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Yamaha FZ6RC Service Manual

Manual is about: FZ6R 2009

Summary of FZ6RC

  • Page 1

    Service manual fz6ry(c) 2009 36p-28197-10 lit-11616-22-77.

  • Page 3

    Eas20050 fz6ry(c) service manual ©2008 by yamaha motor corporation, u.S.A. First edition, december 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-22-77.

  • Page 4

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

  • Page 5

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

  • Page 6

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. G m bf b t r . . Ls m s lt e new serviceable with engine mounted filling fluid lubricant special tool tightening torque wear limit, clearance engine s...

  • Page 7: General Information

    General information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 electrical system 8 troubleshooting 9 eas20110 table of contents.

  • Page 9: General Information

    1 2 3 4 5 6 7 8 9 general information identification ...........................................................................................1-1 vehicle identification number....................................................1-1 model label ..........................................................

  • Page 10: Identification

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

  • Page 11: Features

    Features 1-2 eas20170 features eas4b51038 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixtu...

  • Page 12: Features

    Features 1-3 eas4b51039 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 245 – 255 kpa (2.45 – 2.55 kgf/ cm 2 , 35.5 – 37.0 psi) higher than the intake manifol...

  • Page 13: Features

    Features 1-4 eas20s1001 instrument functions multi-function meter unit warning ewa20s1001 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function ...

  • Page 14: Features

    Features 1-5 4. Push the “select” button, and the minute digits will start flashing. 5. Push the “reset” button to set the minutes. 6. Push the “select” button and then release it to start the clock. Odometer and tripmeter modes push the “select” button to switch the display between the odometer mod...

  • Page 15: Features

    Features 1-6 self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate an error code. If the display indicates any error c...

  • Page 16: Important Information

    Important information 1-7 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-12. 3. When disassem...

  • Page 17: Important Information

    Important information 1-8 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if ...

  • Page 18: Checking The Connections

    Checking the connections 1-9 eas20250 checking the connections notice eca20s1001 electronic parts are very sensitive. Handle with care and do not give impact. Notice eca20s1002 ● mankind has static electricity. It`s voltage is very high and electronic parts are very sensitive. ● it is possible that ...

  • Page 19: Checking The Connections

    Checking the connections 1-10 tip if the pin “1” on the terminal is flattened, bend it up. Tip if the contact seems not good, pull the terminal by hand and check its condition. 4. Connect: ● lead ● coupler ● connector tip make sure all connections are tight. 5. Check: ● continuity (with the pocket t...

  • Page 20: Checking The Connections

    Checking the connections 1-11 eas21850 installing the quick fastener tip to install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head...

  • Page 21: Special Tools

    Special tools 1-12 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 22: Special Tools

    Special tools 1-13 oil pressure adapter h 90890-03139 3-24 compression gauge 90890-03081 engine compression tester yu-33223 5-18 steering nut wrench 90890-01403 spanner wrench yu-33975 3-18, 4-53 damper rod holder 90890-01460 4-46, 4-48 t-handle 90890-01326 ym-01326 4-46, 4-48 fork seal driver weigh...

  • Page 23: Special Tools

    Special tools 1-14 fork seal driver attachment ( ø 41) 90890-01381 replacement 41 mm ym-a5142-2 4-48 ring nut wrench 90890-01268 spanner wrench yu-1268 4-53 valve spring compressor 90890-04019 ym-04019 5-21, 5-26 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym...

  • Page 24: Special Tools

    Special tools 1-15 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-30, 5-31, 5-32 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-30 flywheel puller attachment 90890-04089 crankshaft protector ym-33282 5-30 yamaha bond no. 1215 (three bond no.1215®) 90890-85505 5-32, 5-34, 5-...

  • Page 25: Special Tools

    Special tools 1-16 universal clutch holder 90890-04086 ym-91042 5-50, 5-54 piston pin puller set 90890-01304 piston pin puller yu-01304 5-66 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-3 tool name/tool no. Illustration reference pages yu-01304 yu-24460-01.

  • Page 26: Special Tools

    Special tools 1-17 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-12 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-12 fuel injector pressure adapter 90...

  • Page 27: Specifications

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

  • Page 28: General Specifications

    General specifications 2-1 eas20280 general specifications model fz6ry 36p1 (u49) fz6ry 36p4 (u49) fz6ryc 36p2 (cal) fz6ryc 36p5 (cal) dimensions overall length 2120 mm (83.5 in) overall width 770 mm (30.3 in) overall height 1185 mm (46.7 in) seat height 785 mm (30.9 in) wheelbase 1440 mm (56.7 in) ...

  • Page 29: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 599.8 cm 3 cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) compression ratio 12.20 :1 standard compression pressure (at sea le...

  • Page 30: Engine Specifications

    Engine specifications 2-3 radiator core width 300.0 mm (11.81 in) height 197.0 mm (7.76 in) depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 86/44 × 31/31 (1.955) spark plug (s) manufacturer/model ngk/cr9e spark plug gap 0.7 – 0.8 mm (0.028 – 0.031 i...

  • Page 31: Engine Specifications

    Engine specifications 2-4 valve clearance (cold) intake 0.13 – 0.20 mm (0.0051 – 0.0079 in) exhaust 0.23 – 0.30 mm (0.0091 – 0.0118 in) valve dimensions valve head diameter a (intake) 24.90 – 25.10 mm (0.9803 – 0.9882 in) valve head diameter a (exhaust) 21.90 – 22.10 mm (0.8622 – 0.8701 in) valve fa...

  • Page 32: Engine Specifications

    Engine specifications 2-5 valve spring free length (intake) 39.08 mm (1.54 in) free length (exhaust) 39.08 mm (1.54 in) installed length (intake) 33.40 mm (1.31 in) installed length (exhaust) 33.40 mm (1.31 in) spring rate k1 (intake) 25.05 n/mm (2.55 kgf/mm, 143.04 lb/in) spring rate k2 (intake) 40...

  • Page 33: Engine Specifications

    Engine specifications 2-6 piston ring top ring ring type barrel dimensions (b × t) 0.90 × 2.45 mm (0.04 × 0.10 in) end gap (installed) 0.25 – 0.35 mm (0.0098 – 0.0138 in) ring side clearance 0.030 – 0.065 mm (0.0012 – 0.0026 in) 2nd ring ring type barrel dimensions (b × t) 0.80 × 2.50 mm (0.03 × 0.1...

  • Page 34: Engine Specifications

    Engine specifications 2-7 wear limit 2.80 mm (0.1102 in) plate quantity 6 pcs friction plate thickness 2.92 – 3.08 mm (0.115 – 0.121 in) wear limit 2.80 mm (0.1102 in) plate quantity 1 pcs friction plate thickness 2.94 – 3.06 mm (0.116 – 0.120 in) water limit 2.84 mm (0.1118 in) plate quantity 1 pcs...

  • Page 35: Engine Specifications

    Engine specifications 2-8 output voltage (at idle) adjusted by tachometer idling condition engine idling speed 1250 – 1350 r/min co% 4.5 – 5.5 % intake vacuum 32.0 kpa (238 mmhg, 9.37 inhg) water temperature 95.0 – 105.0 ° c (203.00 – 221.00 ° f) oil temperature 75.0 – 85.0 ° c (167.00 – 185.00 ° f)...

  • Page 36: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 26.00 ° trail 103.5 mm (4.07 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum wheel travel 130.0 mm (5.12 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 37: Chassis Specifications

    Chassis specifications 2-10 master cylinder inside diameter 16.00 mm (0.63 in) caliper cylinder inside diameter 30.16 mm (1.19 in) caliper cylinder inside diameter 25.40 mm (1.00 in) recommended fluid dot 4 rear brake type single disc brake operation right foot operation rear disc brake disc outside...

  • Page 38: Chassis Specifications

    Chassis specifications 2-11 drive chain slack 45.0 – 55.0 mm (1.77 – 2.17 in) 15-link length limit 239.3 mm (9.42 in).

  • Page 39: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 6.5 °/ 1300 r/min engine control unit model/manufacturer fua0032/mitsubishi tci pickup coil resistance 248 – 372 Ω (gy-...

  • Page 40: Electrical Specifications

    Electrical specifications 2-13 electric starting system system type constant mesh starter motor power output 0.60 kw armature coil resistance 0.0012 – 0.0022 Ω brush overall length 10.0 mm (0.39 in) limit 3.50 mm (0.14 in) brush spring force 7.16 – 9.52 n (730 – 971 gf, 25.77 – 34.27 oz) commutator ...

  • Page 41: Tightening Torques

    Tightening torques 2-14 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 42: Tightening Torques

    Tightening torques 2-15 thermostat cover bolt m6 2 12 nm (1.2 m · kgf, 8.7 ft · lbf) water jacket joint bolt m6 2 10 nm (1.0 m · kgf, 7.2 ft · lbf) water pump cover bolt m6 1 10 nm (1.0 m · kgf, 7.2 ft · lbf) coolant drain bolt m6 1 10 nm (1.0 m · kgf, 7.2 ft · lbf) water pump bolt m6 2 10 nm (1.0 m...

  • Page 43: Tightening Torques

    Tightening torques 2-16 clutch cover bolt m6 10 10 nm (1.0 m · kgf, 7.2 ft · lbf) generator cover bolt m6 7 10 nm (1.0 m · kgf, 7.2 ft · lbf) crankcase bolt (main journal) m8 10 see tip apply oil to threads and sur- face crankcase bolt (bolt number “13”, “14”) m6 2 12 nm (1.2 m · kgf, 8.7 ft · lbf) ...

