- pler and ecu coupler. White/yellow–white/yellow between speed sensor cou- pler and joint connector. Blue–blue black/blue–black/blue between joint connector and ecu couple...

  • Page 401: Fuel Injection System

    Fuel injection system 8-66 meter display neutral • “on” (when the transmission is in neutral) • “off” (when the transmission is in gear or the clutch lever released) procedure shift the transmission. Item probable cause of malfunction and check maintenance job confirmation of service completion 1 lo...

  • Page 402: Fuel Injection System

    Fuel injection system 8-67 3 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 securely or replace the wire harness. ...

  • Page 403: Fuel Injection System

    Fuel injection system 8-68 7 faulty shift drum (neutral detection area). Malfunction  replace the shift drum. Refer to “transmission” on page 5-76. Execute the diagnostic mode. (code no. 21) when the transmission is in neutral: “on” when the transmission is in gear with the clutch lever released: “...

  • Page 404: Fuel Injection System

    Fuel injection system 8-69 procedure operate the transmission, clutch lever, and sidestand. Item probable cause of malfunction and check maintenance job confirmation of service completion 1 locate the malfunction. Execute the diagnostic mode. (code no. 07) rotate the rear wheel by hand and check tha...

  • Page 405: Fuel Injection System

    Fuel injection system 8-70 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 securely or replace the wire harness. ...

  • Page 406: Fuel Injection System

    Fuel injection system 8-71 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 mi/h). The fault code can also be delete by activating the diag- nostic mode a...

  • Page 407: Fuel Injection System

    Fuel injection system 8-72 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 securely or replace the wire harness. ...

  • Page 408: Fuel Injection System

    Fuel injection system 8-73 meter display eeprom fault code display • 00 (no history) • 01–03: cylinder fault code number (history exists) if more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defective cylinders in a repeating c...

  • Page 409: Fuel Injection System

    Fuel injection system 8-74 fault code no. 50 item faulty ecu memory. (when this malfunction is detected in the ecu, the fault code number might not appear on the meter display.) fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. — meter display — procedure ...

  • Page 410: Fuel Injection System

    Fuel injection system 8-75 1 connection of accelerator position 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 securely or replace the wir...

  • Page 411: Fuel Injection System

    Fuel injection system 8-76 6 defective accelerator posi- tion sensor. Check accelerator position sensor signal 1. Execute the diagnostic mode. (code no. 14) when the throttle grip is fully closed: a value of 12–22 is indicated. When the throttle grip is fully open: a value of 97–107 is indi- cated. ...

  • Page 412: Fuel Injection System

    Fuel injection system 8-77 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 securely or replace the wire harne...

  • Page 413: Fuel Injection System

    Fuel injection system 8-78 fault code no. 89 (yamaha diagnostic tool) err (multi-function meter display) item multi-function meter: signals cannot be transmitted between the ecu and the multi-function meter. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter disp...

  • Page 414: Fuel Injection System

    Fuel injection system 8-79 5 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-93. Fault code no. 89 (yamaha diagnostic tool) err (multi-function meter display) item multi-function meter: signals cannot be transmitted between the ecu and the multi-func...

  • Page 415: Fuel Injection System

    Fuel injection system 8-80

  • Page 416: Fuel Pump System

    Fuel pump system 8-81 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 417: Fuel Pump System

    Fuel pump system 8-82 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 18.Joint connector 20.Relay unit 22.Fuel pump relay 23.Ecu (engine control unit) 60.Fuel pump 62.Right handlebar switch 64.Start/engine stop switch.

  • Page 418: Fuel Pump System

    Fuel pump system 8-83 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (main, ignition and fuel injection system) refer to “checking the fuses” on pag...

  • Page 419: Fuel Pump System

    Fuel pump system 8-84.

  • Page 420: Electrical Components

    Electrical components 8-85 eas27973 electrical components 4 5 6 7 8 9 10 11 12 13 14 15 16 17.

  • Page 421: Electrical Components

    Electrical components 8-86 1. Main switch 2. Clutch switch 3. Front brake light switch 4. Battery 5. Fuse box 2 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Rectifier/regulator 10.Rear brake light switch 11.Gear position sensor 12.Sidestand switch 13.O 2 sensor 14.Oil level switch ...

  • Page 422: Electrical Components

    Electrical components 8-87.

  • Page 423: Electrical Components

    Electrical components 8-88 1. Intake air temperature sensor 2. Headlight relay 3. Ecu (engine control unit) 4. Fuel pump 5. Lean angle sensor 6. Radiator fan motor relay 7. Turn signal/hazard relay 8. Relay unit 9. Speed sensor 10.Stator coil 11.Crankshaft position sensor 12.Coolant temperature sens...

