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Yamaha FZ6-S 2004 Service Manual

Summary of FZ6-S 2004

  • Page 3

    Eas00000 fz6-s (s) service manual 2003 by yamaha motor co., ltd. First edition, august 2003 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Notice

    Note: warning caution: eas00002 notice 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 manu- al. Therefore, anyone who uses this book to perform maintena...

  • Page 5: How To Use This Manual

    1 2 4 8 3 5 6 7 eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 ...

  • Page 6: Gen

    22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng fi elec cool chk adj trbl shtg chas eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic che...

  • Page 7: General Information

    General information specifications periodic checks and adjustments chassis engine cooling system fuel injection system electrical system troubleshooting gen info 1 spec 2 3 eng 4 cool 5 fi 6 chas 7 elec 8 trbl shtg 9 chk adj eas00012 table of contents.

  • Page 10: Gen

    Gen info chapter 1 general information motorcycle identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle identification number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . Model label 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 11: Gen

    Gen info.

  • Page 12: Gen

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

  • Page 13: Gen

    1-2 features gen info 7 intake air pressure sensor 8 throttle position sen- sor 9 fuel injector 10 catalytic converter 11 crankshaft position sensor 12 coolant temperature sensor 13 spark plug 14 pressure regulator 15 battery 16 ecu 17 fuel injection system relay 18 engine trouble warn- ing light 19...

  • Page 14: Gen

    1-3 features gen info illustration is for reference only. 6 throttle position sen- sor 7 intake air pressure sensor 8 ecu 9 coolant temperature sensor 10 crankshaft position sensor a fuel system b control system 1 fuel pump 2 pressure regulator 3 fuel injector 4 throttle body 5 intake air temperatur...

  • Page 15: Gen

    1-4 features gen info 1 multi-function display 2 “select” button 3 “reset” button 4 engine trouble warning light note: instrument function multi-function display the multi-function display is equipped with the following: sa speedometer (which shows the riding speed) san odometer (which shows the tot...

  • Page 16: Gen

    1-5 features gen info clock mode to set the clock: 1. Push the “select” button and “reset” button together for at least two seconds. 2. When the hour digits start flashing, push the “reset” button to set the hours. 3. Push the “select” button, and the minute digits will start flashing. 4. Push the “...

  • Page 17: Gen

    1-6 important information gen info spring lip oil grease lip eas00020 important information preparation for removal and disassembly 1. Before removal and disassembly, eliminate all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “special tools”...

  • Page 18: Gen

    1-7 important information gen info caution: eas00023 lock washers/ plates and cotter pins after removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals...

  • Page 19: Gen

    1-8 checking the connections gen info note: note: note: eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: slead scoupler sconnector 2. Check: slead scoupler sconnector moisture ! Dry with an air blower. Rust / stains ! Connect...

  • Page 20: Gen

    1-9 special tools gen info note: 1 2 1 eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special t...

  • Page 21: Gen

    1-10 special tools gen info tool no. Tool name / function illustration 90890-01426 yu-38411 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. Fork seal driver 90890-01367 ym-33963 fork seal driver attachment 90890-01374 ym-8020-a fork seal driver weight fork seal d...

  • Page 22: Gen

    1-11 special tools gen info tool no. Tool name / function illustration middle driven shaft bearing driver 90890-04058 ym-4058 mechanical seal installer 90890-04078 ym-33221 middle driven shaft bearing driver mechanical seal installer these tools are used to install the water pump seal. 90890-04086 y...

  • Page 25: Spec

    Spec chapter 2 specifications general specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine specifications 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis specifications 2-10 . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 26: Spec

    Spec.

  • Page 27: Spec

    2-1 general specifications spec specifications general specifications item standard limit model code 5vx1 (eur), 5vx2 (aus) sss dimensions overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 2,095 mm (82.5 in) 750 mm (29.5 in) 1,215 mm (4...

  • Page 28: Spec

    2-2 engine specifications spec engine specifications item standard limit engine engine type displacement cylinder arrangement bore stroke compression ratio engine idling speed vacuum pressure at engine idling speed standard compression pressure (at sea level) liquid-cooled, 4-stroke, dohc 600 cm 3 (...

  • Page 29: Spec

    2-3 engine specifications spec item standard limit oil filter oil filter type bypass valve opening pressure formed 80 x 120 kpa (0.8 x 1.2 kg/cm 2 , 0.8 x 1.2 bar, 11.6 x 17.4 psi) sss sss oil pump oil pump type inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clearance troch...

  • Page 30: Spec

    2-4 engine specifications spec item standard limit camshafts drive system camshaft cap inside diameter camshaft journal diameter camshaft-journal-to-camshaft- cap clearance intake camshaft lobe dimensions measurement a measurement b exhaust camshaft lobe dimensions measurement a measurement b max. C...

  • Page 31: Spec

    2-5 engine specifications spec head diameter face width seat width margin thickness item standard limit timing chain model / number of links tensioning system 92rh2015 / 120 automatic sss sss valves, valve seats, valve guides valve clearance (cold) intake exhaust valve dimensions 0.13 x 0.20 mm (0.0...

  • Page 32: Spec

    2-6 engine specifications spec item standard limit valve springs free length intake (inner) intake (outer) exhaust installed length (valve closed) intake (inner) intake (outer) exhaust compressed spring force (installed) intake (inner) (outer) exhaust spring tilt intake (inner) intake (outer) exhaus...

  • Page 33: Spec

    2-7 engine specifications spec item standard limit piston piston-to-cylinder clearance diameter d height h piston pin bore (in the piston) diameter offset offset direction piston pins outside diameter piston-pin-to-piston-pin-bore clearance piston rings top ring ring type dimensions (b t) end gap (i...

  • Page 34: Spec

    2-8 engine specifications spec item standard limit connecting rods crankshaft-pin-to-big-end-bearing clearance bearing color code 0.028 x 0.052 mm (0.0011 x 0.0020 in) 1 = blue 2 = black 3 = brown 4 = green 0.08 mm (0.0032 in) sss crankshaft width a width b max. Runout c big end side clearance d big...

  • Page 35: Spec

    2-9 engine specifications spec item standard limit transmission transmission type primary reduction system primary reduction ratio secondary reduction system secondary reduction ratio operation gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear max. Main axle runout max. Drive axle ru...

  • Page 36: Spec

    2-10 chassis specifications spec chassis specifications item standard limit frame frame type caster angle trail diamond 25 _ 97.5 mm (3.84 in) sss sss sss front wheel wheel type rim size material wheel travel wheel runout max. Radial wheel runout max. Lateral wheel runout cast wheel 17 m / c mt3.50 ...

  • Page 37: Spec

    2-11 chassis specifications spec item standard limit rear tire tire type size model (manufacturer) tire pressure (cold) 0 x 90 kg (0 x 198 lb) 90 x 190 kg (198 x 419lb) high-speed riding min. Tire tread depth tubeless 180 / 55 zr17 m / c (73w) bt020r gg (bridgestone) d252 (dunlop) 250 kpa (2.5 kgf /...

  • Page 38: Spec

    2-12 chassis specifications spec item standard limit front suspension suspension type front fork type front fork travel spring free length spacer length installed length spring rate (k1) spring rate (k2) spring stroke (k1) spring stroke (k2) inner tube outer diameter inner tube bending limit optiona...

  • Page 39: Spec

    2-13 chassis specifications spec item standard limit steering steering bearing type angular bearing sss rear suspension suspension type rear shock absorber assembly type rear shock absorber assembly travel spring free length installed length spring rate (k1) spring stroke (k1) optional spring availa...

  • Page 40: Spec

    2-14 electrical specifications spec electrical specifications item standard limit system voltage 12 v sss ignition system ignition system type ignition timing advancer type crankshaft position sensor resistance / color t.C.I. Unit model (manufacturer) dc. T.C.I. 5 _ btdc at 1,300 r/min digital 248 x...

  • Page 41: Spec

    2-15 electrical specifications spec item standard limit indicator light (voltage / wattage quantity) neutral indicator light high beam indicator light oil level warning light turn signal indicator light engine trouble warning light immobilizer indicator light led 1 led 1 led 1 led 2 led 1 led 1 sss ...

  • Page 42: Spec

    2-16 electrical specifications spec item standard limit fuses (amperage quantity) main fuse fuel injection system fuse headlight fuse signaling system fuse ignition fuse radiator fan motor fuse backup fuse (odometer and clock) parking light fuse reserve fuse 30 a 1 10 a 1 20 a 1 10 a 1 10 a 1 20 a 1...

  • Page 43: Spec

    2-17 eas00030 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid war- page, tighten ...

  • Page 44: Spec

    2-18 tightening torques spec yamaha bond no.1215 tightening torques engine tightening torques item fastener thread q’ty tightening torque remarks item fastener size q ty nm m skg ft slb remarks spark plugs – m10 4 18 1.8 13 cylinder head bolt m10 10 1st 19 2nd 50 1.9 5.0 14 36 bolt m6 2 12 1.2 8.7 c...

  • Page 45: Spec

    2-19 yamaha bond no.1215 use a lock washer use a lock washer left thread note 1: tightening torques spec note 2: item fastener thread q’ty tightening torque remarks item fastener size q ty nm m skg ft slb remarks crankcase (main journal) bolt m8 10 see note 2 crankcase bolt m6 2 14 1.4 1.0 crankcase...

  • Page 46: Spec

    2-20 tightening torques spec cylinder head tightening sequence: crankcase tightening sequence..

  • Page 47: Spec

    2-21 tightening torques spec chassis tightening torques item thread tightening remarks item size nm m skg ftslb remarks upper bracket pinch blot m8 30 3.0 22 steering stem nut m22 110 11 80 upper bracket and upper handlebar holder m8 23 2.3 17 under bracket pinch blot – 30 3.0 22 lower ring nut m25 ...

  • Page 48: Spec

    2-22 tightening torques spec note 1: note 2: item thread tightening remarks item size nm m skg ftslb remarks engine stop switch and frame m4 2 0.2 1.4 coolant reserver tank bracket and stay 1, 2 m6 10 1.0 7.2 stay 1, 2 and frame m6 10 1.0 7.2 coolant reserver tank bracket and coolant reserver tank m...

  • Page 49: Spec

    2-23 lubrication points and lubricant types spec eas00031 lubrication points and lubricant types engine lubrication point lubricant oil seal lips o-rings bearings and bushes crankshaft pins piston surfaces piston pins connecting rod bolts crankshaft journals camshaft lobes camshaft journals valve st...

  • Page 50: Spec

    2-24 lubrication points and lubricant types spec eas00032 chassis lubrication point lubricant steering bearings and bearing races (upper and lower) front wheel oil seal (right and left) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surface rear brake pedal shaft sides...

  • Page 51: Spec

    2-25 cooling system diagrams spec 1 radiator 2 oil cooler cooling system diagrams.

  • Page 52: Spec

    2-26 cooling system diagrams spec 1 water pump 2 oil cooler 3 radiator.

  • Page 53: Spec

    2-27 cooling system diagrams spec 1 oil cooler 2 water pump.

  • Page 54: Spec

    2-28 cooling system diagrams spec 1 radiator 2 thermostat.

  • Page 55: Spec

    2-29 engine oil lubrication chart spec engine oil lubrication chart.

  • Page 56: Spec

    2-30 lubrication diagrams spec 1 oil level switch 2 oil cooler 3 relief valve lubrication diagrams.

  • Page 57: Spec

    2-31 lubrication diagrams spec 1 oil pump 2 exhaust camshaft 3 intake camshaft 4 oil strainer.

  • Page 58: Spec

    2-32 lubrication diagrams spec 1 oil cooler 2 oil strainer 3 oil level switch 4 oil pump.

  • Page 59: Spec

    2-33 lubrication diagrams spec 1 main axle 2 oil pump 3 relief valve.

  • Page 60: Spec

    2-34 lubrication diagrams spec 1 cylinder head 2 intake camshaft 3 exhaust camshaft 4 crankshaft.

  • Page 61: Spec

    2-35 lubrication diagrams spec 1 main axle 2 drive axle.

  • Page 62: Spec

    2-36 cable routing spec a clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebars. B clamp the horn lead and main switch and immobi- lizer lead to the inner tube. Point the binding section to the outside of the vehicle body and c...

  • Page 63: Spec

    2-37 cable routing spec f clamp the brake hose to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in). G pass the throttle cables through the wire guide. Route the right handlebar switch lead by the outside of...

  • Page 64: Spec

    2-38 cable routing spec 1 right handlebar switch lead 2 rear brake light switch lead 3 neutral switch lead 4 fuel tank breather hose 5 crankshaft position sensor lead a pass the right handlebar switch lead through the hole located on the right side of the frame. B route the right handlebar switch le...

  • Page 65: Spec

    2-39 i pass the neutral switch lead between the engine and coolant reservoir tank bracket. J to the starter motor. K install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. L route the starter motor lead by the inner side of the air cut-off valve hose. M ...

  • Page 66: Spec

    2-40 cable routing spec 16 license plate light lead 17 rear turn signal light lead (right) 18 rear turn signal light lead (left) 19 speed sensor lead 20 side stand switch lead 21 oil level switch lead 22 a.C. Magneto lead 23 throttle cable (return side) 24 throttle cable (pull side) 25 radiator fan ...

  • Page 67: Spec

    2-41 a route the throttle cables above the stay assy 1. B route the main switch and immobilizer lead above the clutch cable. C line up the left handlebar switch lead coupler and fan motor lead coupler behind the head pipe. D to the immobilizer. E to the main switch. F place three couplers on the fla...

  • Page 68: Spec

    2-42 y make sure to pass the neutral switch lead through the hole of the flap. Z clamp the seat lock wire to the frame as shown in the illustration. Secure the clamp to the weld of the cross member with the frame. Position the binding section in front of the vehicle body and cut the tip to be betwee...

  • Page 69: Spec

    2-43 14 seat lock cable 15 rectifier/regulator 16 e.C.U 17 fuel tank drain hose 18 cover 19 starter relay lead 20 battery negative lead 21 battery negative lead coupler 22 clutch cable 23 cover 2 24 spark plug lead 25 air cut-off valve hose 1 right handlebar switch lead 2 throttle cables 3 battery p...