  • Page 44: Tightening Torques

    Tightening torques 2-17 tip ● cylinder head bolt 1.Tighten the bolts to 19 nm (1.9 m·kgf, 14 ft·lbf) “1” – “10” following the tightening order. 2.Retighten the bolts 50 nm (5.0 m·kgf, 36 ft·lbf) “1” – “10” following the tightening order. 3.Loosen the bolt “1” and retighten it 12 nm (1.2 m·kgf, 8.8 f...

  • Page 45: Tightening Torques

    Tightening torques 2-18 cylinder head tightening sequence. Crankcase tightening sequence. Eas20350 chassis tightening torques 6 2 8 10 4 3 1 9 7 5 4 6 8 2 10 5 7 3 9 1 13 21 16 19 20 27 17 11 12 18 15 14 26 24 22 23 25 item threa d size q’ty tightening torque remarks upper bracket pinch bolt m8 2 20...

  • Page 46: Tightening Torques

    Tightening torques 2-19 steering stem nut m22 1 110 nm (11 m · kgf, 80 ft · lbf) upper handlebar holder bolt m8 4 24 nm (2.4 m · kgf, 17 ft · lbf) lower bracket pinch bolt – 2 30 nm (3.0 m · kgf, 22 ft · lbf) lower ring nut m25 1 see tip see tip front fork cap bolt m37 2 24 nm (2.4 m · kgf, 17 ft · ...

  • Page 47: Tightening Torques

    Tightening torques 2-20 fuel pump and fuel tank m5 6 4 nm (0.4 m · kgf, 2.9 ft · lbf) ignition coil screw m6 2 1.5 nm (0.15 m · kgf, 1.1 ft · lbf) seat lock and frame m6 2 7 nm (0.7 m · kgf, 5.0 ft · lbf) seat key cylinder and mud guard m6 2 3 nm (0.3 m · kgf, 2.2 ft · lbf) battery terminal m6 2 2.5...

  • Page 48: Tightening Torques

    Tightening torques 2-21 tip ● lower ring nut 1.First, tighten the ring nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the ring nut completely. 2.Retighten the lower ring nut to 18 nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. ● engine mount bolts and engine mou...

  • Page 49

    Lubrication points and lubricant types 2-22 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings and bushes crankshaft pins piston surfaces piston pins connecting rod bolts crankshaft journals camshaft profile journals valve stems...

  • Page 50

    Lubrication points and lubricant types 2-23 eas20380 chassis cylinder head cover semicircular three bond no.1215b ® crankcase mating surface three bond no.1215 ® generator rotor cover (stator coil assembly lead grommet) three bond no.1215 ® pickup rotor cover (crankshaft position sensor lead grommet...

  • Page 51

    Lubrication points and lubricant types 2-24 sidestand bracket and link mating surface lubrication point lubricant ls.

  • Page 52

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

  • Page 53

    Lubrication system chart and diagrams 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Oil pipe 8. Drive axle 9. Main gallery 10. Oil nozzle 11. Timing chain tensioner 12. Intake camshaft 13. Exhaust camshaft 14. Big end 15. Crankshaft.

  • Page 54

    Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams 1 5 3 2 4.

  • Page 55

    Lubrication system chart and diagrams 2-28 1. Oil level switch 2. Oil cooler 3. Relief valve 4. Ventilation chamber cover 5. Oil delivery pipe.

  • Page 56

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

  • Page 57

    Lubrication system chart and diagrams 2-30 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer 5. Oil pipe 6. Oil delivery pipe 7. Timing chain tensioner 8. Oil check bolt.

  • Page 58

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

  • Page 59

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

  • Page 60

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

  • Page 61

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Oil pump 3. Relief valve 4. Oil pipe 5. Oil delivery pipe.

  • Page 62

    Lubrication system chart and diagrams 2-35 3 2 5 4 1.

  • Page 63

    Lubrication system chart and diagrams 2-36 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle.

  • Page 64

    Lubrication system chart and diagrams 2-37 2 3 1.

  • Page 65

    Lubrication system chart and diagrams 2-38 1. Main axle 2. Drive axle 3. Oil pipe.

  • Page 66: Cooling System Diagrams

    Cooling system diagrams 2-39 eas20420 cooling system diagrams 1 1 2 2 3 5 6 4 4 7.

  • Page 67: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Radiator 2. Oil cooler 3. Water pump 4. Coolant reservoir 5. Fast idle plunger 6. Water pump breather hose 7. Water jacket joint.

  • Page 68: Cable Routing

    Cable routing 2-41 eas20430 cable routing.

  • Page 69: Cable Routing

    Cable routing 2-42 1. Clutch cable 2. Throttle cable (accelerator side) 3. Throttle cable (decelerator side) a. Clamp the left handlebar switch lead, main switch lead, and throttle cables. Clamp the leads at the white tape position. Direct the end of clamp down and outward. No need to cut off its en...

  • Page 70: Cable Routing

    Cable routing 2-43.

  • Page 71: Cable Routing

    Cable routing 2-44 1. Fuel tank drain hose 2. Rear mudguard assembly 3. Ecu lead 4. Starter motor lead 5. Oil level switch lead 6. Sidestand switch lead 7. Sub-wire harness (throttle body) 8. Throttle body joint coupler 9. Wire harness a. Clamp the wire harness and ac magneto lead. Direct the end of...

  • Page 72: Cable Routing

    Cable routing 2-45.

  • Page 73: Cable Routing

    Cable routing 2-46 1. Right handlebar switch lead 2. Radiator fan motor lead 3. Ignition coil #2, #3 connector 4. Main switch lead 2 5. Main switch lead 1 6. Left handlebar switch lead 7. Ignition coil #1, #4 connector 8. Throttle cables 9. High tension code 10. Cover 11. Spark plug cap #4 12. Spark...

  • Page 74: Cable Routing

    Cable routing 2-47.

  • Page 75: Cable Routing

    Cable routing 2-48 1. Fuel tank breather hose 2. Rectifier/regulator 3. Battery negative lead 4. Starter relay 5. Battery positive lead 6. Starter motor lead 7. Fuel tank drain hose 8. Throttle body joint coupler a. To crankshaft position sensor b. To ac magneto c. To oil level switch d. To sidestan...

  • Page 76: Cable Routing

    Cable routing 2-49.

  • Page 77: Cable Routing

    Cable routing 2-50 1. Radiator fan motor relay 2. Relay unit 3. License plate light lead 4. Rear turn signal light leads (left/right) 5. Tail/brake light lead 6. Seat lock cable 7. Turn signal relay 8. Headlight relay 9. Lean angle sensor 10. Fuse box 11. Frame comp. 12. White tape 13. Wire harness ...

  • Page 78: Cable Routing

    Cable routing 2-51.

  • Page 79: Cable Routing

    Cable routing 2-52 1. Front brake hose 2. Front fork assembly a. Clamp it securely. The pawl must be directed toward the right side of the motorcycle. B. Insert it securely until it reaches its end position. C. Secure for 3 or more notches. The pawl must be directed toward the front of the vehicle. ...

  • Page 80: Cable Routing

    Cable routing 2-53.

  • Page 81: Cable Routing

    Cable routing 2-54 1. Rear brake caliper 2. Dust cover 3. Rear brake hose 4. Rear brake reservoir 5. Rear brake light switch lead 6. Frame complete 7. Swingarm 8. Fuel tank 9. Rollover valve (california only) 10. Canister purge hose (california only) 11. Fuel tank breather hose (rollover valve to ca...

  • Page 82: Cable Routing

    Cable routing 2-55.

  • Page 83: Cable Routing

    Cable routing 2-56 1. Clutch cable 2. Left handlebar switch lead 3. Horn lead 4. Throttle cables 5. Right handlebar switch lead 6. Cable guide a. Pass the horn lead front of the inner tube and clamp it on. Direct the end of clamp toward front side of the vehi- cle with its end pointing outside. No n...

  • Page 84: Cable Routing

    Cable routing 2-57.

  • Page 85: Cable Routing

    Cable routing 2-58 1. Radiator fan motor lead 2. Crankshaft position sensor lead 3. Wire harness 4. Connector cover a. To meter b. To headlight c. Clamp the wire harness, right handlebar switch lead, and radiator fan motor lead. Clamp the right handlebar switch lead so that there is no slack when th...

  • Page 86: Cable Routing

    Cable routing 2-59.

  • Page 87: Cable Routing

    Cable routing 2-60 1. Battery negative lead 2. Rear brake light switch lead 3. Fuel tank breather hose 4. Rear turn signal light lead (right/left) 5. License plate light lead 6. Tail/brake light lead 7. Neutral switch lead a. Install the wire harness inside frame from behind of the battery. B. Clamp...

  • Page 88: Cable Routing

    Cable routing 2-61.

  • Page 89: Cable Routing

    Cable routing 2-62 1. Fuel tank cap 2. Fuel tank 3. Fuel pump 4. Fuel hose 5. Fuel tank breather hose (right side) 6. Fuel tank drain hose (left side) 7. Throttle body 8. Fuel hose connector 9. Fuel pump bracket 10. Rubber cover 11. Fuel tank breather pipe (right side) 12. Rollover valve (california...

  • Page 90: Cable Routing

    Cable routing 2-63.

  • Page 91: Cable Routing

    Cable routing 2-64 1. Synchronizing hose #1 2. Synchronizing hose #2 3. Synchronizing hose #3 4. Synchronizing hose #4 5. Fast idle plunger coolant hose 6. Throttle position sensor 7. Fuel injector #4 8. Intake air pressure sensor 9. Fuel injector #3 10. Fuel injector #2 11. Fuel injector #1 12. Fas...