  • Page 424: Electrical Components

    Electrical components 8-89 eas27981 checking the switches 2 1 3 4 5 6 7 11 12 13 8 9 10

  • Page 425: Electrical Components

    Electrical components 8-90 1. Dimmer switch 2. Pass switch 3. Turn signal switch 4. Horn switch 5. Clutch switch 6. Oil level switch 7. Sidestand switch 8. Hazard switch 9. Start/engine stop switch 10.Drive mode switch 11.Front brake light switch 12.Main switch 13.Rear brake light switch.

  • Page 426: Electrical Components

    Electrical components 8-91 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 427: Electrical Components

    Electrical components 8-92 eas27990 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear  repair or replace the bulb, bulb socket or both. Improperly connected  properly connect. No co...

  • Page 428: Electrical Components

    Electrical components 8-93 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 the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb in...

  • Page 429: Electrical Components

    Electrical components 8-94 (idle speed control) learning value. Refer to “checking and cleaning the throttle bodies” on page 7-8. 4. Check: • engine idling speed start the engine, warm it up, and then mea- sure the engine idling speed. Eas28031 checking and charging the battery warning ewa13290 batt...

  • Page 430: Electrical Components

    Electrical components 8-95 • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warni...

  • Page 431: Electrical Components

    Electrical components 8-96 charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat- tery and start charging. Tip set the charging voltage to 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the batter...

  • Page 432: Electrical Components

    Electrical components 8-97 10.Install: • rider seat refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. 1. Disconnect the relay from the wire harness. 2. Connect the...

  • Page 433: Electrical Components

    Electrical components 8-98 headlight relay radiator fan motor relay eas1rc1801 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification  the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must be repai...

  • Page 434: Electrical Components

    Electrical components 8-99 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification  replace. Tip the pocket tester or the analog pocket test...

  • Page 435: Electrical Components

    Electrical components 8-100 unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28100 checking the ignition coils the following procedure applies to all of the igni- tion coils. 1. Check: • pri...

  • Page 436: Electrical Components

    Electrical components 8-101 c. Turn the main switch to “on”. D. Measure the ignition spark gap “a”. E. Crank the engine by pushing the “ ” side of the start/engine stop switch and gradually in- crease the spark gap until a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28120 checking the cranks...

  • Page 437: Electrical Components

    Electrical components 8-102 c. Set the main switch to “on”. D. Turn the lean angle sensor to 65. E. Measure the lean angle sensor output volt- age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28940 checking the starter motor operation 1. Check: • starter motor operation does not operate  perform the elect...

  • Page 438: Electrical Components

    Electrical components 8-103 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. B. Connect the pocket tester (ac 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run at approximate- ly 5000 r/min. D. Measure the rectifie...

  • Page 439: Electrical Components

    Electrical components 8-104 c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • horn sound faulty sound  replace. Eas28190 checking the engine oil level switch 1. Drain: • engine oil 2. Remove: • oil level switch (from the oil pan) 3. Check: • oil level switch resistance ▼▼...

  • Page 440: Electrical Components

    Electrical components 8-105 b. Move the fuel sender float to maximum “3” and minimum “4” level position. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas29040 checking the fuel meter/fuel level warning light this model is equipped with a self-diagnosis de- vice for the fuel level detection circuit. 1. Check: • ...

  • Page 441: Electrical Components

    Electrical components 8-106 c. Set the main switch to “on”. D. Elevate the rear wheel and slowly rotate it. E. Measure the voltage. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28250 checking th...

  • Page 442: Electrical Components

    Electrical components 8-107 e. Measure the coolant temperature sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • coolant temperature sensor eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle bodies) warning ewa1rc1705 • handle th...

  • Page 443: Electrical Components

    Electrical components 8-108 b. Measure the accelerator position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • accelerator position sensor tip when installing the accelerator position sensor, adjust its angle properly. Refer to “adjusting the accelerator position sensor” o...

  • Page 444: Electrical Components

    Electrical components 8-109 c. Measure the air induction system solenoid re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28411 checking the intake air pressure sensor 1. Check: • intake air pressure sensor output voltage out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect t...

  • Page 445: Electrical Components

    Electrical components 8-110 b. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Tip make sure that the intake air temperature sensor terminals do not get wet. C. Place a thermometer “3” in the water. D. Slowly heat the water, then let it cool down to the specified ...

  • Page 446: Electrical Components

    Electrical components 8-111 eas1rc1817 checking the fuel injectors the following procedure applies to all of the fuel injectors. 1. Remove: • fuel injector refer to “throttle bodies” on page 7-5. 2. Check: • fuel injector resistance out of specification  replace the fuel injec- tor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 447: Troubleshooting

    1 2 3 4 5 6 7 8 9 troubleshooting troubleshooting......................................................................................9-1 general information ........................................................................9-1 starting failures ..................................................