  • Page 70: Spec

    2-44 cable routing spec a either right or left side arrangement for the left han- dlebar switch lead coupler and radiator fan motor coupler can be accepted. B point the l-shape terminal to the front side of the ve- hicle. C hook the starter motor lead to the alternate pawls on the battery cover. D r...

  • Page 71: Spec

    2-45 ae press the battery negative lead into the space be- tween the ribs of the frame. Af pass the spark plug leads #1 and #4 through the slit of the cover 2. Ag pass the spark plug lead #2 through the inner hole of the cover 2. Ah pass the spark plug lead #3 through the outer hole of the cover 2. ...

  • Page 72: Spec

    2-46 cable routing spec am route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. An route the spark plug leads #2 and #3 behind the air cut-off valve hose. Then route the spark plug lead #3 by the front side of the spark plug lead #2..

  • Page 74: Chk

    Chk adj chapter 3 periodic checks and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance and lubrication intervals 3-1 . . . . . Seat 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 75: Chk

    Chk adj chassis 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the front brake 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the rear brake 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec...

  • Page 76: Chk

    3-1 introduction/periodic maintenance and lubrication intervals chk adj note: eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more rel...

  • Page 77: Chk

    3-2 note: periodic maintenance and lubrication intervals chk adj no. Item check or maintenance job odometer reading ( 1,000 km) annual check 1 10 20 30 40 check 16 * sidestand switch (see page 3-57, 8-4) s check operation. Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 17 * front fork (see page 3-52) s check operation and for oil lea...

  • Page 78: Chk

    3-3 seat chk adj order job / part q’ty remarks 1 removing the seat seat 1 remove the parts in the order listed. For installation, reverse the removal procedure. Eas00038 seat.

  • Page 79: Chk

    3-4 fuel tank chk adj order job / part q’ty remarks 1 2 3 4 5 6 7 removing the fuel tank seat front cowling inner panel (left and right) fuel hose fuel sender coupler fuel pump coupler fuel tank drain hose fuel tank breather hose fuel tank fuel pump 1 1 1 1 1 1 1 remove the parts in the order listed...

  • Page 80: Chk

    3-5 fuel tank chk adj caution: note: note: caution: removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: sfuel hose although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain-...

  • Page 81: Chk

    3-6 fuel tank chk adj 4 nm (0.4 m skg, 2.9 ftslb) note: caution: note: installing the fuel pump 1. Install: sfuel pump sdo not damage the installation surfaces of the fuel tank when installing the fuel pump. Salways use a new fuel pump gasket. Sinstall the fuel pump as shown in the illustra- tion. S...

  • Page 82: Chk

    3-7 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the cowlings seat front cowling inner panel (left and right) front turn signal light lead couplers front cowling rear view mirrors (left and right) windshield rear cowling frame side cover 2 2 1 2 1 1 2 remove the parts in the order listed. Re...

  • Page 83: Chk

    3-8 air filter case chk adj order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 1 2 1 4 1 1 1 1 1 1 1 remove the parts in the order listed. Refer to “seat”. Refer to “cowlings”. Refer to “fuel tank”. Disconnect. Disconnect. Disconnect. Loosen. Disconnect. Disconnect. Disconnect. For installation, ...

  • Page 84: Chk

    3-9 battery box and battery box bracket chk adj order job / part q’ty remarks 1 2 3 battery box battery box bracket ignition coil assembly 1 3 2 remove the parts in the order listed. This part has to be set properly. For installation, reverse the removal procedure. 7 nm (0.7 m skg, 5.1 ftslb) 7 nm (...

  • Page 85: Chk

    3-10 adjusting the valve clearance chk adj note: eas00045 engine adjusting the valve clearance the following procedure applies to all of the valves. Svalve clearance adjustment should be made on a cold engine, at room temperature. Swhen the valve clearance is to be measured or adjusted, the piston m...

  • Page 86: Chk

    3-11 adjusting the valve clearance chk adj note: note: 4. Measure: svalve clearance out of specification ! Adjust. Valve clearance (cold) intake valve 0.13 x 0.20 mm (0.0051 x 0.0079 in) exhaust valve 0.23 x 0.30 mm (0.0091 x 0.0118 in) a. Turn the crankshaft counterclockwise. B. When piston #1 is a...

  • Page 87: Chk

    3-12 adjusting the valve clearance chk adj note: note: note: 5. Remove: scamshafts srefer to “camshafts” in chapter 5. Swhen removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. 6. Adjust: svalve clearance a. Remove the valve...

  • Page 88: Chk

    3-13 adjusting the valve clearance chk adj note: note: c. Round off the original valve pad number ac- cording to the following table. Last digit rounded value 0 or 2 0 5 5 8 10 example: original valve pad number = 148 (thickness =1.48 mm (0.058 in)) rounded value = 150 d. Locate the rounded number o...

  • Page 89: Chk

    3-14 adjusting the valve clearance chk adj note: srefer to “camshafts” in chapter 5. Slubricate the camshaft bearings, camshaft lobes and camshaft journals. Sfirst, install the exhaust camshaft. Salign the camshaft marks with the camshaft cap marks. Sturn the crankshaft counterclockwise several full...

  • Page 90: Chk

    3-15 adjusting the valve clearance chk adj valve clearance (cold): 0.13 x 0.20 mm (0.0051 x 0.0079 in) example: installed is 175 measured clearance is 0.27 mm (0.0106 in) replace 175 pad with 185 pad pad number: (example) pad no.175 = 1.75 mm (0.0689 in) pad no.185 = 1.85 mm (0.0728 in) measured cle...

  • Page 91: Chk

    3-16 adjusting the valve clearance/ synchronizing the throttle bodies chk adj note: note: note: 7. Install: sall removed parts for installation, reverse the removal procedure. Synchronizing the throttle bodies prior to synchronizing the throttle bodies, the valve clearance and the engine idling spee...

  • Page 92: Chk

    3-17 synchronizing the throttle bodies chk adj note: caution: note: 6. Measure: sengine idling speed out of specification ! Adjust. Refer to “adjusting the engine idling speed”. Engine idling speed 1,250 x 1,350 r/min 7. Adjust: sthrottle body synchronization a. With throttle body #1 as standard, ad...

  • Page 93: Chk

    3-18 adjusting the engine idling speed chk adj note: a b eas00052 adjusting the engine idling speed prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression. ...

  • Page 94: Chk

    3-19 adjusting the throttle cable free play chk adj note: note: a b note: eas00055 adjusting the throttle cable free play prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: sthrottle cable free play a ...

  • Page 95: Chk

    3-20 adjusting the throttle cable free play chk adj a b warning note: note: handlebar side a. Loosen the locknut 1 . B. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction throttle cable free play is increased. Direction throttle cable fre...

  • Page 96: Chk

    3-21 adjusting the exhaust gas volume chk adj note: note: 3. Using the “select” button, select either the co adjustment mode (which appears as “co”) or the diagnosis mode (which appears as “diag”) 4. After “co” appears as a result of pressing the “select” button, simultaneously press the “select” an...

  • Page 97: Chk

    3-22 a b checking the spark plugs chk adj caution: eas00059 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Remove: sradiator lower bolt 1 sradiator lower hose bracket bolt 2 2. Remove: sspark plug caps sspark plugs a right side #1 and #2 and #3 b left side #4 ...

  • Page 98: Chk

    3-23 checking the spark plugs/ measuring the compression pressure chk adj 18 nm (1.8 m skg, 13 ftslb) note: note: 7. Install: sspark plug sspark plug caps before installing the spark plug, clean the spark plug and gasket surface. 8. Install: sradiator lower hose bracket bolt sradiator lower bolt eas...

  • Page 99: Chk

    3-24 measuring the compression pressure chk adj caution: warning note: before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: scompression gauge 1 sadapter compression gauge 90890-03...

  • Page 100: Chk

    3-25 measuring the compression pressure chk adj 18 nm (1.8 m skg, 13 ftslb) d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again. Refer to the following table. Compression pressure (with oil applied into the ...

  • Page 101: Chk

    3-26 checking the engine oil level chk adj note: caution: eas00069 checking the engine oil level 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand. Smake sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3...

  • Page 102: Chk

    3-27 checking the engine oil level/ changing the engine oil chk adj note: note: before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Before checking the en...

  • Page 103: Chk

    3-28 changing the engine oil chk adj caution: 43 nm (4.3 m skg, 31 ftslb) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. A. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426, yu-38411 b. Lubricate the o-ring 3 of th...

  • Page 104: Chk

    3-29 changing the engine oil/ measuring the engine oil pressure chk adj caution: warning 9. Install: sengine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off. 11. Check: sengine (for engine oil leaks) 12. Check: sengine oil level refer to “checking the engi...

  • Page 105: Chk

    3-30 measuring the engine oil pressure chk adj note: 8 nm (0.8 m skg, 5.8 ftslb) 5. Measure: sengine oil pressure (at the following conditions) engine oil pressure 240 kpa (2.4 kg / cm 2 , 2.4 bar, 34.1 psi) engine speed approx. 6,600 r / min engine oil temperature 96 _c (205_f) regarding the oil pr...

  • Page 106: Chk

    3-31 adjusting the clutch cable free play chk adj c b note: a b eas00078 adjusting the clutch cable free play 1. Check: sclutch cable free play a out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 x 15 mm (0.39 x 0.59 in) 2. Adjust: sclutch cable free play hand...

  • Page 107: Chk

    3-32 adjusting the clutch cable free play/ cleaning the air filter element chk adj caution: 4. Install: sair filter case refer to “air filter case”. Sfuel tank refer to “fuel tank”. Sfront cowling inner panel (left and right) refer to “cowlings”. Sseat refer to “seat”. Eas00086 cleaning the air filt...

  • Page 108: Chk

    3-33 cleaning the air filter element/ checking the throttle body joints chk adj note: when installing the air filter element into the air filter case cover, make sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install: sfuel tank refer to “fuel tank”. Sfront cowling inner pane...

  • Page 109: Chk

    3-34 checking the fuel and breather hoses/ checking the crankcase breather hose chk adj note: caution: eas00096 checking the fuel and breather hoses the following procedure applies to all of the fuel and breather hoses. 1. Remove: srider seat refer to “seat”. Sfront cowling inner panel (left and rig...

  • Page 110: Chk

    3-35 checking the crankcase breather hose/ checking the exhaust system chk adj 3. Install: sfuel tank refer to “fuel tank”. Sfront cowling inner panel (left and right) refer to “cowlings”. Srider seat refer to “seat”. Eas00099 checking the exhaust system the following procedure applies to all of the...

  • Page 111: Chk

    3-36 checking the coolant level chk adj note: caution: note: eas00102 checking the coolant level 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand. Smake sure the motorcycle is upright. 2. Check: scoolant level the coolant level should be between the maximum level...

  • Page 112: Chk

    3-37 checking the cooling system/ changing the coolant chk adj eas00104 checking the cooling system 1. Check: sradiator 1 sradiator inlet hose 2 sradiator outlet hose 3 soil cooler 4 soil cooler inlet hose 5 soil cooler outlet hose 6 swater jacket outlet joint 7 swater jacket hose 8 swater pump outl...

  • Page 113: Chk

    3-38 changing the coolant chk adj caution: 10 nm (1.0 m skg, 7.2 ftslb) 3. Disconnect: scoolant reservoir cap 1 4. Drain: scoolant (from the coolant reservoir tank) 5. Remove: sradiator cap lock bolt 1 sradiator cap 2 a hot radiator is under pressure. Therefore, do not remove the radiator cap when t...

  • Page 114: Chk

    3-39 changing the coolant chk adj warning caution: 10. Install: scoolant reservoir tank 11. Connect: scoolant reservoir hose 12. Fill: scooling system (with the specified amount of the recom- mended coolant) recommended antifreeze high-quality ethylene glycol antifreeze containing corrosion inhibito...

  • Page 115: Chk

    3-40 changing the coolant chk adj note: suse only distilled water. However, if dis- tilled water is not available, soft water may be used. Sif coolant comes into contact with painted surfaces, immediately wash them with wa- ter. Sdo not mix different types of antifreeze. 13. Install: sradiator cap 1...

  • Page 116: Chk

    3-41 adjusting the front brake chk adj note: a a warning caution: eas00107 chassis adjusting the front brake 1. Adjust: sbrake lever position (distance a from the throttle grip to the brake lever) swhile pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desir...

  • Page 117: Chk

    3-42 adjusting the rear brake chk adj a b warning warning caution: eas00110 adjusting the rear brake 1. Check: sbrake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) out of specification ! Adjust. Brake pedal position (below the top of the rider footrest)...

  • Page 118: Chk

    3-43 a b adjusting the rear brake/ checking the brake fluid level chk adj note: warning 3. Adjust: srear brake light switch refer to “adjusting the rear brake light switch”. Eas00115 checking the brake fluid level 1. Stand the motorcycle on a level surface. Splace the motorcycle on a suitable stand....

  • Page 119: Chk

    3-44 a b checking the brake fluid level/ checking the front and rear brake pads chk adj caution: note: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. In order to ensure a correct reading of the brake fluid level, make sure the...

  • Page 120: Chk

    3-45 adjusting the rear brake light switch/ checking the front and rear brake hoses chk adj a b note: a b eas00128 adjusting the rear brake light switch the rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light com...

  • Page 121: Chk

    3-46 a b bleeding the hydraulic brake system chk adj warning note: note: eas00135 bleeding the hydraulic brake system bleed the hydraulic brake system whenev- er: sthe system is disassembled. Sa brake hose is loosened, disconnected or replaced. Sthe brake fluid level is very low. Sbrake operation is...

  • Page 122: Chk

    3-47 bleeding the hydraulic brake system/ adjusting the shift pedal chk adj warning a b h. Tighten the bleed screw and then release the brake lever or brake pedal. I. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. J. Tighten the bleed ...

  • Page 123: Chk

    3-48 adjusting the drive chain slack chk adj note: caution: warning note: a b note: eas00140 adjusting the drive chain slack the drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will overload the engine and other vital parts, and one that is too l...