  • Page 92: Cable Routing

    Cable routing 2-65.

  • Page 93: Cable Routing

    Cable routing 2-66 1. Synchronizing hose #1 2. Synchronizing hose #2 3. Canister purge hose (california only) 4. Synchronizing hose #3 5. Synchronizing hose #4 6. Fast idle plunger coolant hose 7. Throttle position sensor 8. Fuel injector #4 9. Intake air pressure sensor 10. Fuel injector #3 11. Fue...

  • Page 94: Cable Routing

    Cable routing 2-67.

  • Page 95: Cable Routing

    Cable routing 2-68 1. Fast idle plunger coolant hose 2. Fast idle plunger 3. Synchronizing hose #1 4. Synchronizing hose #2 5. Fast idle plunger hose (fast idle plunger-throttle body #1) 6. Intake air pressure sensor 7. Throttle position sensor 8. Fast idle plunger hose (fast idle plunger-throttle b...

  • Page 96: Cable Routing

    Cable routing 2-69.

  • Page 97: Cable Routing

    Cable routing 2-70 1. Air cut-off valve hose 1 2. Air cut-off valve hose 2 3. Air cut-off valve 4. Air cut-off valve hose 3 5. Air filter case 6. Bracket 7. Rubber cover 8. Reed valve a. Install the clamp with its end facing the right side of the vehicle. B. Install the clamp with its end facing the...

  • Page 98: Cable Routing

    Cable routing 2-71.

  • Page 99

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

  • Page 100

    Adjusting the headlight beams..................................................3-29 replacing the headlight bulbs ..................................................3-30

  • Page 101: Periodic Maintenance

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

  • Page 102: Periodic Maintenance

    Periodic maintenance 3-2 eau32185 general maintenance and lubrication chart no. Item routine initial odometer readings 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30...

  • Page 103: Periodic Maintenance

    Periodic maintenance 3-3 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Tip from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Tip ● air filter ● this model’s air filt...

  • Page 104: Periodic Maintenance

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

  • Page 105: Periodic Maintenance

    Periodic maintenance 3-5 9. Connect: ● spark plug caps 10.Install: ● rubber cover refer to “air induction system” on page 7-11. ● air filter case refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. ● passenger seat/rider seat refer to “general chassis” on page 4-1. ...

  • Page 106: Periodic Maintenance

    Periodic maintenance 3-6 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: ● camshafts tip ● refer to “camshafts” on page 5-8. ● when remov...

  • Page 107: Periodic Maintenance

    Periodic maintenance 3-7 tip the thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touch- es the valve lifter. Example: if the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062 in) d. Calculate the sum of the values obtained in steps (b) and (c) to ...

  • Page 108: Periodic Maintenance

    Periodic maintenance 3-8 ● spark plugs ● air filter element ● throttle body joints ● fuel hoses ● air induction system ● exhaust system ● canister purge hose (for california only) ● breather hoses ● throttle body hoses ● fast idle plunger outlet hose ● fast idle plunger inlet hose 1. Start the engin...

  • Page 109: Periodic Maintenance

    Periodic maintenance 3-9 4. Install: ● fuel tank refer to “fuel tank” on page 7-1. 5. Start the engine and let it warm up for several minutes. 6. Check: ● engine idling speed out of specification → adjust. Refer to “adjusting the engine idling speed” on page 3-7. ● check the vacuum pressure. If out ...

  • Page 110: Periodic Maintenance

    Periodic maintenance 3-10 eas21090 checking the canister (for california only) 1. Remove: ● right rear side cover refer to “general chassis” on page 4-1. 2. Check: ● canister “1” ● canister purge hose “2” ● fuel tank breather hose (rollover valve to canister) “3” ● fuel tank breather hose (canister ...

  • Page 111: Periodic Maintenance

    Periodic maintenance 3-11 3. Check: ● air filter element damage → replace. Tip ● replace the air filter element every 40000 km of operation. ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 4. Install: ● air filter element ● air filter case cover notice...

  • Page 112: Periodic Maintenance

    Periodic maintenance 3-12 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21240 checking the brake fluid level 1. Stand the vehicle on a level surface. Tip ● place the vehicle on a suitable stand. ● make sure the vehicle is upright. 2. Check: ● brake fluid level below the minimum level mark “a” → add the recomm...

  • Page 113: Periodic Maintenance

    Periodic maintenance 3-13 warning ewa13060 ● after adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial. ● a soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehi...

  • Page 114: Periodic Maintenance

    Periodic maintenance 3-14 warning ewa4s81005 a soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance....

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-15 e. Slowly apply the brake lever several times. F. Fully pull the brake lever or fully press down the brake pedal and hold it in position. G. Loosen the bleed screw. Tip loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle g...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-16 out of specification → regulate. Warning ewa13180 ● the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. ● the tire pressure and the suspension must be adjusted according to the total weight (including cargo, r...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-17 warning ewa13210 new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Tip for tires with a direction of rotation mark “1”: ● inst...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-18 e. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain sh...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-19 lower bearings. Refer to “steering head” on page 4-51. E. Install the rubber washer “2”. F. Install the upper ring nut “3”. G. Finger tighten the upper ring nut “3”, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-20 b. Loosen the lower handlebar holder nuts “4”. C. Adjust the handlebar position by rotating both of the lower handlebar holders in 180 ° de- grees. D. Tighten the lower handlebar holder nuts “4”. E. Install the handlebar “3”, upper handlebar holders “2” and handlebar holder...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-21 2. Adjust: ● shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “a” or “b” until the specified shift rod length is obtained. C. Tighten both locknuts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21720 lubricatin...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-22 moving parts of the rear suspension. Eas21590 adjusting the rear shock absorber assembly warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Spring preload notice eca13590 never go beyond the maximum or minimum adjustment positions. ...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-23 oils with a grade of cd “a” or higher and do not use oils labeled “energy conserv- ing ii” “b” or higher. ● do not allow foreign materials to enter the crankcase. Tip before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, wa...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-24 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: ● engine oil drain bolt gasket 7. Install: ● engine oil drain bolt (along with the new gasket) 8. Fill: ● crankcase (with the specified amount of the recom- mended engine oil) 9. Install: ● engine oil filler cap ● side cowling refe...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-25 6. Install: ● main gallery bolt “1” eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip ● place the vehicle on a suitable stand. ● make sure the vehicle is upright. 2. Check: ● coolant level the coolant level should be between the maximum level ...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-26 eas21130 changing the coolant 1. Remove: ● coolant reservoir “1” ● coolant reservoir cap “2” 2. Drain: ● coolant (from the coolant reservoir) 3. Remove: ● right side cowling refer to “general chassis” on page 4-1. ● radiator cap “1” warning ewa13030 a hot radiator is under ...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-27 8. Install: ● coolant reservoir 9. Fill: ● cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning ewa13040 ● if coolant splashes in your eyes, thoroug...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-28 rear brake light comes on at the proper time. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21690 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Warning ewa13270 damaged outer cable may cause the cable to corrode and interf...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-29 use the adjusting nut on the handlebar side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. C. Tighte...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-30 “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21790 replacing the headlight bulbs 1. Disconnect: ● headlight coupler “1” 2. Remove: ● headlight bulb cover “2” 3. Remove: ● headlight bulb holder “1” 4. Remove: ● headlight bulb “2” warning ewa13320 since the headlight bulb gets ex...

  • Page 131: Chassis

    1 2 3 4 5 6 7 8 9 chassis general chassis .....................................................................................4-1 front wheel .............................................................................................4-6 removing the front wheel ......................................

  • Page 132

    Front fork ................................................................................................4-44 removing the front fork legs...................................................4-46 disassembling the front fork legs.........................................4-46 checking the front fork l...

  • Page 133: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats and covers order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 1 3 rider seat height position adjuster 1 4 rear side cover 2 5 grab bar 1 6 rear cowling 2 for installation, reverse the removal proce- dure. 1 4 5 6 6 1...

  • Page 134: General Chassis

    General chassis 4-2 removing the front cowling assembly order job/parts to remove q’ty remarks 1 bottom cowling 1 2 left side cowling 1 3 front left turn signal coupler 1 4 right side cowling 1 5 front right turn signal coupler 1 6 left side panel 1 7 right side panel 1 8 front cowling left inner pa...

  • Page 135: General Chassis

    General chassis 4-3 disassembling the front cowling assembly order job/parts to remove q’ty remarks 1 left air duct cover 1 2 left air duct 1 3 right air duct cover 1 4 right air duct 1 5 windshield 1 6 front cowling center inner panel 1 7 right rearview mirror 1 8 left rearview mirror 1 9 cowling s...

  • Page 136: General Chassis

    General chassis 4-4 removing the air filter case order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 clamp screw 4 loosen. 2 intake air temperature sensor coupler 1 disconnect. 3 throttle body hose 2 d...

  • Page 137: General Chassis

    General chassis 4-5 removing the battery order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Rider seat height position adjuster refer to “general chassis” on page 4-1. 1 battery band 1 2 battery cover 1 3 negative battery lead 1 4 positive batter...

  • Page 138: Front Wheel

    Front wheel 4-6 eas21880 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 brake hose holder 3 2 front brake caliper 2 3 front wheel axle pinch bolt 1 loosen. 4 front wheel axle 1 5 collar 2 6 front wheel 1 7 front brake disc 2 for installation, reverse th...