  • Page 448: Troubleshooting

    Troubleshooting 9-1 eas28451 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ad...

  • Page 449: Troubleshooting

    Troubleshooting 9-2 • worn or damaged electrode • worn or damaged insulator 3. Ignition coil(s) • broken or shorted primary or secondary coils • cracked or broken ignition coil 4. Ignition system • faulty ecu • faulty crankshaft position sensor • broken generator rotor woodruff key eas30450 poor med...

  • Page 450: Troubleshooting

    Troubleshooting 9-3 • damaged pipe • improperly connected pipe fuel system 1. Throttle body (-ies) • damaged or loose throttle body joint 2. Air filter • clogged air filter element chassis 1. Brake(s) • dragging brake electrical system 1. Spark plug(s) • incorrect spark plug gap • incorrect spark pl...

  • Page 451: Troubleshooting

    Troubleshooting 9-4 • faulty rectifier/regulator • improperly grounded circuit • faulty main switch • faulty dimmer switch • headlight bulb life expired tail/brake light does not come on • too many electrical accessories • incorrect connection turn signal does not come on • faulty turn signal switch...

  • Page 452

    Self-diagnostic function and diagnostic code table 9-5 eas1rc1902 self-diagnostic function and diagnostic code table self-diagnostic function table fault code no. Item reference pages 12 crankshaft position sensor: no normal signals are received from the crankshaft position sensor. 8-38 13 intake ai...

  • Page 453

    Self-diagnostic function and diagnostic code table 9-6 communication error with the meter diagnostic code: sensor operation table 59 accelerator position sensor: open or short circuit detected. 8-74 60 ycc-t drive system: malfunction detected. 8-76 70 engine idling stop — fault code no. Item referen...

  • Page 454

    Self-diagnostic function and diagnostic code table 9-7 06 coolant temperature when engine is cold: dis- plays temperature closer to air temperature. When engine is hot: dis- plays current coolant tem- perature. Compare the actually measured coolant temper- ature with the meter dis- play value. 07 ve...

  • Page 455

    Self-diagnostic function and diagnostic code table 9-8 20 sidestand switch extend and retract the sid- estand (with the transmis- sion in gear). • stand retracted on • stand extended off 21 gear position sensor and clutch switch operate the transmission, clutch lever, and sides- tand. • transmission...

  • Page 456

    Self-diagnostic function and diagnostic code table 9-9 61 malfunction history code display — • no history 00 • history exists fault codes 12–89 • (if more than one code number is detected, the display alternates every two seconds to show all the detected code num- bers. When all code numbers are sho...

  • Page 457

    Self-diagnostic function and diagnostic code table 9-10 diagnostic code: actuator operation table 67 isc (idle speed control) learning condition display isc (idle speed control) learning data erasure 00 isc (idle speed control) learning data has been erased. 01 it is not necessary to erase the isc (...

  • Page 458

    Self-diagnostic function and diagnostic code table 9-11 48 air induction system sole- noid actuates the air induction system solenoid five times at one-second intervals. Illuminates the engine trouble warning light. Check that the air induc- tion system solenoid is actuated five times by lis- tening...

  • Page 459: Event Code Table

    Event code table 9-12 eas1rc1903 event code table tip the event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the yamaha diagnostic tool. No. Item symptom possible causes note 192 intake air pres- sure sensor 1 brief abnormality detected in the in...

  • Page 460: Event Code Table

    Event code table 9-13 240 o 2 sensor (stuck at the upper limit for adjustment) during o 2 feed- back, the adjust- ment is maintained at the upper limit – open or short cir- cuit in the wire har- ness between the sensor and ecu – drop in fuel pres- sure – clogged fuel injec- tor – fault in sensor – m...

  • Page 461: Event Code Table

    Event code table 9-14 243 isc (stuck at the lower limit for adjustment) during idling, the adjustment is main- tained at the lower limit idling engine speed is fast – poorly adjusted throttle cable – poorly adjusted clutch cable – malfunction in the fuel injection sys- tem – dirty or worn spark plug...

  • Page 462: Event Code Table

    Event code table 9-15.

  • Page 463

    Eas28740 wiring diagram fz09e/fz09ec 2014 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Electric throttle valve fuse 6. Backup fuse 7. Radiator fan fuse 8. Parking lighting fuse 9. Ignition fuse 10.Signal fuse 11.Headlight fuse 12.Auxiliary dc outlet fuse 13.Battery 14.Engine g...

  • Page 467

    Fz09e/fz09ec 2014 wiring diagram 1rc-28197-10_w.D.Indd 1 2013/09/20 13:52:03.

  • Page 468

    Fz09e/fz09ec 2014 wiring diagram 1rc-28197-10_w.D.Indd 2 2013/09/20 13:52:04.