  • Page 124: Chk

    3-49 adjusting the drive chain slack/ lubricating the drive chain chk adj f. Tighten both locknuts to specification. Locknut 16 nm (1.6 m skg, 12 ftslb) g. Tighten the wheel axle nut to specification. Wheel axle nut 120 nm (12 m skg, 87 ftslb) eas00142 lubricating the drive chain the drive chain con...

  • Page 125: Chk

    3-50 checking and adjusting the steering head chk adj warning note: note: eas00146 checking and adjusting the steering head 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the ...

  • Page 126: Chk

    3-51 checking and adjusting the steering head chk adj warning note: note: c. Loosen the lower ring nut 6 completely, then tighten it to specification. Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 nm (1.8 m skg, 13 ftslb) d. Check the steering head for looseness ...

  • Page 127: Chk

    3-52 checking and adjusting the steering head/ checking the front fork chk adj warning steering head tension 200 x 500 g e. Repeat the above procedure on the opposite handlebar. F. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upp...

  • Page 128: Chk

    3-53 adjusting the rear shock absorber assembly chk adj warning caution: a b eas00156 adjusting the rear shock absorber assembly securely support the motorcycle so that there is no danger of it falling over. Spring preload never go beyond the maximum or minimum adjustment positions. 1. Adjust: sspri...

  • Page 129: Chk

    3-54 checking the tires chk adj warning warning eas00162 checking the tires the following procedure applies to both of the tires. 1. Check: stire pressure out of specification ! Regulate. Sthe tire pressure should only be checked and regulated when the tire temperature equals the ambient air tempera...

  • Page 130: Chk

    3-55 checking the tires chk adj warning warning 2. Check: stire surfaces damage / wear ! Replace the tire. Minimum tire tread depth 1.6 mm (0.06 in) 1 tire tread depth 2 sidewall 3 wear indicator sdo not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and person...

  • Page 131: Chk

    3-56 checking the tires/checking the wheels chk adj warning note: warning note: front tire manufacturer size model bridgestone 120 / 70zr 17 m / c (58w) bt020f gg dunlop 120 / 70zr 17 m / c (58w) d252f rear tire manufacturer size model bridgestone 180 / 55zr 17 m / c (73w) bt020r gg dunlop 180 / 55z...

  • Page 132: Chk

    3-57 checking and lubricating the cables / lubricating the levers and pedals / lubricating the sidestand / lubricating the centerstand chk adj warning note: eas00170 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Damaged outer cable may ca...

  • Page 133: Chk

    3-58 lubricating the rear suspension chk adj eas00174 lubricating the rear suspension lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant molybdenum disulfide grease.

  • Page 134: Chk

    3-59 checking and charging the battery chk adj warning caution: eas00178 electrical system checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive meas...

  • Page 135: Chk

    3-60 checking and charging the battery chk adj relationship between the open-circuit voltage and the charging time at 20 _c open-circuit voltage (v) these values vary with the temperature, the condition of the battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 charging time (hou...

  • Page 136: Chk

    3-61 charging ambient temperature 20 _c open-circuit voltage (v) check the open-circuit voltage. Time (minutes) checking and charging the battery chk adj warning caution: 5. Charge: sbattery (refer to the appropriate charging method il- lustration) do not quick charge a battery. Snever remove the mf...

  • Page 137: Chk

    3-62 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charged and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. By turning the charging voltage adjust...

  • Page 138: Chk

    3-63 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s...

  • Page 139: Chk

    3-64 checking and charging the battery chk adj caution: charging method using a variable-current (voltage) charger charging method using a constant voltage charger 6. Install: sbattery 7. Connect: sbattery leads (to the battery terminals) first, connect the positive battery lead 1 , and then the neg...

  • Page 140: Chk

    3-65 checking the fuses chk adj caution: note: eas00181 checking the fuses the following procedure applies to all of the fuses. To avoid a short circuit, always set the main switch to “off” when checking or replacing a fuse. 1. Remove: sright side cover refer to “cowlings”. 2. Check: fuse a. Connect...

  • Page 141: Chk

    3-66 checking the fuses chk adj warning never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly ca...

  • Page 142: Chk

    3-67 replacing the headlight bulbs chk adj warning caution: eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Remove: sfront cowling inner panels refer to “cowlings”. 2. Disconnect: sheadlight bulb cover sheadlight coupler 1 3. Remove: sheadlig...

  • Page 143: Chk

    3-68 adjusting the headlight beams chk adj a b a b a b eas00185 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: sheadlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . Direction headlight beam is raised. Direction headlight...

  • Page 145: Chas

    Chas chapter 4 chassis front wheel and brake discs 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front wheel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the front wheel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the brake disc...

  • Page 146: Chas

    Chas front fork 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front fork legs 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front fork legs 4-48 . . . . . . . . . . . . . . . . . . . . . . . Disa...

  • Page 147: Chas

    4-1 front wheel and brake discs chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front wheel and brake discs brake hose holder (left and right) front brake caliper (left and right) front wheel axle pinch bolt front wheel axle collar (left and right) front wheel front brake disc (left an...

  • Page 148: Chas

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

  • Page 149: Chas

    4-3 front wheel and brake discs chas warning note: note: note: warning eas00521 removing the front wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elev...

  • Page 150: Chas

    4-4 front wheel and brake discs chas note: 2. Check: stire sfront wheel damage / wear ! Replace. Refer to “checking the tires” and “checking the wheels” in chapter 3. 3. Measure: sradial wheel runout 1 slateral wheel runout 2 over the specified limits ! Replace. Radial wheel runout limit 1 mm (0.04 ...

  • Page 151: Chas

    4-5 front wheel and brake discs chas caution: c. Remove the wheel bearings 3 with a gener- al bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 1 or balls 2 . Contact should be made only with the outer rac...

  • Page 152: Chas

    4-6 front wheel and brake discs chas note: 3. Measure: sbrake disc thickness measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) front: 4.5 mm (0.18 in) rear: 4.5 mm (0.18 in) 4. Adjust: sbrake disc deflection a. Remove ...

  • Page 153: Chas

    4-7 front wheel and brake discs chas note: 72 nm (7.2 m skg, 52 ftslb) 23 nm (2.3 m skg, 17 ftslb) caution: 40 nm (4.0 m skg, 29 ftslb) note: 10 nm (1.0 m skg, 7.2 ftslb) warning note: note: 3. Insert the wheel axle. Install the tire and wheel with the mark 1 point- ing in the direction of wheel rot...

  • Page 154: Chas

    4-8 front wheel and brake discs chas note: a. Spin the front wheel. B. When the front wheel stops, put an “x 1 ” mark at the bottom of the wheel. C. Turn the front wheel 90 _ so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at th...

  • Page 155: Chas

    4-9 rear wheel and brake disc chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the rear wheel brake caliper lock nut (left and right) adjusting nut (left and right) wheel axle nut washer rear wheel axle washer drive chain puller (left and right) rear wheel rear brake caliper bracket ...

  • Page 156: Chas

    4-10 rear wheel and brake disc chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the rear brake disc and rear wheel sprocket rear brake disc rear wheel sprocket collar oil seal bearing rear wheel drive hub rear wheel drive hub damper rear wheel 1 1 2 2 2 1 6 1 remove the parts in the order...

  • Page 157: Chas

    4-11 rear wheel and brake disc chas order job / part q’ty remarks disassembling the rear wheel collar bearing spacer oil seal circlip bearing 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 3 2 4 5 6 eas00560

  • Page 158: Chas

    4-12 rear wheel and brake disc chas warning note: note: note: eas00561 removing the rear wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Re...

  • Page 159: Chas

    4-13 rear wheel and brake disc chas eas00565 checking the rear wheel 1. Check: swheel axle srear wheel swheel bearings soil seals refer to “checking the front wheel”. 2. Check: stire srear wheel damage / wear ! Replace. Refer to “checking the tires” and “checking the wheels” in chapter 3. 3. Measure...

  • Page 160: Chas

    4-14 rear wheel and brake disc chas note: 120 nm (12 m skg, 87 ftslb) 27 nm (2.7 m skg, 20 ftslb) 22 nm (2.2 m skg, 16 ftslb) 2. Replace: srear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. B. Clean the rear wheel drive hub with a clean cloth, especially the surfaces th...

  • Page 161: Chas

    4-15 rear wheel and brake disc chas note: eas00575 adjusting the rear wheel static balance safter replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Sadjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: srear wheel ...

  • Page 162: Chas

    4-16 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the front brake pads front brake caliper brake pad brake pad spring bleed screw 1 2 2 1 remove the parts in the order listed. The following procedure applies to both of the front brake calipers. For installation, reverse ...

  • Page 163: Chas

    4-17 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the rear brake pads. Screw plug brake pad pin rear brake caliper brake pad shim brake pad brake screw brake pad spring 1 1 1 4 2 1 1 remove the parts in the order listed for installation, reverse the removal procedu...

  • Page 164: Chas

    4-18 front and rear brakes chas caution: warning eas00579 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: snever disassemble brake components un- less absolutely necessary. Sif any connection on the hydraulic brake system is disconnected, the e...

  • Page 165: Chas

    4-19 front and rear brakes chas note: note: eas00582 replacing the front brake pads the following procedure applies to both brake calipers. When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: sbrake hose holder 1 sbrake cal...

  • Page 166: Chas

    4-20 front and rear brakes chas 40 nm (4.0 m skg, 29 ftslb) 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 pistons into the brake caliper with your finger. C. Tighten the blee...

  • Page 167: Chas

    4-21 front and rear brakes chas note: note: eas00583 replacing the rear brake pads when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: sscrew plug 1 sbrake pad pin 2 sbrake caliper 3 sbrake pad spring 4 2. Remove: sbrake pa...

  • Page 168: Chas

    4-22 front and rear brakes chas 27 nm (2.7 m skg, 20 ftslb) 22 nm (2.2 m skg, 16 ftslb) 17 nm (1.7 m skg, 12 ftslb) 3 nm (0.3 m skg, 2.2 ftslb) b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. Bleed screw 6 nm (0.6 m sk...

  • Page 169: Chas

    4-23 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the front brake master cylinder brake fluid brake master cylinder reservoir cap brake master cylinder reservoir diaphragm holder brake master cylinder reservoir diaphragm brake lever front brake light switch lea...

  • Page 170: Chas

    4-24 front and rear brakes chas order job / part q’ty remarks 10 master cylinder assembly 1 for installation, reverse the removal procedure. 2 nm (0.2 m skg, 1.4 ftslb) 30 nm (3.0 m skg, 22 ftslb) 10 nm (1.0 m skg, 72 ftslb).

  • Page 171: Chas

    4-25 front and rear brakes chas order job / part q’ty remarks disassembling the front brake master cylinder dust boot circlip master cylinder kit spring master cylinder push rod 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 eas005...

  • Page 172: Chas

    4-26 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the rear brake master cylinder brake fluid brake fluid reservoir cap rear brake fluid reservoir diaphragm holder rear brake fluid reservoir diaphragm brake fluid reservoir tank brake fluid reservoir hose union b...

  • Page 173: Chas

    4-27 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake master cylinder dust boot circlip master cylinder kit spring master cylinder body 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 eas00587.

  • Page 174: Chas

    4-28 a b c d front and rear brakes chas note: note: eas00588 disassembling the front brake master cylinder before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: sbrake light switch coupler 1 (from the brake light switch) 2. Remove: s...

  • Page 175: Chas

    4-29 front and rear brakes chas note: 3. Check: srear brake fluid reservoir 1 cracks / damage ! Replace. Srear brake fluid reservoir diaphragm 2 cracks / damage ! Replace. 4. Check: sfront brake master cylinder reservoir 1 cracks / damage ! Replace. Sfront brake master cylinder reservoir dia- phragm...

  • Page 176: Chas

    4-30 front and rear brakes chas a warning note: 30 nm (3.0 m skg, 22 ftslb) warning caution: eas00598 assembling and installing the front brake master cylinder sbefore installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Snever use solvents on...

  • Page 177: Chas

    4-31 front and rear brakes chas note: warning swhile holding the brake hose, tighten the union bolt as shown. Sturn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.G., wire harness, cables, leads). Correct if necessary. 3. Fill: sbrake master cylinder re...

  • Page 178: Chas

    4-32 front and rear brakes chas 30 nm (3.0 m skg, 22 ftslb) warning caution: warning eas00608 assembling the rear brake master cylinder 1. Install: sbrake master cylinder kit scirclip sdust boot 2. Install: scopper washers new sbrake hoses sunion bolt proper brake hose routing is essential to in- su...

  • Page 179: Chas

    4-33 front and rear brakes chas caution: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: sbrake system refer to “bleeding the hydraulic brake system” in chapter 3. 5. Check: sbrake fluid level below the minimum level ...

  • Page 180: Chas

    4-34 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 removing the front brake calipers brake fluid union bolt copper washer brake hose brake caliper brake pad brake caliper bracket 1 2 1 1 2 1 remove the parts in the order listed. The following procedure applies to both of the f...

  • Page 181: Chas

    4-35 front and rear brakes chas order job / part q’ty remarks disassembling the front brake calipers brake pad brake caliper piston brake caliper piston seal brake pad spring bleed screw 2 2 4 1 1 disassemble the parts in the order listed. The following procedure applies to both of the front brake c...

  • Page 182: Chas

    4-36 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the rear brake caliper brake fluid union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. Drain. Refer to “bleeding the hydraulic brake system” in chapter 3. For installation, reve...

  • Page 183: Chas

    4-37 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake caliper screw plug brake pad pin brake pad brake pad shim brake pad spring brake caliper piston brake caliper piston seal bleed screw 1 1 2 4 1 1 2 1 disassemble the parts in the order listed. For assembly, re...

  • Page 184: Chas

    4-38 front and rear brakes chas note: note: warning eas00625 disassembling the front brake calipers the following procedure applies to both of the brake calipers. Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: sunion bolt 1 scopper washers 2 sb...