  • Page 139: Front Wheel

    Front wheel 4-7 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure. 1 1 2 2 3.

  • Page 140: Front Wheel

    Front wheel 4-8 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: ● left brake caliper ● rig...

  • Page 141: Front Wheel

    Front wheel 4-9 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. Notice eca14130 do not contact the wheel bearing inner race “4” or balls “5”. Contact should be made only with the outer race “6”. Ti...

  • Page 142: Front Wheel

    Front wheel 4-10 tip start with the lightest weight. B. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ is bala...

  • Page 143: Rear Wheel

    Rear wheel 4-11 eas22030 rear wheel removing the rear wheel order job/parts to remove q’ty remarks 1 locknut 2 loosen. 2 adjusting nut 2 loosen. 3 cap 2 4 rear wheel axle nut 1 5 rear wheel axle 1 6 washer 1 7 indicator plate 2 8 drive chain puller 2 9 rear wheel 1 10 rear brake caliper assembly 1 f...

  • Page 144: Rear Wheel

    Rear wheel 4-12 removing the rear brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sprocket 1 3 collar 1 4 collar 1 5 oil seal 2 6 bearing 2 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 rear wheel 1 for installation, reverse the...

  • Page 145: Rear Wheel

    Rear wheel 4-13 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 oil seal 1 3 bearing 2 4 spacer 1 for assembly, reverse the disassembly pro- cedure. 1 3 4 3 2.

  • Page 146: Rear Wheel

    Rear wheel 4-14 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Loosen: ● locknut “1” ● adjusting nu...

  • Page 147: Rear Wheel

    Rear wheel 4-15 2. Replace: ● rear 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 that contact the sprocket. C. Install the new rear wheel sprocket. Tip tighten...

  • Page 148: Front Brake

    Front brake 4-16 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks 1 front brake caliper 1 2 brake pad 2 3 brake pad spring 2 for installation, reverse the removal proce- dure. 27 nm (2.7 m • kgf, 19 ft • ibf) 1 2 3 s.

  • Page 149: Front Brake

    Front brake 4-17 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm holder 1 3 brake master cylinder reserv...

  • Page 150: Front Brake

    Front brake 4-18 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 master cylinder kit 1 2 master cylinder 1 for assembly, reverse the disassembly pro- cedure. 1 2.

  • Page 151: Front Brake

    Front brake 4-19 removing the front brake calipers order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. 1 union bolt 2 2 copper washer 5 3 brake hose 2 4 brake caliper 1 5 brake pad 2 6 brake pad spring 2 7 brake caliper bracket 1 for...

  • Page 152: Front Brake

    Front brake 4-20 disassembling the front brake calipers order job/parts to remove q’ty remarks 1 brake pad 2 2 brake caliper piston 2 3 brake caliper piston dust seal 2 4 brake caliper piston seal 2 5 brake pad spring 1 6 bleed screw 1 for assembly, reverse the disassembly pro- cedure. 6 nm (0.6 m •...

  • Page 153: Front Brake

    Front brake 4-21 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: ● never disassemble brake components un- less absolutely necessary. ● if any connection on the hydraulic brake system is disconnected, the...

  • Page 154: Front Brake

    Front brake 4-22 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ within specification, replace the brake disc. Eas...

  • Page 155: Front Brake

    Front brake 4-23 eas22300 removing the front brake calipers the following procedure applies to both of the brake calipers. Tip before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: ● union bolt “1” ● copper washers “2” ● brake hose “3” ● brake caliper tip ...

  • Page 156: Front Brake

    Front brake 4-24 warning ewa13600 whenever a brake caliper is disassembled, replace the piston seals. Eas22410 assembling the front brake calipers warning ewa13620 ● before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. ● never use solve...

  • Page 157: Front Brake

    Front brake 4-25 deteriorate, causing leakage and poor brake performance. ● refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. ● when refilling, be careful that water does not e...

  • Page 158: Front Brake

    Front brake 4-26 3. Check: ● brake master cylinder reservoir “1” cracks/damage → replace. ● brake master cylinder reservoir diaphragm “2” damage/wear → replace. 4. Check: ● brake hoses cracks/damage/wear → replace. Eas22520 assembling the front brake master cylinder warning ewa13520 ● before install...

  • Page 159: Front Brake

    Front brake 4-27 warning ewa13540 ● use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. ● refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful c...

  • Page 160: Rear Brake

    Rear brake 4-28 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad 2 5 bleed screw 1 6 brake pad spring 2 for installation, reverse the removal proce- dure. 22 nm (2.2 m • kgf, 15 ft • ibf) 5 nm ...

  • Page 161: Rear Brake

    Rear brake 4-29 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. Right rear side cover refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 rear brake fluid reservoir diap...

  • Page 162: Rear Brake

    Rear brake 4-30 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 3 connector 1 4 bushing 1 for installation, reverse the removal proce- dure. 14 nm (1.4 m • kgf, 10 ft • ibf) 1 2 3 4 18 nm (1.8 m • kgf, 1...

  • Page 163: Rear Brake

    Rear brake 4-31 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-14. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure. 22 nm (2.2 ...

  • Page 164: Rear Brake

    Rear brake 4-32 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad 2 4 brake pad spring 2 5 brake caliper piston 1 6 brake caliper piston dust seal 1 7 brake caliper piston seal 1 8 bleed screw 1 for assembly, reverse the disassem...

  • Page 165: Rear Brake

    Rear brake 4-33 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: ● never disassemble brake components un- less absolutely necessary. ● if any connection on the hydraulic brake system is disconnected, the ...

  • Page 166: Rear Brake

    Rear brake 4-34 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: ● brake caliper ● brake pad pin ● screw plug 4. Check: ● brake fluid level below the minimum level mark “a” →...

  • Page 167: Rear Brake

    Rear brake 4-35 be careful not to get injured when the pis- ton is expelled from the brake caliper. ● never try to pry out the brake caliper pis- ton. C. Remove the brake caliper piston dust seal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ and brake caliper piston seal. Eas22640 checking the rear brake caliper...

  • Page 168: Rear Brake

    Rear brake 4-36 warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca- ble routing” on page 2-41. Notice eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper...

  • Page 169: Rear Brake

    Rear brake 4-37 8. Check: ● brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-14. Eas22700 removing the rear brake master cylinder 1. Remove: ● union bolt “1” ● copper washers “2” ● brake hose “3” tip to collect any remain...

  • Page 170: Rear Brake

    Rear brake 4-38 1. Install: ● master cylinder kit ● circlip eas22740 installing the rear brake master cylinder 1. Install: ● cotter pin “1” ● copper washers “2” ● brake hose “3” ● union bolt “4” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca-...

  • Page 171: Rear Brake

    Rear brake 4-39 below the minimum level mark “b” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-12. 4. Adjust: ● brake pedal position “c” refer to “adjusting the rear disc brake” on page 3-13. 5. Adjust: ● rear brake light operation timing ...

  • Page 172: Handlebar

    Handlebar 4-40 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 grip end 2 2 handlebar grip 1 3 clutch switch connector 2 disconnect. 4 left handlebar switch 1 5 clutch cable 1 6 clutch switch 1 7 clutch lever 1 8 right handlebar switch 1 9 throttle grip 1 10 thrott...

  • Page 173: Handlebar

    Handlebar 4-41 eas22860 removing the handlebars 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: ● handlebar grip “1” tip blow compressed air between the left handlebar and the handlebar grip, and gradual...

  • Page 174: Handlebar

    Handlebar 4-42 notice eca14250 ● first, tighten the bolts on the front side of the handlebar holder, and then on the rear side. ● turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. Tip ● the upper handlebar holders should ...

  • Page 175: Handlebar

    Handlebar 4-43 7. Install: ● clutch lever holder “1” ● clutch cable tip align the slit on the clutch lever holder with the punch mark “a” on the handlebar. 8. Install: ● left handlebar switch tip align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 9. Install: ● ...

  • Page 176: Front Fork

    Front fork 4-44 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks bottom cowling refer to “general chassis” on page 4-1. Side cowling refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-6. Front brake calipers refer to “front bra...

  • Page 177: Front Fork

    Front fork 4-45 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt/o-ring 1/1 2 spacer 1 3 spring seat 1 4 front fork spring 1 5 dust seal 1 6 oil seal clip 1 7 damper rod assembly bolt/copper washer 1/1 8 damper rod assembly 1 9 oil seal 1 10 washer 1 11 inner tube ...

  • Page 178: Front Fork

    Front fork 4-46 eas22970 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...

  • Page 179: Front Fork

    Front fork 4-47 vise with soft jaws. C. Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful- ly. Notice eca14190 ● excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. ● avoid bottoming the inner tube into th...

  • Page 180: Front Fork

    Front fork 4-48 eas23020 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13660 ● make sure the oil levels in both front fork legs are equal. ● uneven oil levels can result in poor han- dling and a loss of stability. Tip ● when assembling the ...

  • Page 181: Front Fork

    Front fork 4-49 tip ● before installing the oil seal, lubricate its lips with lithium soap base grease. ● lubricate the outer surface of the inner tube with fork oil. ● before installing the oil seal, cover the top of the front fork leg with a plastic bag “2” to protect the oil seal during installat...

  • Page 182: Front Fork

    Front fork 4-50 10.Install: ● spring “1” ● spring seat “2” ● spacer “3” ● cap bolt tip ● install the spring with the smaller pitch “a” fac- ing up. ● before installing the cap bolt, lubricate its o-ring with grease. ● temporarily tighten the cap bolt. Eas23050 installing the front fork legs the foll...