  • Page 185: Chas

    4-39 front and rear brakes chas note: note: warning eas00627 disassembling the rear brake caliper before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: sunion bolt 1 scopper washers 2 sbrake hose 3 sbrake caliper 4 put the end of the brake hose into a...

  • Page 186: Chas

    4-40 a b front and rear brakes chas warning eas00633 checking the front and rear brake calipers recommended brake component p replacement schedule brake pads if necessary piston seals every two years brake hoses every four years brake fluid every two years and whenever the brake is disas- sembled 1....

  • Page 187: Chas

    4-41 front and rear brakes chas warning 22 nm (2.2 m skg, 16 ftslb) 40 nm (4.0 m skg, 29 ftslb) 30 nm (3.0 m skg, 22 ftslb) warning caution: eas00638 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. Sbefore installation, all internal b...

  • Page 188: Chas

    4-42 front and rear brakes chas warning caution: 2. Fill: sbrake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 suse only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage an...

  • Page 189: Chas

    4-43 front and rear brakes chas warning 27 nm (2.7 m skg, 20 ftslb) 22 nm (2.2 m skg, 16 ftslb) 30 nm (3.0 m skg, 22 ftslb) warning caution: eas00642 assembling and installing the rear brake caliper sbefore installation, all internal brake com- ponents should be cleaned and lubricated with clean or ...

  • Page 190: Chas

    4-44 front and rear brakes chas warning caution: suse only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Srefill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in ...

  • Page 191: Chas

    4-45 front fork chas order job / part q’ty remarks 1 2 3 4 5 removing the front fork legs front wheel front brake calipers front fender cap bolt upper bracket pinch bolt under bracket pinch bolt front fork leg 1 1 1 1 1 remove the parts in the order listed. Refer to “front wheel and brake discs”. Re...

  • Page 192: Chas

    4-46 front fork chas order job / part q’ty remarks disassembling the front fork legs cap bolt o-ring spacer washer front fork spring dust seal oil seal clip damper rod assembly bolt copper washer damper rod assembly oil seal washer 1 1 1 1 1 1 1 1 1 1 1 1 disassemble the parts in the order listed. T...

  • Page 193: Chas

    4-47 front fork chas order job / part q’ty remarks inner tube outer tube bushing inner tube bushing oil flow stopper outer tube 1 1 1 1 1 for assembly, reverse the disassembly procedure. 13 14 15 16 17 24 nm (2.4 m skg, 17 ftslb) 23 nm (2.3 m skg, 17 ftslb).

  • Page 194: Chas

    4-48 front fork chas warning warning note: eas00649 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitab...

  • Page 195: Chas

    4-49 front fork chas caution: note: caution: 3. Remove: sdust seal 1 soil seal clip 2 (with a flat-head screwdriver) do not scratch the inner tube. 4. Remove: sdamper rod assembly bolt while holding the damper rod assembly with the damper rod holder 1 and t-handle 2 , loosen the damper rod assembly ...

  • Page 196: Chas

    4-50 front fork chas warning caution: eas00657 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: sinner tube 1 souter tube 2 bends / damage / scratches ! Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2....

  • Page 197: Chas

    4-51 front fork chas warning note: warning caution: 23 nm (2.3 m skg, 17 ftslb) note: eas00659 assembling the front fork legs the following procedure applies to both of the front fork legs. Smake sure the oil levels in both front fork legs are equal. Suneven oil levels can result in poor han- dling ...

  • Page 198: Chas

    4-52 front fork chas caution: note: note: damper rod holder 90890-01294 t-handle 90890-01326 4. Install: souter tube bushing 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) fork seal driver weight 90890-01367 fork seal driver attachment 90890-01374 5. Install: swasher soil ...

  • Page 199: Chas

    4-53 front fork chas caution: note: 7. Install: sdust seal 1 (with the fork seal driver weight) fork seal driver weight 90890-01367 8. Fill: sfront fork leg (with the specified amount of the recom- mended fork oil) quantity (each front fork leg) 0.467 l (0.41 imp qt, 0.49 us qt) recommended oil susp...

  • Page 200: Chas

    4-54 front fork chas note: note: 30 nm (3.0 m skg, 22 ftslb) 24 nm (2.4 m skg, 17 ftslb) 30 nm (3.0 m skg, 22 ftslb) warning 10. Install: sspring 1 sspring seat 2 sspacer 3 scap bolt sinstall the spring with the smaller pitch a fac- ing up. Sbefore installing the cap bolt, lubricate its o- ring with...

  • Page 201: Chas

    4-55 handlebar chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 removing the handlebar grip end handlebar grip (left) clutch switch connector left handlebar switch clutch cable clutch lever right handlebar switch throttle grip throttle cable front brake light switch connector fron...

  • Page 202: Chas

    4-56 1 handlebar chas warning note: warning eas00666 removing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: sgrip end shandlebar grip 1 blow compressed air between the handlebar and the handlebar gr...

  • Page 203: Chas

    4-57 handlebar chas warning 23 nm (2.3 m skg, 17 ftslb) caution: note: note: note: eas00672 installing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Install: shandlebar 1 supper handlebar holders 2 supper h...

  • Page 204: Chas

    4-58 handlebar chas 26 nm (2.6 m skg, 19 ftslb) note: note: 26 nm (2.6 m skg, 19 ftslb) warning 5. Install: sgrip end 6. Adjust: sthrottle cable free play refer to “adjusting the throttle cable free play” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3 x 5 mm (0.12 x 0....

  • Page 205: Chas

    4-59 steering head chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the under bracket front wheel front fender front fork handlebar front cowling inner panel (left and right) fuel tank main switch coupler immobilizer coupler steering stem nut washer upper bracket horn stay lock washer 2 1 1...

  • Page 206: Chas

    4-60 steering head chas order job / part q’ty remarks 8 9 10 11 12 13 14 15 16 17 upper ring nut rubber washer lower ring nut under bracket bearing cover bearing inner race upper bearing lower bearing dust seal bearing outer race 1 1 1 1 1 2 1 1 1 2 for installation, reverse the removal procedure. 3...

  • Page 207: Chas

    4-61 steering head chas warning note: warning eas00677 removing the under bracket 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: ssteering stem nut swasher supper bracket slock washer srubber washer sring nut 1 (w...

  • Page 208: Chas

    4-62 steering head chas caution: note: 3. Replace: sbearing balls sbearing races a. Remove the bearing races 1 from the steer- ing head pipe with a long rod 2 and hammer. B. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. C. Install a new dust seal and new bearing ...

  • Page 209: Chas

    4-63 steering head chas 110 nm (11 m skg, 80 ftslb) 3. Install: supper bracket swasher ssteering stem nut 4. Install: sfront fork legs refer to “installing the front fork legs”..

  • Page 210: Chas

    4-64 rear shock absorber assembly chas order job / part q’ty remarks 1 2 3 4 removing the rear shock absorber assembly rear wheel self-locking nut / collar / bolt (swingarm-rear shock absorber) self-locking nut / washer / bolt (frame-rear shock absorber) rear shock absorber oil seal / bearing 1/1/1 ...

  • Page 211: Chas

    4-65 rear shock absorber assembly chas warning note: note: eas00694 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is ...

  • Page 212: Chas

    4-66 rear shock absorber assembly chas warning warning eas00686 handling the rear shock absorber 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 res...

  • Page 213: Chas

    4-67 rear shock absorber assembly chas note: 40 nm (4.0 m skg, 29 ftslb) 40 nm (4.0 m skg, 29ftslb) sspring damage / wear ! Replace the rear shock ab- sorber assembly. Sbushings damage / wear ! Replace. Sdust seals damage / wear ! Replace. Sbolts bends / damage / wear ! Replace. Eas00697 installing ...

  • Page 214: Chas

    4-68 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the swingarm and drive chain muffler assembly catalyst assembly exhaust pipe assembly rear wheel rear shock absorber assembly drive sprocket cover lock nut adjusting nut rear fender pivot shaft nut / washer pivot shaft swingarm drive chain 2 ...

  • Page 215: Chas

    4-69 swingarm and drive chain chas order job / part q’ty remarks 8 9 10 11 drive chain guide dust cover bearing spacer 1 2 2 1 for installation, reverse the removal procedure. 120 nm (12 m skg, 87 ftslb) 7 nm (0.7 m skg, 5.1 ftslb) 16 nm (1.6 m skg, 12 ftslb).

  • Page 216: Chas

    4-70 swingarm and drive chain chas warning note: eas00703 removing the swingarm 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: srear whe...

  • Page 217: Chas

    4-71 swingarm and drive chain chas warning note: warning eas00704 removing the drive chain 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove...

  • Page 218: Chas

    4-72 swingarm and drive chain chas 120 nm (12 m skg, 87 ftslb) 4. Check: sdust covers 1 sspacer 2 damage / wear ! Replace. Sbearings damage / pitting ! Replace. As00711 installing the swingarm 1. Lubricate: sbearings sspacer sdust covers spivot shaft recommended lubricant lithium-soap-based grease 2...

  • Page 219: Chas

    4-73 swingarm and drive chain chas note: caution: eas00709 checking the drive chain 1. Measure: sten-link section a of the drive chain out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) swhile measuring the ten-link section, push down on t...

  • Page 220: Chas

    4-74 swingarm and drive chain chas 4. Check: so-rings 1 damage ! Replace the drive chain. Sdrive chain rollers 2 damage / wear ! Replace the drive chain. Sdrive chain side plates 3 damage / wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose ...

  • Page 222: Eng

    Eng chapter 5 engine engine 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive sprocket 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust pipe 5-2 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 223: Eng

    Eng crankshaft position sensor and pickup rotor 5-42 . . . . . . . Removing the pickup rotor 5-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the pickup rotor 5-44 . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch 5-46 . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 224: Eng

    Eng crankshaft 5-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the crankshaft 5-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the crankshaft journal bearings 5-80 . . . . . . . . Installing the crankshaft 5-83 . . . ...

  • Page 225: Eng

    Eng.

  • Page 226: Eng

    5-1 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the drive sprocket drive chain lock nut shift rod shift arm drive sprocket cover nut lock washer drive sprocket 2 1 1 1 1 1 1 loosen. Refer to “adjusting the drive chain slack” in chapter 3. Loosen. For installation, reverse the removal proced...

  • Page 227: Eng

    5-2 order job / part q’ty remarks 1 2 3 4 5 removing the exhaust pipe exhaust pipe assembly exhaust pipe gasket catalyst pipe assembly muffler protector assembly muffler 1 4 1 1 1 remove the parts in the order listed. For installation, reverse the removal procedure. 20 nm (2.0 m skg, 15 ftslb) 16 nm...

  • Page 228: Eng

    5-3 order job / part q’ty remarks disconnecting the leads and hoses seat front cowling inner panel (left and right) fuel tank battery air filter case battery box and battery box bracket throttle body assembly engine oil oil filter cartridge oil cooler air cut-off valve disconnect the parts in the or...

  • Page 229: Eng

    5-4 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 radiator starter motor battery negative lead battery positive lead clutch cable ground lead stator coil assembly coupler crankshaft position sensor coupler oil level switch connector neutral switch connector speed sensor coupler 1 1 1 1 1 1 1 1 1 r...

  • Page 230: Eng

    5-5 order job / part q’ty remarks 1 2 3 4 5 removing the engine right front engine mounting bolt left front engine mounting bolt self locking nut rear engine mounting bolt engine 1 2 2 2 1 remove the parts in the order listed. Place a suitable stand under the frame and engine. For installation, reve...

  • Page 231: Eng

    5-6 engine eng note: note: 55 nm (5.5 m skg, 40 ftslb) note: 55 nm (5.5 m skg, 40 ftslb) eas00192 installing the engine 1. Install: srear engine mounting bolts 1 lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: sright front engine mounting bolt 2 sleft fron...

  • Page 232: Eng

    5-7 engine eng 55 nm (5.5 m skg, 40 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) note: 5. Tighten sright front engine mounting bolts 6 6. Install: sshift arm 7 salign the punch mark a in the shift shaft with the slot in the shift arm. Salign the bottom edge of the shift pedal with the mark on the frame-to-sw...

  • Page 233: Eng

    5-8 order job / part q’ty remarks 1 2 3 4 5 removing the cylinder head cover battery air filter case battery box and battery box bracket throttle body assembly radiator assembly air cut-off valve ignition coil spark plug cylinder head cover cylinder head cover gasket timing chain guide (top side) 4 ...

  • Page 234: Eng

    5-9 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the camshafts pickup rotor cover camshaft sprocket bolt timing chain tensioner timing chain tensioner gasket timing chain guide (exhaust side) intake camshaft cap dowel pin exhaust camshaft cap dowel pin intake camshaft 4 1 1 1 3 6 3 6 1 r...

  • Page 235: Eng

    5-10 camshafts eng order job / part q’ty remarks 10 11 12 13 exhaust camshaft pin timing chain guide (intake side) cam sprocket 1 1 1 2 for installation, reverse the removal procedure. 10 nm (1.0 m skg, 7.2 ftslb) 20 nm (2.0 m skg, 15 ftslb) 20 nm (2.0 m skg, 15 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) 1...

  • Page 236: Eng

    5-11 camshafts eng note: caution: eas00198 removing the camshafts 1. Remove: spickup rotor cover refer to “crankshaft position sen- sor and pickup rotor”. 2. Align: s“t” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on...

  • Page 237: Eng

    5-12 camshafts eng note: 7. Remove: sintake camshaft 1 sexhaust camshaft 2 to prevent the timing chain from falling into the crankcase, fasten it with a wire a . 8. Remove: scamshaft sprockets eas00204 checking the camshafts 1. Check: scamshaft lobes blue discoloration / pitting / scratches ! Re- pl...

  • Page 238: Eng

    5-13 camshafts eng note: 3. Measure: scamshaft runout out of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: scamshaft-journal-to-camshaft-cap clear- ance out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 x ...

  • Page 239: Eng

    5-14 camshafts eng note: eas00208 checking the timing chain, camshaft sprockets, and timing chain guides the following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: stiming chain 1 damage / stiffness ! Replace the timing chain and camshaft sprockets as a set. ...

  • Page 240: Eng

    5-15 camshafts eng note: b. Remove the screwdriver and slowly release the timing chain tensioner rod. C. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 3. Check: scap bolt salum...

  • Page 241: Eng

    5-16 camshafts eng note: 10 nm (1.0 m skg, 7.2 ftslb) note: caution: note: 3. Install: sdowel pins sexhaust camshaft caps sintake camshaft caps smake sure each camshaft cap is installed in its original place. Smake sure the arrow mark a on each cam- shaft cap points towards the right side of the eng...

  • Page 242: Eng

    5-17 camshafts eng warning 20 nm (2.0 m skg, 15 ftslb) caution: 6. Install: stiming chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1 . B. With the timing chain tensioner rod turned all the way into ...

  • Page 243: Eng

    5-18 camshafts eng 10. Measure: svalve clearance out of specification ! Adjust. Refer to “adjusting the valve clear- ance” in chapter 3..

  • Page 244: Eng

    5-19 order job / part q’ty remarks 1 2 3 removing the cylinder head intake and exhaust camshaft engine bracket cylinder head cylinder head gasket dowel pin 1 1 2 remove the parts in the order listed. Refer to “camshafts”. Refer to “engine”. For installation, reverse the removal procedure. 12 nm (1.2...

  • Page 245: Eng

    5-20 cylinder head eng note: note: note: eas00222 removing the cylinder head 1. Remove: scylinder head bolts sloosen the bolts in the proper sequence as shown. Sloosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas00229 checking the cylinder head 1. El...

  • Page 246: Eng

    5-21 cylinder head eng note: 19 nm (1.9 m skg, 14 ftslb) 50 nm (5.0 m skg, 36 ftslb) 12 nm (1.2 m skg, 8.7 ftslb) note: eas00233 installing the cylinder head 1. Install: sgasket new 1 sdowel pins 2 2. Install: scylinder head pass the timing chain through the timing chain cavity. 3. Tighten: scylinde...

  • Page 247: Eng

    5-22 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 remove the valves and valve springs cylinder head intake valve lifter intake valve pad intake valve cotter intake valve upper spring seat intake valve spring outer intake valve spring inner intake valve stem seal intake valve lower spr...

  • Page 248: Eng

    5-23 valves and valve springs eng order job / part q’ty remarks 14 15 16 17 18 19 exhaust valve upper spring seat exhaust valve spring exhaust valve stem seal exhaust valve lower spring seat exhaust valve exhaust valve guide 8 8 8 8 8 8 for installation, reverse the removal procedure. Refer to “remo...

  • Page 249: Eng

    5-24 valves and valve springs eng note: note: note: note: eas00238 removing the valves the following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal...

  • Page 250: Eng

    5-25 valves and valve springs eng note: valve spring compressor 90890-04019, ym-04019 valve spring compressor attachment 90890-04108, ym-01253 4. Remove: supper spring seat 1 svalve spring outer 2 svalve spring inner (intake only) 3 svalve 4 svalve stem seal 5 slower spring seat 6 identify the posit...

  • Page 251: Eng

    5-26 valves and valve springs eng note: note: 2. Replace: svalve guide 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. Install the new valve guide with th...

  • Page 252: Eng

    5-27 valves and valve springs eng note: 5. Measure: svalve margin thickness a out of specification ! Replace the valve. Valve margin thickness 0.6 x 0.8 mm (0.0236 x 0.0315 in) : 0.5 mm (0.02 in) 6. Measure: svalve stem runout out of specification ! Replace the valve. Swhen installing a new valve, a...

  • Page 253: Eng

    5-28 valves and valve springs eng note: note: caution: note: where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: svalve face svalve seat after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should...

  • Page 254: Eng

    5-29 valves and valve springs eng j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. Eas00241 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: svalve spring free length a out of s...

  • Page 255: Eng

    5-30 valves and valve springs eng 3. Measure: svalve spring tilt a out of specification ! Replace the valve spring. Spring tilt limit intake valve spring (inner) 2.5 _/1.6 mm (0.06 in) (outer) 2.5 _/1.7 mm (0.07 in) exhaust valve spring 2.5 _/1.8 mm (0.07 in) eas00242 checking the valve lifters the ...

  • Page 256: Eng

    5-31 valves and valve springs eng note: note: caution: note: smake sure that each valve is installed in its original place. Sinstall the valve springs with the larger pitch a facing up. B smaller pitch 4. Install: svalve cotters 1 install the valve cotters by compressing the valve springs with the v...

  • Page 257: Eng

    5-32 order job / part q’ty remarks 1 2 3 4 5 removing the stator coil assembly seat and fuel tank coolant coolant reservoir tank engine oil stator coil assembly coupler generator rotor cover generator rotor cover gasket dowel pin stator coil assembly lead holder 1 1 1 2 1 remove the parts in the ord...

  • Page 258: Eng

    5-33 starter clutch and generator eng order job / part q’ty remarks 6 7 8 9 10 11 12 13 stator coil assembly generator rotor bolt washer generator rotor starter clutch assembly idler gear shaft idler gear starter clutch drive gear 1 1 1 1 1 1 1 1 for installation, reverse the removal procedure. Refe...

  • Page 259: Eng

    5-34 starter clutch and generator eng note: note: eas00347 removing the generator 1. Remove: sseat refer to “seat” in chapter 3. Sfront cowling inner panel (left and right) refer to “cowlings” in chapter 3. Sfuel tank refer to “fuel tank” in chapter 3. 2. Drain: scoolant refer to “changing the coola...

  • Page 260: Eng

    5-35 starter clutch and generator eng caution: note: note: 5. Remove: sgenerator rotor 1 (with the flywheel puller 2 and flywheel pull- er attachment) swoodruff key to protect the end of the crankshaft, place an appropriate sized socket between the fly- wheel puller set’s center bolt and the crank- ...

  • Page 261: Eng

    5-36 starter clutch and generator eng 32 nm (3.2 m skg, 23 ftslb) loctite r note: eas00351 checking the starter clutch 1. Check: sstarter clutch rollers 1 damage / wear ! Replace. 2. Check: sstarter clutch idle gear 1 sstarter clutch drive gear 2 burrs / chips / roughness / wear ! Replace the defect...

  • Page 262: Eng

    5-37 starter clutch and generator eng note: 75 nm (7.5 m skg, 54 ftslb) note: 12 nm (1.2 m skg, 8.7 ftslb) sdo not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701, ys-01880-a eas00354 installing the generator 1. Install: sgenerator rotor swasher new ...

  • Page 263: Eng

    5-38 starter clutch and generator eng note: tighten the generator rotor cover bolts in stages and in a crisscross pattern. 6. Fill: sengine oil refer to “changing the engine oil” in chapter 3. Scoolant refer to “changing the coolant” in chapter 3. 7. Install: sfuel tank refer to “fuel tank” in chapt...

  • Page 264: Eng

    5-39 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the shift shaft and stopper lever coolant coolant reservoir tank drive sprocket cover shift shaft cover shift shaft cover gasket dowel pin oil seal shift shaft shift shaft spring collar stopper lever spring circlip washer 1 1 1 1 1 1 1...

  • Page 265: Eng

    5-40 shift shaft eng order job / part q’ty remarks 11 12 13 14 stopper lever collar washer shift shaft spring stopper 1 1 1 1 for installation, reverse the removal procedure. 22 nm (2.2 m skg, 16 ftslb) 12 nm (1.2 m skg, 8.7 ftslb).

  • Page 266: Eng

    5-41 shift shaft eng 22 nm (2.2 m skg, 16 ftslb) note: note: eas00328 checking the shift shaft 1. Check: sshift shaft 1 bends / damage / wear ! Replace. Sshift shaft spring 2 damage / wear ! Replace. Eas00330 checking the stopper lever 1. Check: sstopper lever 1 bends / damage ! Replace. Roller turn...

  • Page 267: Eng

    5-42 order job / part q’ty remarks 1 2 3 4 removing the crankshaft position sensor and pickup rotor seat front cowling inner panel (left and right) fuel tank engine oil generator cover crankshaft position sensor lead coupler pickup rotor cover pickup rotor cover gasket dowel pin 1 1 1 2 remove the p...

  • Page 268: Eng

    5-43 crankshaft position sensor and pickup rotor eng order job / part q’ty remarks 5 6 7 crankshaft position sensor pickup rotor plug screw 1 1 1 for installation, reverse the removal procedure. 10 nm (1.0 m skg, 7.2 ftslb) 15 nm (1.5 m skg, 11 ftslb) 35 nm (3.5 m skg, 25 ftslb) 12 nm (1.2 m skg, 8....

  • Page 269: Eng

    5-44 crankshaft position sensor and pickup rotor eng note: note: note: removing the pickup rotor 1. Remove: spickup rotor cover 1 loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: spickup rotor bolt 1...

  • Page 270: Eng

    5-45 crankshaft position sensor and pickup rotor eng 35 nm (3.5 m skg, 25 ftslb) note: note: 2. Tighten: spickup rotor bolt 1 while holding the generator rotor 2 with the sheave holder 3 , tighten the pickup rotor bolt. Sheave holder 90890-01701, ys-01880-a 3. Apply: ssealant (onto the crankshaft po...

  • Page 271: Eng

    5-46 order job / part q’ty remarks 1 2 3 4 5 6 removing the clutch cover engine oil coolant coolant hose clutch cable clutch cable holder clutch cover clutch cover gasket dowel pin 1 1 1 1 1 2 remove the parts in the order listed. Drain. Refer to “changing the engine oil” in chapter 3. Drain. Refer ...

  • Page 272: Eng

    5-47 clutch eng order job / part q’ty remarks disassembling the clutch cover circlip washer pull lever pull lever spring washer oil seal bearing pull lever shaft washer 2 1 1 1 1 1 2 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 9.

  • Page 273: Eng

    5-48 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 removing the clutch compression spring pressure plate pull rod bearing friction plate (brown) clutch plate (t=2.0 mm, 0.08 in) friction plate clutch plate (t=2.3 mm, 0.09 in) clutch boss nut lock plate clutch boss thrust plate 6 1 1 1 6 7...

  • Page 274: Eng

    5-49 clutch eng note: note: eas00276 removing the clutch 1. Remove: sclutch cable holder 1 sclutch cover 2 sgasket loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: scompression spring bolts 1 scompre...

  • Page 275: Eng

    5-50 clutch eng note: 2. Measure: sfriction plate thickness out of specification ! Replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness 2.9 x 3.1 mm (0.114 x 0.122 in) : 2.8 mm (0.110 in) eas00281 checking the clutch plates the following procedure...

  • Page 276: Eng

    5-51 clutch eng note: note: 2. Measure: sclutch spring free length a out of specification ! Replace the clutch springs as a set. Clutch spring free length 55 mm (2.17 in) : 52.3 mm (2.06 in) eas00284 checking the clutch housing 1. Check: sclutch housing dogs damage / pitting / wear ! Deburr the clut...

  • Page 277: Eng

    5-52 clutch eng 90 nm (9.0 m skg, 65 ftslb) note: eas00287 checking the pull lever shaft and pull rod 1. Check: spull lever shaft pinion gear teeth a spull rod teeth b damage / wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: spull rod bearing damage / wear ! Replace....

  • Page 278: Eng

    5-53 clutch eng note: note: 8 nm (0.8 m skg, 5.8 ftslb) note: 5. Install: sfriction plates sclutch plates first, install a clutch plate and then alternate be- tween a friction plate and a friction plate. A. Install the clutch plate and friction plate as shown in the illustration. Clutch plate 1 : t=...

  • Page 279: Eng

    5-54 clutch eng note: 9. Install: sclutch cover sgasket new sclutch cable holder sinstall the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover. Sapply oil onto the bearing. Sapply molybdenum disulfide grease onto the pull rod. Swhen installing th...

  • Page 280: Eng

    5-55 order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the oil pan and oil pump engine oil coolant exhaust pipe assembly water pump oil level switch coupler oil level switch oil level switch lead holder oil pan oil pan gasket dowel pin oil strainer oil strainer gasket 1 1 1 1 1 2 1 1 remove the...

  • Page 281: Eng

    5-56 order job / part q’ty remarks 9 10 11 12 13 oil pipe oil delivery pipe oil pump assembly dowel pin relief valve assembly 1 1 1 2 1 for installation, reverse the removal procedure. 12 nm (1.2 m skg, 8.7 ftslb) 12 nm (1.2 m skg, 8.7 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) 43 nm (4.3 m skg, 31 ftslb) ...

  • Page 282: Eng

    5-57 oil pan and oil pump eng order job / part q’ty remarks disassembling the oil pump assembly oil pump cover pin oil pump inner rotor oil pump outer rotor pin washer oil pump rotor housing oil pump driver sprocket 1 2 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the...

  • Page 283: Eng

    5-58 oil pan and oil pump eng note: eas00362 removing the oil pan 1. Remove: soil level switch 1 soil pan 2 soil pan gasket sdowel pins loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas00364 checking the oil...

  • Page 284: Eng

    5-59 oil pan and oil pump eng 3. Check: soil pump operation rough movement ! Repeat steps (1) and (2) or replace the defective part(s). Eas00365 checking the relief valve 1. Check: srelief valve body 1 srelief valve 2 sspring 3 so-ring 4 damage / wear ! Replace the defective part(s). Eas00367 checki...

  • Page 285: Eng

    5-60 oil pan and oil pump eng 12 nm (1.2 m skg, 8.7 ftslb) note: 12 nm (1.2 m skg, 8.7 ftslb) caution: eas00374 assembling the oil pump 1. Lubricate: sinner rotor souter rotor soil pump shaft (with the recommended lubricant) recommended lubricant engine oil 2. Install: soil pump housing 1 soil pump ...

  • Page 286: Eng

    5-61 oil pan and oil pump eng note: 12 nm (1.2 m skg, 8.7 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) 43 nm (4.3 m skg, 31 ftslb) warning note: eas00378 installing the oil strainer 1. Install: soil strainer 1 srelief valve 2 make sure to check the arrow mark a located on the oil strainer housing for the fro...