  • Page 183: Steering Head

    Steering head 4-51 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-6. Front fender refer to “front fork” on page 4-44. Front fork refer to “front fork”...

  • Page 184: Steering Head

    Steering head 4-52 removing the lower bracket order job/parts to remove q’ty remarks 12 bearing inner race 2 13 upper bearing/lower bearing 1/1 14 dust seal 1 15 bearing outer race 2 for installation, reverse the removal proce- dure. 110 nm (11.0 m • kgf, 79 ft • ibf) 13 14 15 13 15 t r . . 1st 52 n...

  • Page 185: Steering Head

    Steering head 4-53 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: ● steering stem nut ● washer ● lock washer ● upper ring nut “1” ● rubber washer ● lower ring nut “2”...

  • Page 186: Steering Head

    Steering head 4-54 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: ● upper bracket ● lower bracket (along with the steering stem) bends/cracks/damage → replace. Eas23140 installing the steering head 1. Lubricate: ● upper bearing ● lower bearing ● bearing races 2. Install: ● lower bracket ● lower ring nut...

  • Page 187: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-55 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rear side cover refer to “general chassis” on page 4-1. 1 self-locking nut/washer/bolt 1/1/1 2 self-locking nut/washer/bolt 1/1/1 3 plate 1 4 rear ...

  • Page 188: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-56 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 189: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-57 gas leaks/oil leaks → replace the rear shock absorber assembly. ● spring damage/wear → replace the rear shock ab- sorber assembly. ● bushings damage/wear → replace. ● oil seals damage/wear → replace. ● bolts bends/damage/wear → replace. Eas23300 installing the rear ...

  • Page 190: Swingarm

    Swingarm 4-58 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-28. Rear wheel refer to “rear wheel” on page 4-11. Rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-55. Drive sprocket refer t...

  • Page 191: Swingarm

    Swingarm 4-59 eas23340 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: ● rear shock absorber refer to “...

  • Page 192: Swingarm

    Swingarm 4-60 eas23380 installing the swingarm 1. Lubricate: ● bearings ● spacers ● oil seals ● dust covers ● pivot shaft 2. Install: ● bearing “1” ● spacer ● oil seal ● dust cover 3. Install: ● swingarm ● pivot shaft “1” ● pivot shaft nut “2” 4. Install: ● rear shock absorber assembly refer to “ins...

  • Page 193: Chain Drive

    Chain drive 4-61 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to “engine removal” on page 5-1. Shift rod refer to “engine removal” on page 5-1. Swingarm refer to “removing the swingarm” on page 4-59. 1 chain cover 1 2 drive chain 1 for ins...

  • Page 194: Chain Drive

    Chain drive 4-62 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: ● swingarm refer to “remov...

  • Page 195: Chain Drive

    Chain drive 4-63 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: ● o-rings “1” damage → replace the drive chain. ● drive chain rollers “2” damage/wear → replace the drive chain. ● drive chain side plates “3” damage/wear → replace the drive chain. Cracks → replace the drive chain and make sure the battery...

  • Page 196: Chain Drive

    Chain drive 4-64.

  • Page 197: Engine

    1 2 3 4 5 6 7 8 9 engine engine removal .......................................................................................5-1 installing the engine .....................................................................5-6 installing the drive chain ..................................................

  • Page 198

    Checking the oil nozzles..............................................................5-44 checking the oil pump drive chain............................................5-44 assembling the oil pump................................................................5-44 installing the oil pump ..............

  • Page 199: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen push lever assembly refer to “clutch” on page 5-47. 1 locknut 2 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive sprocket nut 1 6 washer 1 7 drive sprocket 1 f...

  • Page 200: Engine Removal

    Engine removal 5-2 removing the exhaust pipe order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Radiator lower mount bolt refer to “radiator” on page 6-1. 1 nut 8 2 bolt 2 3 bracket 2 4 muffler comp. 1 5 cap 1 6 radiator stay 1 for installation, reverse the r...

  • Page 201: Engine Removal

    Engine removal 5-3 disconnecting the leads and hoses order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Side cowling refer to “general chassis” on page 4-1. Rear side cover refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on...

  • Page 202: Engine Removal

    Engine removal 5-4 disconnecting the leads and hoses order job/parts to remove q’ty remarks 8 speed sensor coupler 1 disconnect. For assembly, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 5 nm (0.5 m • kgf, 3.6 ft • ibf) 8.

  • Page 203: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks left footrest bracket assembly 1 right front engine mounting bolt 2 2 left front engine mounting bolt 2 3 self-locking nut 2 4 rear engine mounting bolt 2 5 engine 1 for installation, reverse the removal proce- dure. 1 2 3...

  • Page 204: Engine Removal

    Engine removal 5-6 eas23720 installing the engine 1. Install: ● rear engine mounting bolts “1” tip lubricate the rear engine mounting bolt threads with engine oil. 2. Install: ● right front engine mounting bolt “2” ● left front engine mounting bolts “3” tip do not fully tighten the bolts. 3. Tighten...

  • Page 205: Engine Removal

    Engine removal 5-7 7. Install: ● shift arm bolt “8” tip before installing, make sure to align the mark “a” of the shift shaft with the punch mark “b” of the shift arm. Eas20s15001 installing the drive chain 1. Lubricate: ● drive chain 2. Install: ● drive sprocket ● washer ● drive sprocket nut “1” ti...

  • Page 206: Camshafts

    Camshafts 5-8 eas23760 camshafts *yamaha bond no.1215 (three bond no.1215®) removing the cylinder head cover order job/parts to remove q’ty remarks side cowling refer to “general chassis” on page 4-1. Passenger seat/rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on...

  • Page 207: Camshafts

    Camshafts 5-9 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “pickup rotor” on page 5-33. 1 camshaft sprocket bolt 4 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 pin 2 5 timing chain guide (exhaust side)/timing chain guide (intake side) 1/...

  • Page 208: Camshafts

    Camshafts 5-10 eas23810 removing the camshafts 1. Remove: ● pickup rotor cover refer to “pickup rotor” on page 5-33. 2. Align: ● “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 209: Camshafts

    Camshafts 5-11 7. Remove: ● camshaft sprockets eas23850 checking the camshafts 1. Check: ● camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: ● camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: ● camshaft runout out o...

  • Page 210: Camshafts

    Camshafts 5-12 d. Remove the camshaft caps and then mea- sure the width of the plastigauge® “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: ● camshaft journal diameter “a” out of specification → replace the camshaft. Within specification → replace the cylinder head and the camshaft caps as a set. ...

  • Page 211: Camshafts

    Camshafts 5-13 ● timing chain tensioner outer spring “5” ● timing chain tensioner housing “6” tip squeeze the timing chain tensioner clip “4”, and then remove the timing chain tensioner springs and timing chain tensioner rod. 2. Check: ● timing chain tensioner housing ● timing chain tensioner rod ● ...

  • Page 212: Camshafts

    Camshafts 5-14 “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: ● exhaust camshaft “1” ● intake camshaft “2” (with the camshaft sprockets temporarily tightened) tip make sure the match mark “a” on the camshaft sprockets is aligned with the cylinder head edge “b...

  • Page 213: Camshafts

    Camshafts 5-15 warning ewa5d01008 always use a new gasket. Notice eca5d01011 ● be sure to install the timing chain tensioner gasket so that its section with the “l” mark “a” is protruding from the lower left side of the timing chain tensioner. ● the arrow mark “b” on the timing chain ten- sioner sho...

  • Page 214: Cylinder Head

    Cylinder head 5-16 eas24100 cylinder head *refer to “engine tightening torques” on page 2-14. Removing the cylinder head order job/parts to remove q’ty remarks thermostat refer to “thermostat” on page 6-6. Intake camshaft refer to “camshafts” on page 5-8. Exhaust camshaft refer to “camshafts” on pag...

  • Page 215: Cylinder Head

    Cylinder head 5-17 eas24120 removing the cylinder head 1. Remove: ● cylinder head bolts tip ● loosen the bolts in the proper sequence as shown. ● loosen each bolts 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: ● com...

  • Page 216: Cylinder Head

    Cylinder head 5-18 2. Install: ● cylinder head tip pass the timing chain through the timing chain cavity. 3. Tighten: ● cylinder head bolts “1” – “10” refer to “engine tightening torques” on page 2-14 *loosen the bolt and retighten to specifica- tion torque. ● cylinder head bolts “11” “12” tip ● lub...

  • Page 217: Cylinder Head

    Cylinder head 5-19 7. Measure: ● compression pressure out of specification → refer to steps (c) and (d). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning ewa4s81003 to prev...

  • Page 218: Valves and Valve Springs

    Valves and valve springs 5-20 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-16. 1 intake valve lifter/exhaust valve lifter 8/8 2 intake valve pad/exhaust valve pad 8/8 3 intake valve cot...

  • Page 219: Valves and Valve Springs

    Valves and valve springs 5-21 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: ● valve lif...

  • Page 220: Valves and Valve Springs

    Valves and valve springs 5-22 guide. 2. Replace: ● valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 ° c (212 ° f) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”. B. In...

  • Page 221: Valves and Valve Springs

    Valves and valve springs 5-23 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: ● carbon deposits (from the valve face and valve seat) 4. Check: ● valve face pitting/wear → grind the valve face. ● valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. M...

  • Page 222: Valves and Valve Springs

    Valves and valve springs 5-24 b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Tip where the valve seat and valve face contacted one another, the blueing will have been re- m...