  • Page 287: Eng

    5-62 order job / part q’ty remarks 1 2 3 4 5 removing the crankcase engine cylinder head starter clutch and generator shift shaft crankshaft position sensor and pickup rotor clutch water pump assembly oil pan and oil pump timing chain oil pump drive chain oil pump drive chain guide lower crankcase d...

  • Page 288: Eng

    5-63 order job / part q’ty remarks 6 7 8 thrust plate washer plate 1 1 1 for installation, reverse the removal procedure. 12 nm (1.2 m skg, 8.7 ftslb) 12 nm (1.2 m skg, 8.7 ftslb) crankcase eng.

  • Page 289: Eng

    5-64 crankcase eng note: caution: note: eas00384 disassembling the crankcase 1. Place the engine upside down. 2. Remove: scrankcase bolts sloosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Sloosen the bolts in dec...

  • Page 290: Eng

    5-65 crankcase eng eas00399 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: scrankcase cracks / damage ! Replace. Soil delivery passages obstruction ! Blow out with compressed air. ...

  • Page 291: Eng

    5-66 crankcase eng note: caution: note: do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 x 3 mm of the crankshaft journal bearings. 3. Install: sdowel pin 4. Set the shift drum assembly and transmis- sion gears in t...

  • Page 292: Eng

    5-67 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the connecting rods and pistons lower crankcase connecting rod cap big end lower bearing big end upper bearing piston pin clip piston pin piston connecting rod top ring 2nd ring oil ring 4 4 4 8 4 4 4 4 4 4 remove the parts in the orde...

  • Page 293: Eng

    5-68 connecting rods and pistons eng note: caution: note: note: eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: sconnecting rod cap 1 sbig end bearings identify the position of each big end bearing so that it can...

  • Page 294: Eng

    5-69 connecting rods and pistons eng note: note: eas00387 removing the crankshaft assembly 1. Remove: scrankshaft assembly scrankshaft journal upper bearings (from the upper crankcase) refer to “crankshaft”. Identify the position of each crankshaft journal upper bearing so that it can be reinstalled...

  • Page 295: Eng

    5-70 connecting rods and pistons eng note: cylinder bore “c” 65.50 x 65.51 mm (2.5787 x 2.5791 in) wear limit 65.56 mm (2.5811 in) taper limit “t” 0.05 mm (0.002 in) out of round “r” 0.05 mm (0.002 in) “c” = maximum of d 1 x d 6 “t” = maximum of d 1 or d 2 – maximum of d 5 or d 6 “r” = maximum of d ...

  • Page 296: Eng

    5-71 connecting rods and pistons eng note: note: piston ring side clearance top ring 0.030 x 0.065 mm (0.0012 x 0.0026 in) : 0.115 mm (0.0045 in) 2nd ring 0.030 x 0.065 mm (0.0012 x 0.0026 in) : 0.125 mm (0.0049 in) 2. Install: spiston ring (into the cylinder) level the piston ring into the cylinder...

  • Page 297: Eng

    5-72 connecting rods and pistons eng 2. Measure: spiston pin outside diameter a out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 x 16.000 mm (0.6296 x 0.6299 in) : 15.971 mm (0.6288 in) 3. Measure: spiston pin bore inside diameter b out of specification ! Replace the...

  • Page 298: Eng

    5-73 caution: connecting rods and pistons eng note: note: do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions. A. Clean the big...

  • Page 299: Eng

    5-74 connecting rods and pistons eng caution: warning caution: note: e. Tighten the connecting rod nuts. Connecting rod nut 15 nm (1.5 m skg, 11 ftslb) + 150_ f. Replace the connecting rod bolts with new ones. Tighten the connecting rod bolts using the plastic-region tightening angle method. Always ...

  • Page 300: Eng

    5-75 connecting rods and pistons eng note: note: 2. Select: sbig end bearings (p1 x p4) sthe numbers a stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S“p1” x “p4” refer to the bearings shown in the crankshaft illu...

  • Page 301: Eng

    5-76 connecting rods and pistons eng note: 2. Install: spiston 1 (onto the respective connecting rod 2 ) spiston pin 3 spiston pin clip new 4 sapply engine oil onto the piston pin. Smake sure that the “y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up. R...

  • Page 302: Eng

    5-77 connecting rods and pistons eng note: 15 nm (1.5 m skg, 11 ftslb) + 150_ caution: 6. Install: sbig end bearings sconnecting rod assembly (into the cylinder and onto the crankshaft pin) sconnecting rod cap (onto the connecting rod) salign the projections on the big end bearings with the notches ...

  • Page 303: Eng

    5-78 connecting rods and pistons eng warning caution: note: e. Tighten the nut further to reach the specified angle (150 _). When the nut is tightened more than the spe- cified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again. Sdo n...

  • Page 304: Eng

    5-79 order job / part q’ty remarks 1 2 3 removing the crankshaft crankcase connecting rod caps crankshaft crankshaft journal lower bearing crankshaft journal upper bearing 1 5 5 remove the parts in the order listed. Separate. Refer to “crankcase”. Refer to “connecting rods and pistons”. For installa...

  • Page 305: Eng

    5-80 crankshaft eng caution: eas00395 checking the crankshaft 1. Measure: scrankshaft runout out of specification ! Replace the crank- shaft. Crankshaft runout less than 0.03 mm (0.0012 in) 2. Check: scrankshaft journal surfaces scrankshaft pin surfaces sbearing surfaces scratches / wear ! Replace t...

  • Page 306: Eng

    5-81 crankshaft eng note: note: note: note: c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the up- per crankcase. D. Put a piece of plastigauge 2 on each cranks...

  • Page 307: Eng

    5-82 crankshaft eng note: g. Remove the lower crankcase and the crank- shaft journal lower bearings. H. Measure the compressed plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft jo...

  • Page 308: Eng

    5-83 crankshaft eng note: eas00407 installing the crankshaft 1. Install: scrankshaft journal upper bearings 1 (into the upper crankcase) salign the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. Sbe sure to install each crankshaft journal up- per ...

  • Page 309: Eng

    5-84 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the transmission, shift drum assembly, and shift forks crankcase lower drive axle assembly circlip oil seal bearing shift drum retainer shift fork guide bar spring shift fork “l” shift fork “r” shift drum assembly shift fork “c” 1 1...

  • Page 310: Eng

    5-85 transmission eng order job / part q’ty remarks 12 13 14 15 16 main axle assembly oil pipe oil baffle plate thrust plate washer 1 1 1 1 1 for installation, reverse the removal procedure. 12 nm (1.2 m skg, 8.7 ftslb) 12 nm (1.2 m skg, 8.7 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) 10 nm (1.0 m skg, 7.2 ...

  • Page 311: Eng

    5-86 order job / part q’ty remarks disassembling the main axle assembly bearing 2nd pinion gear toothed lock washer toothed lock washer retainer 6th pinion gear collar washer circlip 3rd pinion gear circlip washer 5th pinion gear collar main axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 disassemble the parts in ...

  • Page 312: Eng

    5-87 order job / part q’ty remarks bearing housing bearing 1 1 for installation, reverse the removal procedure. 15 16 transmission eng.

  • Page 313: Eng

    5-88 order job / part q’ty remarks disassembling the drive axle assembly washer 1st wheel gear collar 5th wheel gear circlip washer collar 3rd wheel gear toothed lock washer toothed lock washer retainer 4th wheel gear collar washer circlip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 disassemble the parts in the ord...

  • Page 314: Eng

    5-89 transmission eng order job / part q’ty remarks 6th wheel gear circlip washer 2nd wheel gear collar collar oil seal bearing circlip drive axle 1 1 1 1 1 1 1 1 1 1 for installation, reverse the removal procedure. 15 16 17 18 19 20 21 22 23 24.

  • Page 315: Eng

    5-90 transmission eng warning eas00420 removing the transmission 1. Remove: smain axle assembly 1 (with the torx wrench t30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten the bolts until they contact the crank- case su...

  • Page 316: Eng

    5-91 transmission eng eas00422 checking the shift drum assembly 1. Check: sshift drum grooves damage / scratches / wear ! Replace the shift drum assembly. Sshift drum segment 1 damage / wear ! Replace the shift drum as- sembly. Sshift drum bearing 2 damage / pitting ! Replace the shift drum assembly...

  • Page 317: Eng

    5-92 transmission eng note: note: 4. Check: stransmission gear engagement (each pinion gear to its respective wheel gear) incorrect ! Reassemble the transmission axle assemblies. 5. Check: stransmission gear movement rough movement ! Replace the defective part(s). 6. Check: scirclips bends / damage ...

  • Page 318: Eng

    5-93 transmission eng 10 nm (1.0 m skg, 7.2 ftslb) note: note: 3. Install: sshift fork “r” 1 and “l” 2 sdrive axle 3 sshift fork guide bar sshift drum retainer sinstall shift fork “l” into the groove in the 6th wheel gear and shift fork “r” into the groove in the 5th wheel gear on the drive axle. Sm...

  • Page 320: Cool

    Cool 6.

  • Page 321: Cool

    Cool chapter 6 cooling system radiator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the radiator 6-4 . . . . . . . . . . . . . . . . . . ....

  • Page 322: Cool

    Cool.

  • Page 323: Cool

    6-1 order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the radiator seat front cowling inner panel (left and right) fuel tank air filter case coolant coolant reservoir hose throttle body hose water pump breather hose radiator outlet hose radiator inlet hose oil cooler outlet hose radiator radiat...

  • Page 324: Cool

    6-2 radiator cool order job / part q’ty remarks 9 radiator fan 1 for installation, reverse the removal procedure. 10 nm (1.0 m skg, 7.2 ftslb) 7 nm (0.7 m skg, 5.1 ftslb) 7 nm (0.7 m skg, 5.1 ftslb).

  • Page 325: Cool

    6-3 radiator cool note: eas00455 checking the radiator 1. Check: sradiator fins obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: sradiator hoses sradiator pipes cracks / d...

  • Page 326: Cool

    6-4 radiator cool eas00456 installing the radiator 1. Install: sradiator scoolant hoses 2. Fill: scooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 3. Check: scooling system leaks ! Repair or replace any faulty part. 4. Measure: sra...

  • Page 327: Cool

    6-5 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the oil cooler radiator assembly engine oil oil cooler outlet hose union bolt washer oil cooler o-ring oil cooler inlet hose oil cooler inlet pipe water jacket joint hose water jacket joint 1 1 1 1 1 1 1 1 1 remove the parts in the order l...

  • Page 328: Cool

    6-6 oil cooler cool order job / part q’ty remarks 10 11 12 o-ring water pump outlet hose radiator outlet hose 1 1 1 for installation, reverse the removal procedure. 10 nm (1.0 m skg, 7.2 ftslb) 63 nm (6.3 m skg, 46 ftslb).

  • Page 329: Cool

    6-7 oil cooler cool 63 nm (6.3 m skg, 46 ftslb) note: eas00458 checking the oil cooler 1. Check: soil cooler cracks / damage ! Replace. 2. Check: soil cooler inlet hose soil cooler outlet hose cracks / damage / wear ! Replace. Eas00459 installing the oil cooler 1. Clean: smating surfaces of the oil ...

  • Page 330: Cool

    6-8 order job / part q’ty remarks 1 2 3 removing the thermostat seat front cowling inner panel (left and right) fuel tank air filter case coolant throttle body assembly radiator inlet hose thermostat cover thermostat 1 1 1 remove the parts in the order listed. Refer to “seat” in chapter 3. Refer to ...

  • Page 331: Cool

    6-9 1 thermostat cool note: eas00462 checking the thermostat 1. Check: sthermostat 1 does not open at 71 x 85_c (160 x 185_f) ! Replace. A. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring the water, observe the...

  • Page 332: Cool

    6-10 thermostat cool note: 12 nm (1.2 m skg, 8.7 ftslb) note: eas00466 installing the thermostat 1. Install: sthermostat install the thermostat with its breather hole a facing up. 2. Install: sthermostat cover before installing the thermostat cover to the cyl- inder head, lubricate the o-ring with a...

  • Page 333: Cool

    6-11 order job / part q’ty remarks 1 2 3 4 removing the water pump coolant radiator outlet hose water pump outlet hose water pump breather hose water pump 1 1 1 1 remove the parts in the order listed. It is not necessary to remove the water pump unless the coolant level is extremely low or the coola...

  • Page 334: Cool

    6-12 order job / part q’ty remarks disassembling the water pump water pump cover o-ring impeller shaft circlip water pump seal oil seal bearing water pump housing o-ring copper washer 1 1 1 1 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 ...

  • Page 335: Cool

    6-13 water pump cool note: note: note: note: eas00471 disassembling the water pump 1. Remove: swater pump cover so-ring scirclip simpeller shaft 2. Remove: swater pump seal 1 remove the water pump seal from the outside of the water pump housing. 2 water pump housing 3. Remove: soil seal 1 (with a th...

  • Page 336: Cool

    6-14 water pump cool note: caution: note: eas00473 checking the water pump 1. Check: swater pump housing 1 swater pump cover 2 simpeller 3 srubber damper 4 srubber damper holder 5 swater pump seals soil seal cracks / damage / wear ! Replace. 2. Check: sbearing rough movement ! Replace. 3. Check: swa...

  • Page 337: Cool

    6-15 water pump cool note: caution: 10 nm (1.0 m skg, 7.2 ftslb) mechanical seal installer 90890-04078, ym-33221 4 middle driven shaft bearing driver 90890-04058, ym-04058 5 quick gasket acc-11001-05-01 yamaha bond #1215 90890-85505 a push down. 3. Install: srubber damper new 1 srubber damper holder...

  • Page 338: Cool

    6-16 water pump cool 10 nm (1.0 m skg, 7.2 ftslb) note: note: installing the water pump 1. Install: so-ring new scopper washer new swater pump assembly align the projection a at the oil pump shaft and water pump shaft groove b . 2. Install: swater pump outlet hose 1 sradiator outlet hose 2 sinstall ...

  • Page 340

    Fi chapter 7 fuel injection system fuel injection system 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring diagram 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecu’s self-diagnostic function 7-3 . . . . . . . . . . . . . . . . ....

  • Page 341

    Fi.

  • Page 342: Fuel Injection System

    7-1 fuel injection system fi 1 ignition coil 2 air filter case 3 intake air temperature sensor 4 fuel delivery hose 5 fuel tank 6 fuel pump 7 intake air pressure sensor 8 throttle position sensor 9 fuel injector 10 catalytic converter 11 crankshaft position sensor 12 coolant temperature sensor 13 sp...

  • Page 343

    7-2 1 main switch 5 fuse (fuel injection) 7 fuse (main) 10 battery 11 starting circuit cut-off relay 12 sidestand switch 13 neutral switch 14 fuel pump 15 throttle position sensor 16 intake air pressure sensor 17 lean angle cut-off switch 18 crankshaft position sensor 19 intake air temperature senso...

  • Page 344

    7-3 41: lean angle cut-off switch (open or short circuit) 50: ecu internal malfunction (memory check error) fuel injection system fi eas00899 ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If...

  • Page 345

    7-4 fuel injection system fi eas00902 alternate instructions operation control (fail-safe action) 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 instruction...

  • Page 346

    7-5 fuel injection system fi communication error with the meter er-1 ecu internal malfunction (output signal error) no signals are received from the ecu. – unable unable er-2 ecu internal malfunction (output signal error) no signals are received from the ecu within the specified duration. – unable u...

  • Page 347

    7-6 engine operation is not normal or the engine trouble warning light is on. * engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displayed on the me- ter. Identify the system with the malfu...

  • Page 348

    7-7 fuel injection system fi note: note: eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators without con- necting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Sett...

  • Page 349

    7-8 fuel injection system fi note: 7. Verify the operation of the sensor or actuator. Ssensor operation the data representing the operating condi- tions of the sensor appears on the trip lcd. Sactuator operation set the engine stop switch to “on” to operate the actuator. * if the engine stop switch ...

  • Page 350

    7-9 fuel injection system fi fault code table fault code no. Symptom probable cause of malfunction diagnostic code 12 no normal signals are received from the crankshaft position sensor. S open or short circuit in wiring harness. S defective crankshaft position sensor. S malfunction in pickup rotor. ...

  • Page 351

    7-10 fuel injection system fi fault code no. Symptom probable cause of malfunction diagnostic code 50 faulty ecu memory. When this malfunction is detected, the code number might not appear on the meter. S malfunction in ecu. (the program and data are not properly written on or read from the internal...

  • Page 352

    7-11 fuel injection system fi note: eas00907 diagnostic mode table switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “diagnostic mode”. Scheck the intake air temperature and coolant temperature as close as possible to the intake air tem- perature ...

  • Page 353

    7-12 fuel injection system fi diagnostic code item description of action data displayed on meter (reference value) 48 ai system solenoid after 1 second has elapsed from the time the engine stop switch has been turned from off to on, it actuates the ai system solenoid five times every second and illu...

  • Page 354

    7-13 fuel injection system fi crankshaft position sensor resistance 248 x 372 Ω at 20_c (68_f) (between gray and black) tester positive probe ! Gray tester negative probe ! Black 1 2 when installing or removing the con- nector, main switch turn to “off”. Note: eas00908 troubleshooting details this s...

  • Page 355

    7-14 intake air pressure sensor output voltage 3.75 x 4.25 v tester positive probe ! Pink/white tester negative probe ! Black/blue 1 2 1 2 when installing or removing the con- nector, main switch turn to “off”. Note: fuel injection system fi fault code no. 13 symptom intake air pressure sensor - ope...

  • Page 356

    7-15 fuel injection system fi fault code no. 14 symptom intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code no. 03 (intake air pressure sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method ...

  • Page 357

    7-16 fuel injection system fi fault code no. 16 symptom stuck throttle position sensor detected. Used diagnostic code no. 01 (throttle position sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed condition of throttle position...

  • Page 358

    7-17 fuel injection system fi intake air temperature sensor resistance 2.2 x 2.7 kΩ at 20_c (68_f) tester positive probe ! Brown/white tester negative probe ! Black/blue 1 2 s handle the intake air temperature sensor with special care. S never subject the intake air temperature sen- sor to strong sh...

  • Page 359

    7-18 fuel injection system fi tester positive prove ! Yellow/green tester negative prove ! Black/blue 1 2 fault code no. 30 symptom the motorcycle has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) order inspection operation item and probable cause operation item and countermeas...

  • Page 360

    7-19 fuel injection system fi fault code no. 33 symptom malfunction detected in the primary lead of the ignition coil (#1, #4). Used diagnostic code no. 30 (ignition coil #1, #4) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected con...

  • Page 361

    7-20 fuel injection system fi speed sensor output voltage when sensor is on dc 4.8 v or more when sensor is off dc 0.6 v or less tester positive probe ! Pink tester negative probe ! Black/white 1 2 fault code no. 42 symptom 1 no normal signals are received from the speed sensor. 2 open or short circ...

  • Page 362

    7-21 fuel injection system fi battery positive terminal ! Red/black battery positive terminal ! Blue/yellow 1 2 tester positive probe ! Red tester negative probe ! Red/blue 3 4 when the leads are disconnected, the voltage check by the code no. 09 is impossible. Note: fault code no. 43 symptom the ec...

  • Page 363

    7-22 fuel injection system fi fault code no. 44 symptom error is detected while reading or writing on eep-rom (co adjustment value). Used diagnostic no. 60 (eep-rom improper cylinder indication) order inspection operation item and probable cause operation item and countermeasure reinstatement method...

  • Page 364

    7-23 fuel injection system fi fault code no. Er-1 symptom no signals are received from the ecu. Used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected condition of connector inspect the coupler for any pins t...

  • Page 365

    7-24 fuel injection system fi fault code no. Er-4 symptom non-registered data has been received from the meter. Used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected condition of connector inspect the couple...

  • Page 366

    7-25 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the throttle bodies seat front cowling inner panel (left and right) fuel tank battery air filter case battery box and battery box bracket sub-wire harness coupler coolant temperature sensor coupler throttle body joint clamp screw throttle bod...

  • Page 367

    7-26 throttle bodies fi order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 removing the injectors throttle position sensor coupler intake air pressure sensor coupler cylinder #1-injector coupler cylinder #2-injector coupler cylinder #3-injector coupler cylinder #4-injector coupler sub wi...

  • Page 368

    7-27 throttle bodies fi caution: caution: eas00911 the throttle bodies should not be disas- sembled. Eas00912 checking the injectors 1. Check: sinjectors damage ! Replace. Eas00913 checking the throttle bodies 1. Check: sthrottle bodies cracks / damage ! Replace the throttle bo- dies as a set. 2. Ch...

  • Page 369

    7-28 throttle bodies fi checking the fuel pump and pressure regulator operation 1. Check: sfuel pump operation refer to “fuel tank” in chapter 3. A. Remove the seat fuel tank. Refer to “seat and fuel tank” in chapter 3. B. Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe. Pres...

  • Page 370

    7-29 throttle bodies fi note: eas00916 checking and adjusting the throttle position sensor before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: sthrottle position sensor a. Disconnect the throttle position sensor cou- pler. B. Remove the thr...

  • Page 371

    7-30 throttle bodies fi note: tester positive probe ! Yellow terminal tester negative probe ! Black / blue terminal 1 2 f. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly ! Re...

  • Page 372

    7-31 air induction system fi eas00507 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 reed valve op...

  • Page 373

    7-32 air induction system fi a to cylinder #1 and #2 b to cylinder #3 and #4 1 air cut-off valve 2 reed valve 3 to air filter case eas00509 air induction system diagrams.

  • Page 374

    7-33 air induction system fi eas00510 checking the air induction system 1. Check: shoses loose connection ! Connect properly. Cracks / damage ! Replace. Spipes cracks / damage ! Replace. 2. Check: s reed valve 1 s reed valve stopper sreed valve seat cracks / damage ! Replace the reed valve. 3. Measu...

  • Page 375

    7-34 air induction system fi 5. Check sai system solenoid a. Remove the ai system solenoid coupler from the wire harness. B. Connect the pocket tester ( Ω 1) to the ai system solenoid terminal as shown. Tester positive probe ! Brown/red 1 tester negative probe ! Red/white 2 c. Measure the ai system ...

  • Page 376: Elec

    Elec 8.

  • Page 377: Elec

    Elec chapter 8 electrical system electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking switch continuity 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the switches 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 378: Elec

    Elec fuel pump system 8-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 8-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump system 8-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 379: Elec

    8-1 electrical components elec 9 oil level switch 10 radiator fan motor 11 horn 12 ignition coil 1 main switch (immobilizer unit) 2 front brake light switch 3 starter relay 4 battery 5 fuse box 6 rear brake light switch 7 neutral switch 8 sidestand switch eas00729 electrical system electrical compon...

  • Page 380: Elec

    8-2 9 radiator fan motor relay 10 turn signal relay 11 rectifier / regulator 12 throttle position sensor 1 coolant temperature sensor 2 intake air temperature sensor 3 intake air pressure sensor 4 fuel pump 5 ecu 6 lean angle cut-off switch 7 starting circuit cut-off relay 8 dimmer relay electrical ...

  • Page 381: Elec

    8-3 checking switch continuity elec caution: note: note: eas00730 checking switch continuity 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. Never insert the tester probes into the cou...

  • Page 382: Elec

    8-4 11 oil level switch 12 neutral switch 13 rear brake light switch 14 fuse box 15 hazard switch 1 main switch 2 horn switch 3 dimmer switch 4 pass switch 5 turn signal switch 6 clutch switch 7 sidestand switch 8 engine stop switch 9 front brake light switch 10 start switch checking the switches el...

  • Page 383: Elec

    8-5 checking the bulbs and bulb sockets elec warning eas00732 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage / wear ! Repair or replace the bulb, bulb socket or both. Improperly conne...

  • Page 384: Elec

    8-6 checking the bulbs and bulb sockets elec caution: note: sbe sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. Savoid touching the glass part of the head- light bulb to keep it free from oil, otherwise th...

  • Page 385: Elec

    8-7 checking the bulbs and bulb sockets elec note: note: warning pocket tester 90890-03112, yu-3112 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 into the bulb socket. B. Connect the pocket tester probes...

  • Page 386: Elec

    8-8 1 main switch 7 fuse (main) 10 battery 11 starting circuit cut-off relay 12 sidestand switch 13 neutral switch 17 lean angle cut-off switch 18 crankshaft position sensor 21 ecu 28 ignition coil #1 and #4 29 ignition coil #2 and #3 30 spark plug 43 engine stop switch 50 fuse (ignition) 57 clutch ...

  • Page 387: Elec

    8-9 yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _c (68_f) s is the battery ok? S clean the battery terminals. S recharge or re- place the battery. Eas00739 yes no eas00741 3. Spar...

  • Page 388: Elec

    8-10 ignition system elec no yes 1 a 2 4. Ignition spark gap the following procedure applies to all of the spark plugs. S disconnect the spark plug cap from the spark plug. S connect the ignition checker and spark plug cap as shown. S set the main switch to “on”. S measure the ignition spark gap . S...

  • Page 389: Elec

    8-11 ignition system elec negative tester probe ! Spark plug lead positive tester probe ! Spark lug lead 1 2 s measure the secondary coil resistance. Secondary coil resistance 12 x 18 kΩ at 20_c (68_f) s is the ignition coil ok? Yes no replace the ignition coil. 7. Crankshaft position sensor resista...

  • Page 390: Elec

    8-12 ignition system elec eas00752 11. Sidestand switch s check the sidestand switch for continuity. Refer to “checking the switches”. S is the sidestand switch ok? Yes no replace the side- stand switch. Eas00763 12. Clutch switch s check the clutch switch for continuity. Refer to “checking the swit...

  • Page 391: Elec

    8-13 ignition system elec eas00754 15. Wiring s check the entire ignition system’s wiring. Refer to “circuit diagram”. S is the ignition system’s wiring properly con- nected and without defects? Yes no properly connect or repair the ignition system’s wiring. Replace the ecu..

  • Page 392: Elec

    8-14 1 main switch 7 fuse (main) 8 starter relay 9 starter motor 10 battery 11 starting circuit cut-off relay 12 sidestand switch 13 neutral switch 43 engine stop switch 44 start switch 50 fuse (ignition) 57 clutch switch electric starting system elec eas00755 electric starting system circuit diagra...

  • Page 393: Elec

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

  • Page 394: Elec

    8-16 yes no 3. Starter motor s connect the positive battery terminal and starter motor lead with a jumper lead . Repair or replace the starter motor. S a wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, other- wise the jumper lead may burn....

  • Page 395: Elec

    8-17 4. Starting circuit cut-off relay s disconnect the starting circuit cut-off relay coupler from the wire harness. S connect the pocket tester (Ω 1) and bat- tery (12 v) to the starting circuit cut-off relay coupler as shown. Yes no replace the starting circuit cut-off relay. Positive tester prob...

  • Page 396: Elec

    8-18 s check the entire starting system’s wiring. Refer to “circuit diagram”. S is the starting system’s wiring properly con- nected and without defects? Eas00766 12. Wiring yes no properly connect or repair the starting system’s wiring. The starting system circuit is ok. 11. Start switch s check th...

  • Page 397: Elec

    8-19 starter motor elec order job / part q’ty remarks 1 2 removing the starter motor seat front cowling inner panel (left and right) fuel tank throttle bodies starter motor lead starter motor 1 1 remove the parts in the order listed. Refer to “seat” in chapter 3. Refer to “cowlings” in chapter 3. Re...

  • Page 398: Elec

    8-20 starter motor elec order job / part q’ty remarks disassembling the starter motor o-ring front cover lock washer oil seal bearing washer set rear cover washer set o-ring brush holder armature assembly starter motor yoke o-ring 1 1 1 1 1 1 1 1 2 1 1 1 2 disassembly the parts in the order listed. ...

  • Page 399: Elec

    8-21 starter motor elec note: eas00770 checking the starter motor 1. Check: scommutator dirt ! Clean with 600 grit sandpaper. 2. Measure: scommutator diameter a out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: smica undercut a out of specification !...