  • Page 223: Valves and Valve Springs

    Valves and valve springs 5-25 sion. J. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure:...

  • Page 224: Valves and Valve Springs

    Valves and valve springs 5-26 eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: ● valve lifter damage/scratches → replace the valve lift- ers and cylinder head. Eas24340 installing the valves the following procedure applies to all of the valve...

  • Page 225: Valves and Valve Springs

    Valves and valve springs 5-27 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Notice eca13800 hitting the valve tip with excessive force could damage the valve. 6. Lubricate: ● valve pad “1” ● valve lifter “2” (with the recommended lubricant) ti...

  • Page 226: Generator and Starter Clutch

    Generator and starter clutch 5-28 eas4s81014 generator and starter clutch removing the generator and starter clutch order job/parts to remove q ’ ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1 . Fuel tank refer to “fuel tank” on page 7-1 . Left side cowling refer to “gen...

  • Page 227: Generator and Starter Clutch

    Generator and starter clutch 5-29 removing the generator and starter clutch order job/parts to remove q ’ ty remarks 12 idler gear 1 for installation, reverse the removal proce- dure. Lt lt lt 10 nm (1.0 m • kgf, 7.2 ft • ibf) 12 lt e e e 32 nm (3.2 m • kgf, 23 ft • ibf) 75 nm (7.5 m • kgf, 54 ft • ...

  • Page 228: Generator and Starter Clutch

    Generator and starter clutch 5-30 eas24490 removing the generator 1. Remove: ● passenger seat/rider seat refer to “general chassis” on page 4-1. ● fuel tank refer to “fuel tank” on page 7-1. 2. Drain: ● engine oil refer to “changing the engine oil” on page 3-23. 3. Remove: ● generator rotor cover ti...

  • Page 229: Generator and Starter Clutch

    Generator and starter clutch 5-31 2. Check: ● starter clutch idler gear “1” ● starter clutch drive gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: ● starter clutch gear’s contacting surfaces “a” damage/pitting/wear → replace the starter clutch gear. 4. Check: ● starter...

  • Page 230: Generator and Starter Clutch

    Generator and starter clutch 5-32 2. Tighten: ● generator rotor bolt “1” tip ● while holding the generator rotor “2” with the sheave holder “3”, tighten the generator rotor bolt. ● do not allow the sheave holder to touch the projection on the generator rotor. 3. Apply: ● sealant (onto the stator coi...

  • Page 231: Pickup Rotor

    Pickup rotor 5-33 eas4s81015 pickup rotor removing the pickup rotor order job/parts to remove q ’ ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1 . Side cowling refer to “general chassis” on page 4-1 . Fuel tank refer to “fuel tank” on page 7-1 . Engine oil drain refer to...

  • Page 232: Pickup Rotor

    Pickup rotor 5-34 eas4s81041 removing the pickup rotor 1. Remove: ● pickup rotor cover “1” ● pickup rotor cover gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: ● pickup rotor bolt “1” ● w...

  • Page 233: Pickup Rotor

    Pickup rotor 5-35 4. Install: ● pickup rotor cover gasket ● pickup rotor cover tip ● when installing the pickup rotor cover, align the timing chain guide pins “1” with the holes “2” in the pickup rotor cover. ● tighten the pickup rotor cover bolts in stages and in a crisscross pattern. Pickup rotor ...

  • Page 234: Electric Starter

    Electric starter 5-36 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. Throttle body refer ...

  • Page 235: Electric Starter

    Electric starter 5-37 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 lock washer 1 4 oil seal 1 5 bearing 1 6 washer set 1 7 starter motor rear cover 1 8 washer set 1 9 brush holder 1 10 armature assembly 1 11 starter motor yoke 1 12...

  • Page 236: Electric Starter

    Electric starter 5-38 eas24790 checking the starter motor 1. Check: ● commutator dirt → clean with 600 grit sandpaper. 2. Measure: ● commutator diameter “a” out of specification → replace the starter motor. 3. Measure: ● mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 237: Electric Starter

    Electric starter 5-39 7. Check: ● gear teeth damage/wear → replace the gear. 8. Check: ● bearing ● oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: ● brush holder “1” 2. Install: ● armature “2” ● o-ring “3” tip align the tab “a” on the brush sea...

  • Page 238: Oil Pump

    Oil pump 5-40 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Clutch assembly refer to “clutch” on page 5-47. Engine oil drain. Refer to “changing ...

  • Page 239: Oil Pump

    Oil pump 5-41 removing the oil pan and oil pump order job/parts to remove q’ty remarks 10 oil strainer gasket 1 11 oil pump assembly 1 12 dowel pin 2 13 oil pump drive chain 1 14 chain guide 1 for installation, reverse the removal proce- dure. E 10 nm (1.0 m • kgf, 7.2 ft • ibf) 10 11 13 14 lt lt lt...

  • Page 240: Oil Pump

    Oil pump 5-42 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump rotor housing 1 8 oil pump driven sprocket 1 for assembly, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7...

  • Page 241: Oil Pump

    Oil pump 5-43 eas24930 removing the oil pan 1. Remove: ● oil level switch lead holder ● oil level switch “1” ● oil pan “2” ● oil pan gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas24960 checking...

  • Page 242: Oil Pump

    Oil pump 5-44 eas24980 checking the oil delivery pipes 1. Check: ● oil delivery pipe “1” ● oil pipe “2” damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: ● oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas256...

  • Page 243: Oil Pump

    Oil pump 5-45 tip when installing the inner rotor, align the pin “4” in the oil pump shaft with the groove in the inner rotor “5”. 3. Check: ● oil pump operation refer to “checking the oil pump” on page 5-43. Eas25030 installing the oil pump 1. Install: ● oil pump drive chain ● oil pump ● oil pump b...

  • Page 244: Oil Pump

    Oil pump 5-46 1 2.

  • Page 245: Clutch

    Clutch 5-47 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Engine oil drain refer to “changing the engine oil” on page 3-23. 1 dipstick 1 2 holder 1 3 clutch cover 1 4 clutch cover gasket 1 5 dowel pin 2 for...

  • Page 246: Clutch

    Clutch 5-48 removing the push lever shaft order job/parts to remove q’ty remarks drive sprocket cover refer to “engine removal” on page 5-1. 1 push lever case 1 2 oil seal 1 3 dowel pin 2 4 drive chain guide 1 5 oil seal protector 1 6 oil seal 1 7 seat plate 1 8 push lever 1 9 spring 1 10 oil seal 1...

  • Page 247: Clutch

    Clutch 5-49 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 push rod 2 1 4 friction plate 1 1 5 clutch plate 6 6 friction plate 2 6 7 clutch boss nut 1 8 clutch boss 1 9 wire circlip 1 10 clutch plate 2/friction plate 3 1/1 11 spring/spring seat...

  • Page 248: Clutch

    Clutch 5-50 eas25070 removing the clutch 1. Remove: ● right side cowling refer to “general chassis” on page 4-1. ● clutch cover “1” ● gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: ● com...

  • Page 249: Clutch

    Clutch 5-51 7. Remove: ● clutch plate 2 “1” ● friction plate 3 “2” 8. Remove: ● spring “1” ● spring seat plate “2” 9. Remove: ● collar ● bearing ● clutch housing “1” ● ball ● push rod 1 tip ● turn the crankshaft and remove the clutch housing. ● carefully hung the oil pump drive chain “2” on the main...

  • Page 250: Clutch

    Clutch 5-52 eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: ● clutch spring damage → replace the clutch springs as a set. 2. Measure: ● clutch spring free length “a” out of specification → replace the clutch springs as a set. Eas25150 chec...

  • Page 251: Clutch

    Clutch 5-53 eas25190 checking the clutch push rods 1. Check: ● o-ring ● push rod 2 “1” ● ball “2” ● push rod 1 “3” cracks/damage/wear → replace the defec- tive part(s). ● push rod bearing damage/wear → replace. 2. Measure: ● clutch push rod 1 bending limit out of specification → replace the push rod...

  • Page 252: Clutch

    Clutch 5-54 6. Tighten: ● clutch boss nut tip while holding the clutch boss with the universal clutch holder “1”, tighten the clutch boss nut. 7. Lock the threads on the clutch boss nut “1” by staking them with a drift punch “2” at the point aligned with the groove “a” in the axle. 8. Lubricate: ● f...

  • Page 253: Clutch

    Clutch 5-55 tip ● align the punch mark “a” in the pressure plate with the punch mark “b” in the clutch boss. ● tighten the clutch spring bolts in stages and in a crisscross pattern. 11.Install: ● push lever assembly (left side of the engine) 12.Check: ● push lever position push lever mark “a” and pu...

  • Page 254: Shift Shaft

    Shift shaft 5-56 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-47. Shift arm and shift rod refer to “engine removal” on page 5-1. 1 circlip 1 2 washer 1 3 shift shaft 1 4 stopper lever spring 1 5 was...

  • Page 255: Shift Shaft

    Shift shaft 5-57 eas5d01019 removing the shift shaft 1. Remove: ● clutch assembly refer to “clutch” on page 5-47 2. Remove: ● shift arm ● shift rod refer to “engine removal” on page 5-1 3. Remove: ● circlip “1” ● washer “2” (left side of the engine) 4. Remove ● shift shaft assembly “1” tip unhook th...

  • Page 256: Shift Shaft

    Shift shaft 5-58 ● stopper lever “2” ● washer “3” ● circlip “4” ● stopper lever spring “5” 2. Install: ● shift shaft assembly “1” tip ● mesh the stopper lever with the shift drum seg- ment assembly. ● lubricate the oil seal lips with lithium soap base grease. ● install the end of the shift shaft spr...

  • Page 257: Crankcase

    Crankcase 5-59 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-16. Starter motor refer to “electric starter” on page 5-36. Generator refer to “generator and starter clutc...

  • Page 258: Crankcase

    Crankcase 5-60 *refer to “engine tightening torques” on page 2-14 separating the crankcase order job/parts to remove q’ty remarks 6 plate 1 for installation, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 6 lt lt e e e e e e 12 nm (1.2 m • kgf, 8.6 ft • ibf) 12 nm (1.2 m • kgf, 8...

  • Page 259: Crankcase

    Crankcase 5-61 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: ● crankcase bolts tip ● loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. ● loosen the bolts in decreasing numerica...

  • Page 260: Crankcase

    Crankcase 5-62 3. Install: ● dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: ● lower crankcase “1” (onto the upper crankcase “2”) notice eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the sh...

  • Page 261: Crankcase

    Crankcase 5-63 8. Tighten: crankcase bolts “11” – “27” tip tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt (m8 ×××× 65 mm) “11, 12” 24 nm (2.4 m·kgf, 17 ft·lbf) crankcase bolt (m6 ×××× 65 mm) “13, 14” 12 nm (1.2 m·kgf, 8.6 ft·lbf) crankcase bolt (m6) “15 – 27” 10 n...

  • Page 262: Crankshaft

    Crankshaft 5-64 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-59. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 piston pin 4 6 piston 4 7 connecting...

  • Page 263: Crankshaft

    Crankshaft 5-65 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-59. Connecting rods and connecting rod caps refer to “crankshaft” on page 5-64. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft journal upper bearing 5 f...

  • Page 264: Crankshaft

    Crankshaft 5-66 eas26030 removing the connecting rods and pistons the following procedure applies to all of the con- necting rods and pistons. 1. Remove: ● connecting rod cap “1” ● big end bearings tip identify the position of each big end bearing so that it can be reinstalled in its original place....

  • Page 265: Crankshaft

    Crankshaft 5-67 eas24390 checking the cylinder and piston 1. Check: ● piston wall ● cylinder wall vertical scratches → replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: ● piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “c” with...

  • Page 266: Crankshaft

    Crankshaft 5-68 2. Install: ● piston ring (into the cylinder) tip level the piston ring into the cylinder with the piston crown. 3. Measure: ● piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap...

  • Page 267: Crankshaft

    Crankshaft 5-69 4. Calculate: ● piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas4s81037 checking the big end bearings 1. Measure: ● crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼▼▼...

  • Page 268: Crankshaft

    Crankshaft 5-70 d. Assemble the connecting rod halves. Tip ● do not move the connecting rod or crankshaft until the clearance measurement has been completed. ● lubricate the bolt threads and seats with mo- lybdenum disulfide grease. ● make sure that the “y” mark “c” on the connect- ing rod faces tow...

  • Page 269: Crankshaft

    Crankshaft 5-71 eas26190 installing the connecting rod and piston the following procedure applies to all of the con- necting rods and pistons. 1. Install: ● top ring “1” ● 2nd ring “2” ● upper oil ring rail “3” ● oil ring expander “4” ● lower oil ring rail “5” tip be sure to install the piston rings...

  • Page 270: Crankshaft

    Crankshaft 5-72 ● nut seats (with the recommended lubricant) 6. Lubricate: ● crankshaft pins ● big end bearings ● connecting rod big end inner surface (with the recommended lubricant) 7. Install: ● big end bearings ● connecting rod and piston assembly ● connecting rod cap (onto the connecting rod) t...

  • Page 271: Crankshaft

    Crankshaft 5-73 d. After the installation, check that the section shown “a” is flush with each other by touching the surface. Warning ewa13990 ● when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the pro...

  • Page 272: Crankshaft

    Crankshaft 5-74 e. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves. Tip ● align the projections “a” of the crankshaft jour- nal lower bearings with the notches “b” in the lower crankcase. ● do not move the crankshaft until the clearance me...

  • Page 273: Crankshaft

    Crankshaft 5-75 eas4s81040 installing the crankshaft 1. Install: ● crankshaft journal upper bearings “1” (into the upper crankcase) tip ● align the projections “a” on the crankshaft jour- nal upper bearings with the notches “b” in the upper crankcase. ● be sure to install each crankshaft journal upp...

  • Page 274: Transmission

    Transmission 5-76 eas26240 transmission removing the drive axle order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-59. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 shift fork guide bar retainer 1 5 shift fork guide bar 1 6 shift fork-l 1 7 shift fork-r 1 8 pl...

  • Page 275: Transmission

    Transmission 5-77 removing the main axle and shift drum order job/parts to remove q’ty remarks 1 shift fork guide bar retainer 1 2 shift fork guide bar 1 3 shift drum assembly 1 4 bearing housing 1 5 bearing 1 6 main axle assembly 1 7 bearing 1 8 shift fork-c 1 9 oil pipe 1 10 o-ring 3 12 nm (1.2 m ...

  • Page 276: Transmission

    Transmission 5-78 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 3rd wheel gear 1 8 collar 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 277: Transmission

    Transmission 5-79 disassembling the drive axle assembly order job/parts to remove q’ty remarks 16 circlip 1 17 washer 1 18 2nd wheel gear 1 19 collar 1 20 oil seal 1 21 collar 1 22 bearing 1 23 circlip 1 24 drive axle 1 for installation, reverse the removal proce- dure. 16 17 18 19 23 24 m m e m 22 ...

  • Page 278: Transmission

    Transmission 5-80 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 279: Transmission

    Transmission 5-81 eas26250 removing the transmission 1. Remove: ● drive axle assembly ● main axle assembly “1” (with the torx® wrench) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “2” of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten th...

  • Page 280: Transmission

    Transmission 5-82 eas26300 checking the transmission 1. Measure: ● main axle runout (with a centering device and dial gauge “1”) out of specification → replace the main axle. 2. Measure: ● drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3...

  • Page 281: Transmission

    Transmission 5-83 2. Install: ● toothed lock washer retainer “1” ● toothed lock washer “2” tip ● with the toothed lock washer retainer “1” in the groove “a” in the axle, align the projection on the retainer with an axle spline, and then install the toothed lock washer “2”. ● be sure to align the pro...

  • Page 282: Transmission

    Transmission 5-84 tip ● install 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. ● make sure that the drive axle bearing circlip “a” is inserted into the grooves in the upper crank- case. ● make sure that the drive axle bear...

  • Page 283: Cooling System

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

  • Page 284: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Side cowling refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on...

  • Page 285: Radiator

    Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 12 coolant reservoir cover/coolant reservoir 1/1 13 coolant reservoir cap 1 for installation, reverse the removal proce- dure. 10 nm (1.0 m • kgf, 7.2 ft • ibf) 4 nm (0.4 m • kgf, 2.9 ft • ibf) lt 7 nm (0.7 m • kgf, 5.1 ft • i...

  • Page 286: Radiator

    Radiator 6-3 eas26390 checking the radiator 1. Check: ● radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: ● radiator hoses ● radiator pipes cracks/damage →...

  • Page 287: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q ’ ty remarks coolant reservoir refer to “radiator” on page 6-1 . Radiator assembly refer to “radiator” on page 6-1 . Engine oil drain. Refer to “changing the engine oil” on page 3-23 . 1 oil cooler outlet hose 1 2...

  • Page 288: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: ● oil cooler cracks/damage → replace. 2. Check: ● oil cooler inlet hose ● oil cooler outlet hose cracks/damage/wear → replace. Eas26430 installing the oil cooler 1. Clean: ● mating surfaces of the oil cooler and the crankcase (with a cloth da...

  • Page 289: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Left side cowling refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general ...

  • Page 290: Thermostat

    Thermostat 6-7 eas26450 checking the thermostat 1. Check: ● thermostat “1” does not open at 71 – 85 ° c (160 – 185 ° f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. B. Slowly heat the water “2”. C. Place a thermometer “1” in the wate...

  • Page 291: Thermostat

    Thermostat 6-8 below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3..

  • Page 292: Water Pump

    Water pump 6-9 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant drain. Refer to “changing the coolant” on page 3-26. 1 radiator outlet ...

  • Page 293: Water Pump

    Water pump 6-10 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump cover 1 2 o-ring 1 3 circlip 1 4 impeller shaft 1 5 water pump seal 1 6 oil seal 1 7 bearing 1 8 water pump housing 1 9 o-ring 1 for assembly, reverse the disassembly pro- cedure. 10 nm (1.0 m • kgf, 7.2...

  • Page 294: Water Pump

    Water pump 6-11 eas26510 disassembling the water pump 1. Remove: ● water pump cover ● o-ring ● circlip ● impeller shaft 2. Remove: ● water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 3. Remove: ● oil seal “3” (with a thin, flat-head screwdriver) tip re...

  • Page 295: Water Pump

    Water pump 6-12 coolant onto its out surface. ● install the oil seal with a socket that matches its outside diameter. 2. Install: ● water pump seal “1” notice eca14080 never lubricate the water pump seal surface with oil or grease. Tip ● install the water pump seal with the special tools. ● before i...

  • Page 296: Water Pump

    Water pump 6-13 ● water pump assembly “1” tip ● align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft. ● lubricate the o-ring with a thin coat of lithi- um-soap-based grease. 2. Install: ● o-ring ● radiator outlet “1” ● o-rings ● water pump outlet hose “2” ● copper w...