  • Page 400: Elec

    8-22 starter motor elec note: 5. Measure: sbrush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: sbrush spring force out of specification ! Replace the brush springs as a set. Brush spring force 7.16 x 9.52 n (730 x 971 gf, 25.77 x...

  • Page 401: Elec

    8-23 starter motor elec 3.4 nm (0.34 m skg, 2.5 ftslb) note: 3. Install: sstarter motor yoke 1 so-ring 2 new sfront cover 3 srear cover 4 sbolts 5 align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers..

  • Page 402: Elec

    8-24 2 a.C. Magneto 3 rectifier / regulator 7 fuse (main) 10 battery charging system elec eas00773 charging system circuit diagram.

  • Page 403: Elec

    8-25 no yes 3. Charging voltage s set the engine tachometer to the ignition coil of cylinder #1. S connect the pocket tester (dc 20 v) to the battery as shown. The charging circuit is ok. Positive tester probe ! Positive battery terminal negative tester probe ! Negative battery terminal s start the ...

  • Page 404: Elec

    8-26 charging system elec yes no 5. Stator coil resistance s remove the generator cover. S connect the pocket tester (Ω 1) to the sta- tor coils as shown. Replace the stator coil assembly. Eas00776 positive tester probe ! White negative tester probe ! White positive tester probe ! White negative tes...

  • Page 405: Elec

    8-27 ch b ch b r/b r/b c g/b g/b c ll c b/l b /l d p/w p /w d yy d br/w br/w d g/w g/wd r/l r/l c b/l g/w b b/l b b b b b/l dg g/l r/w ch r/g y dg b dg b lg w b/w g/w y/l l/r dg g/l r/w ch r/g y l g/b r/b bb bb b/y b b/g b l/r b l/r b b b ch dg y b b/l y l p/w b/l l br/w b/l l/r l/r b b/g b/g b dg d...

  • Page 406: Elec

    8-28 lighting system elec 1 main switch 7 fuse (main) 10 battery 21 ecu 37 high beam indicator light 49 fuse (headlight) 50 fuse (ignition) 51 fuse (park) 54 license plate light 55 tail / brake light 58 pass switch 59 dimmer switch 64 dimmer relay 65 auxiliary light 66 headlight (high beam) 67 headl...

  • Page 407: Elec

    8-29 yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Eas00784 yes no 4. Dimmer switch s check the dimmer switch for co...

  • Page 408: Elec

    8-30 s does the dimmer relay have continuity be- tween red / yellow and green? No yes replace the dimmer relay. Positive tester probe ! Red/yellow negative tester probe ! Green 1 2 3 4 6. Dimmer relay s disconnect the dimmer relay from the cou- pler. S connect the pocket tester (Ω 1) and bat- tery (...

  • Page 409: Elec

    8-31 high beam indicator light (leds) positive tester probe ! Yellow negative tester probe ! Black / white yes no 1. Headlight bulb and socket s check the headlight bulb and socket for con- tinuity. Refer to “checking the bulbs and bulb sockets”. S are the headlight bulb and socket ok? Replace the h...

  • Page 410: Elec

    8-32 lighting system elec yes no 1. License plate light bulb and socket s check the license plate light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the license plate light bulb and socket ok? Replace the license plate light bulb, sock- et or both. Eas00792 2...

  • Page 411: Elec

    8-33 lighting system elec yes no 1. Tail / brake light bulb and socket s check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the tail/brake light bulb and socket ok? Replace the tail / brake light bulb, socket or both. Eas00790 3. The tail...

  • Page 412: Elec

    8-34 signaling system elec eas00793 signaling system circuit diagram.

  • Page 413: Elec

    8-35 signaling system elec 1 main switch 4 fuse (backup) 7 fuse (main) 10 battery 11 starting circuit cut-off relay 13 neutral switch 14 fuel pump 21 ecu 33 oil level waning light 35 neutral indicator light 36 multi-function meter 38 turn signal indicator light 39 oil level switch 42 front brake lig...

  • Page 414: Elec

    8-36 yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Yes no 1. Horn switch s check the horn switch for continuity. Ref...

  • Page 415: Elec

    8-37 signaling system elec yes no 1. Tail / brake light bulb and socket s check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the tail/brake light bulb and socket ok? Replace the tail / brake light bulb, socket or both. Eas00797 2. The tai...

  • Page 416: Elec

    8-38 signaling system elec no yes no the wiring circuit from the main switch to the tail / brake light coupler is faulty and must be repaired. This circuit is ok. Yes 1. Turn signal indicator light (leds) s check the turn signal indicator light for conti- nuity. Refer to “checking the leds”. S are t...

  • Page 417: Elec

    8-39 signaling system elec yes no the wiring circuit from the turn signal switch to the turn sig- nal light connector is faulty and must be repaired. Left turn signal light positive tester probe ! Ground negative tester probe ! Chocolate right turn signal light positive tester probe ! Ground negativ...

  • Page 418: Elec

    8-40 signaling system elec yes no replace the starting circuit cut-off relay. Yes no 4. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. ...

  • Page 419: Elec

    8-41 signaling system elec 3. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! Black/white negative tester probe ! Red/white 1 2 s turn the main switch to “on”. S measure the voltage (dc 12v) of black/ white and red / w...

  • Page 420: Elec

    8-42 signaling system elec yes no 2. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. Positive tester probe ! Green/white negative tester...

  • Page 421: Elec

    8-43 1 main switch 7 fuse (main) 10 battery 20 coolant temperature sensor 21 ecu 45 fuse (radiator fan motor) 46 radiator fan motor relay 47 radiator fan motor 50 fuse (ignition) cooling system elec eas00807 cooling system circuit diagram.

  • Page 422: Elec

    8-44 yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _c (68_f) s is the battery ok? S clean the battery terminals. S recharge or re- place the battery. Eas00739 eas00749 3. Main switc...

  • Page 423: Elec

    8-45 yes no 4. Radiator fan motor s disconnect the radiator fan motor coupler from the wire harness. S connect the battery (dc 12 v) as shown. The radiator fan mo- tor is faulty and must be replaced. Positive battery lead ! Blue negative battery lead ! Black 1 2 s does the radiator fan motor turn? 5...

  • Page 424: Elec

    8-46 cooling system elec s remove the coolant temperature sensor. S connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. S immerse the coolant temperature sensor in a container filled with coolant . Make sure the coolant temperature sensor terminals do not get wet. S place a ...

  • Page 425: Elec

    8-47 1 main switch 5 fuse (fuel injection) 7 fuse (main) 10 battery 11 starting circuit cut-off relay 14 fuel pump 21 ecu 43 engine stop switch 50 fuse (ignition) fuel pump system elec eas00814 fuel pump system circuit diagram.

  • Page 426: Elec

    8-48 fuel pump system elec 1 battery 2 fuse (main) 3 main switch 4 fuse (ignition) 5 engine stop switch 6 ecu 7 fuse (fuel injection) 8 starting circuit cut-off relay (fuel injection system relay) 9 fuel pump eas00815 fuel pump system the ecu includes the control unit for the fuel pump..

  • Page 427: Elec

    8-49 fuel pump system elec yes no 2. Battery s check the condition of the battery refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _c (68_f) s is the battery ok? S clean the battery terminals. S recharge or re- place the battery. Eas00739 e...

  • Page 428: Elec

    8-50 fuel pump system elec yes no 5 starting circuit cut-off relay (fuel injection system relay) s disconnect the starting circuit cut-off relay coupler from the wire harness. S connect the pocket tester (Ω 1) and bat- tery (12v) to the starting circuit cut-off relay coupler as shown. Replace the st...

  • Page 429: Elec

    8-51 fuel pump system elec warning eas00819 checking the fuel pump gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: sstop the engine before refueling. Sdo not smoke, and keep away from o...

  • Page 430: Elec

    8-52 immobilizer system elec br brown . . . . . Lg light green . . . . . Br / l brown / blue . . . R / g red / green . . . R / w red / white . . . Y / l yellow / blue . . . . 1 main switch and immobilizer unit 2 immobilizer indicator light 3 ecu immobilizer system system diagram.

  • Page 431: Elec

    8-53 1 main switch 4 fuse (backup) 6 immobilizer unit 7 fuse (main) 10 battery 21 ecu 32 immobilizer indicator light 36 multi-function meter 50 fuse (ignition) immobilizer system elec circuit diagram.

  • Page 432: Elec

    8-54 immobilizer system elec general information swhen the main switch is turned “on” with the registered key, the immobilizer system indicator light comes on for about 0.5 second and then goes off. Sto check the immobilizer system, follow the steps in the troubleshooting chart. Sto use the immobili...

  • Page 433: Elec

    8-55 immobilizer system elec note: key id registration method initially one code re-registering key and two standard keys have been registered with the immobilizer system. In the course of use, you may encounter the following case where re-registration of code re-register- ing / standard key is requ...

  • Page 434: Elec

    8-56 immobilizer system elec when one standard key is registered. Code re-registering key first unregistered standard key flashing ends when it elapses 5 seconds and the registration for the seconds standard key is impossible. When two standard keys are registered. Code re-registering key first unre...

  • Page 435: Elec

    8-57 immobilizer system elec 52 light on light off self-diagnosis error code indication when the system failure occurred, the error code number is indicated in the lcd display of meter and the immobilizer indicator light flashes at the same time. The pattern of flashing also shows the error code. Er...

  • Page 436: Elec

    8-58 yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. 2. Battery s check the condition of the battery. Refer to “checki...

  • Page 437: Elec

    8-59 yes no 1. Immobilizer system indicator light (leds) s check the immobilizer system indicator light for continuity. Refer to “checking the leds”. S are the immobilizer system indicator light ok? Replace the meter assembly. Eas00788 checking the immobilizer system 1. The immobilizer system indica...

  • Page 438: Elec

    8-60 immobilizer system elec correct turn “on” the main switch with another standard key and check the indicator. The indicator goes on for about one se- cond and then goes off. First standard key (transponder) de- fective correct failure check the self-diagnosis code indica- tion. Read the error co...

  • Page 439: Elec

    8-61 immobilizer system elec note: replacement parts on troubles replacement parts transponder key immobilizer unit ecu * 1 main switch * 2 accessory lock and key when standard key is missing and the replace standard key is required f all keys have been lost (includ- ing code re-registering key) f f...

  • Page 440: Elec

    8-62 self-diagnosis elec self-diagnosis the fz6-s(s) features a self-diagnosing system for the following circuit(-s): sfuel pump thermistor soil level switch if any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turned...

  • Page 441: Elec

    8-63 self-diagnosis elec repair or replace the wire harness. No 1. Wire harness s check the wire harness for continuity. Refer to “circuit diagram”. S is the wire harness ok? Yes no 2. Fuel pump thermistor s check the fuel pump thermistor for continuity. Refer to “the fuel level indicator light fail...

  • Page 442: Elec

    8-64 self-diagnosis elec replace the oil level switch. No 2. Oil level switch s check the oil level switch for continuity. Refer to “the oil level warning light fails to come on”. S is the oil level switch ok? Yes repair or replace the wire harness. No 1. Wire harness s check the wire harness for co...

  • Page 443: Trbl

    9 trbl shtg.

  • Page 444: Trbl

    Trbl shtg chapter 9 troubleshooting starting failures 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 9-1 . . . . . . . . . . . . . . . . ....

  • Page 445: Trbl

    Trbl shtg faulty lighting or signaling system 9-6 . . . . . . . . . . . . . . . . . . . Headlight does not come on 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulb burnt out 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail / brake light does not come on 9-6 . . . ...

  • Page 446: Trbl

    9-1 starting failures trbl shtg note: air filter simproperly installed air filter sclogged air filter element crankcase and crankshaft simproperly assembled crankcase sseized crankshaft fuel system fuel tank sempty fuel tank sclogged fuel filter sclogged fuel tank drain hose sdeteriorated or contami...

  • Page 447: Trbl

    9-2 starting failure/incorrect engine idling speed/ poor medium-and-high-speed performance trbl shtg starting system sfaulty starter motor sfaulty starter relay sfaulty starting circuit cut-off relay sfaulty starter clutch electrical systems battery sdischarged battery sfaulty battery spark plug(s) ...

  • Page 448: Trbl

    9-3 faulty gear shifting/faulty clutch trbl shtg jumps out of gear shift shaft sincorrect shift pedal position simproperly returned stopper lever shift forks sworn shift fork shift drum sincorrect axial play sworn shift drum groove transmission sworn gear dog clutch drags clutch sunevenly tensioned ...

  • Page 449: Trbl

    9-4 overheating/overcooling/ poor braking performance trbl shtg fuel system throttle body(-ies) sdamaged or loose carburetor joint air filter sclogged air filter element chassis brake(s) sdragging brake electrical systems spark plug(s) sincorrect spark plug gap sincorrect spark plug heat range ignit...

  • Page 450: Trbl

    9-5 faulty front fork legs/unstable handling trbl shtg rear shock absorber assembly(-ies) sfaulty rear shock absorber spring sleaking oil or gas tire(s) suneven tire pressures (front and rear) sincorrect tire pressure suneven tire wear wheel(s) sincorrect wheel balance sdeformed cast wheel sdamaged ...

  • Page 451: Trbl

    9-6 faulty lighting or signaling system trbl shtg turn signal does not come on sfaulty turn signal switch sfaulty turn signal relay sburnt-out turn signal bulb sincorrect connection sdamaged or faulty wire harness simproperly grounded circuit sfaulty battery sblown, damaged or incorrect fuse turn si...

  • Page 452

    56 left handlebar switch 57 clutch switch 58 pass switch 59 dimmer switch 60 hazard switch 61 turn signal switch 62 horn switch 63 horn 64 dimmer relay 65 auxiliary light 66 headlight (high beam) 67 headlight (low beam) 68 rear turn signal light (right) 69 rear turn signal light (left) 70 front turn...

  • Page 456

    B l b l color code b black . . . . Br brown . . . . Ch chocolate . . . . Dg dark green . . . . G green . . . . Gy gray . . . . L blue . . . . Lg light green . . . . P pink . . . . R red . . . . Sb sky blue . . . . W white . . . . Y yellow . . . . B / g black / green . . . . B / l black / blue . . . ...