  • Page 297: Fuel System

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

  • Page 298: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Front cowling inner panel refer to “general chassis” on page 4-1. 1 cover 1 2 fuel hose 1 disconnect. 3 fuel sender coupler 1 disconnect. 4...

  • Page 299: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: ● fuel sender coupler ● fuel pump coupler ● fuel tank breather hose ● fuel tank drain hose ● fuel hose notice eca4s81003 ● be sure to disconnect the fuel hose by hand....

  • Page 300: Fuel Tank

    Fuel tank 7-3 eas4s81001 installing the fuel tank 1. Install: ● fuel hose notice eca4s81001 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, oth- erwise the fuel hose will not be properly in- stalled. Tip ● install th...

  • Page 301: Throttle Bodies

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

  • Page 302: Throttle Bodies

    Throttle bodies 7-5 eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: ● throttle bodies refer to “throttle bodies” on page 7-4. 2. Check: ● throttle body joints “1” cracks/damage → replace. 3. Install: ● thr...

  • Page 303: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor coupler 1 disconnect. 3 fuel injector coupler 4 disconnect. 4 sub-wire harness 1 5 negative pressure hose 1 6 canister purge hose 1 for cali...

  • Page 304: Throttle Bodies

    Throttle bodies 7-7 eas26980 checking the fuel injectors warning ewa2s31037 ● check the injectors in a well-ventilated area free of combustible materials. Make sure that there is no smoking or use of electric tools in the vicinity of the injectors. ● be careful when disconnecting the fuel hoses. Any...

  • Page 305: Throttle Bodies

    Throttle bodies 7-8 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the injector. Eas2s31095 checking and cleaning the throttle bodies warning ewa2s31033 if the throttle bodies are subjected to strong shocks or dropped during cleaning, replace them as a set. Tip clean the throttle bodies only if they cannot be syn...

  • Page 306: Throttle Bodies

    Throttle bodies 7-9 ● do not apply any petroleum-based solvent to the portions of the throttle valve shafts be- tween the throttle bodies. E. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the engine side of the throttle body to the air filter case sid...

  • Page 307: Throttle Bodies

    Throttle bodies 7-10 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ faulty → replace the fuel pump. Eas27030 adjusting the throttle position sensor tip before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: ● throttle position sensor refer to “checking the th...

  • Page 308: Air Induction System

    Air induction system 7-11 eas27040 air induction system 1 2 3 4 5 2 3 6.

  • Page 309: Air Induction System

    Air induction system 7-12 1. Air filter case 2. Air cut-off valve hose (air filter case—air cut-off valve) 3. Air cut-off valve 4. Air cut-off valve hose (air cut-off valve—reed valve) 5. Air cut-off valve hose (air cut-off valve—reed valve) 6. Reed valve.

  • Page 310: Air Induction System

    Air induction system 7-13 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis” on page 4-1. 1 air cut-off valve...

  • Page 311: Air Induction System

    Air induction system 7-14 eas27060 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 312: Canister (For California)

    Canister (for california) 7-15 canister (for california) removing the canister (for california) order job/parts to remove q’ty remarks right footrest assembly refer to “rear brake” on page 4-28. Right rear side cover refer to “general chassis” on page 4-1. 1 fuel tank breather hose (rollover valve t...

  • Page 313: Electrical System

    1 2 3 4 5 6 7 8 9 electrical system ignition system ........................................................................................8-1 circuit diagram .................................................................................8-1 troubleshooting ..........................................

  • Page 314

    Checking the ignition spark gap ...............................................8-85 checking the spark plug caps ...................................................8-86 checking the ignition coil............................................................8-86 checking the crankshaft position sensor ...

  • Page 316: Ignition System

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

  • Page 317: Ignition System

    Ignition system 8-2 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 31. Crankshaft position sensor 32. Ecu (engine control unit) 37. Ignition coil #1,4 38. Ignition coil #2,3 39. Spark plug 53. C...

  • Page 318: Ignition System

    Ignition system 8-3 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Fuel tank 3.Side cowling 1. Check the fuses. (main and ignition) refer to “checking the fuses”...

  • Page 319: Ignition System

    Ignition system 8-4 ok ↓ 11.Check the clutch switch. Refer to “checking the switches” on page 8-75 . Ng → replace the clutch switch. Ok ↓ 12.Check the starting circuit cut-off relay. Refer to “checking the relays” on page 8-83 . Ng → replace the relay unit. Ok ↓ 13.Check the entire ignition system ’...

  • Page 320: Electric Starting System

    Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram.

  • Page 321: Electric Starting System

    Electric starting system 8-6 3. Battery 4. Main fuse 5. Starter relay 6. Starter motor 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 22. Start switch 53. Clutch switch 65. Ignition fuse.

  • Page 322: Electric Starting System

    Electric starting system 8-7 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: ● the transmission is in neutr...

  • Page 323: Electric Starting System

    Electric starting system 8-8 a. When the transmission is in neu- tral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Sidestand swi...

  • Page 324: Electric Starting System

    Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Rear side cover 3.Fuel tank 1. Check the fuses. (main and ignition) refer to “checking the fuses” on page 8-79 . Ng → repla...

  • Page 325: Electric Starting System

    Electric starting system 8-10 ok ↓ 11.Check the start switch. Refer to “checking the switches” on page 8-75 . Ng → replace the right handlebar switch. Ok ↓ 12.Check the entire starting system ’ s wiring. Refer to “circuit diagram” on page 8-5 . Ng → properly connect or repair the starting system’s w...

  • Page 326: Charging System

    Charging system 8-11 eas27200 charging system eas27210 circuit diagram.

  • Page 327: Charging System

    Charging system 8-12 1. Ac magneto 2. Rectifier/regulator 3. Battery 4. Main fuse.

  • Page 328: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Rear side cover 3.Fuel tank 1. Check the fuse. (main) refer to “checking the fuses” on page 8-79 . Ng → replace the fuse. Ok ↓ 2. ...

  • Page 329: Charging System

    Charging system 8-14.

  • Page 330: Lighting System

    Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram.

  • Page 331: Lighting System

    Lighting system 8-16 3. Battery 4. Main fuse 10. Main switch 32. Ecu (engine control unit) 48. High beam indicator light 50. Meter light 54. Dimmer switch 60. Front left turn signal light 61. Front right turn signal light 62. License plate light 63. Tail/brake light 64. Headlight 65. Ignition fuse 6...

  • Page 332: Lighting System

    Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Fuel tank 1. Check the each bulbs and bulb socket...

  • Page 333: Lighting System

    Lighting system 8-18.

  • Page 334: Signaling System

    Signaling system 8-19 eas27270 signaling system eas27280 circuit diagram.

  • Page 335: Signaling System

    Signaling system 8-20 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 16. Neutral switch 18. Rear brake light switch 20. Front brake light switch 24. Fuel sender 28. Coolant temperature sensor 30. Speed sensor 32. Ecu (engine control unit) 42. Oil level warning light 43. Neutral indicator lig...

  • Page 336: Signaling System

    Signaling system 8-21 eas27290 troubleshooting ● any of the following fail to light: turn signal light, brake light or an indicator light. ● the horn fails to sound. Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Rear side cover 3.Fuel tank check the signal...

  • Page 337: Signaling System

    Signaling system 8-22 the tail/brake light fails to come on. The turn signal light, turn signal indicator light or both fail to blink. 1. Check the tail/brake light bulb and socket. Refer to “checking the bulbs and bulb sockets” on page 8-78 . Ng → replace the tail/brake light bulb, socket or both. ...

  • Page 338: Signaling System

    Signaling system 8-23 the neutral indicator light fails to come. The oil level warning light fails to come. The fuel meter fails to come. 1. Check the neutral indicator light bulb and socket. Ng → replace the neutral indicator light bulb, socket or both. Ok ↓ 2. Check the neutral switch. Refer to “c...

  • Page 339: Signaling System

    Signaling system 8-24 the speedometer fails to operate. 1. Check the speed sensor. Refer to “checking the speed sensor” on page 8-91 . Ng → replace the speed sensor. Ok ↓ 2. Check the entire signaling system ’ s wiring. Refer to “circuit diagram” on page 8-19 . Ng → properly connect or repair the si...

  • Page 340: Cooling System

    Cooling system 8-25 eas27300 cooling system eas27310 circuit diagram.

  • Page 341: Cooling System

    Cooling system 8-26 3. Battery 4. Main fuse 9. Radiator fan fuse 10. Main switch 11. Radiator fan motor relay 12. Radiator fan motor 28. Coolant temperature sensor 32. Ecu (engine control unit) 65. Ignition fuse.

  • Page 342: Cooling System

    Cooling system 8-27 eas27320 troubleshooting tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Side cowling 3.Fuel tank 1. Check the fuses. (main, ignition and radiator fan) refer to “checking the fuses” on page 8-79 . Ng → replace the fuse(s). Ok ↓ 2. Check t...

  • Page 343: Cooling System

    Cooling system 8-28.

  • Page 344: Fuel Injection System

    Fuel injection system 8-29 eas27330 fuel injection system eas27340 circuit diagram.

  • Page 345: Fuel Injection System

    Fuel injection system 8-30 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 11. Radiator fan motor relay 13. Relay unit 14. Starting circuit cut-off relay 15. Fuel injection system relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 25. Throttle position sensor ...

  • Page 346: Fuel Injection System

    Fuel injection system 8-31 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 347: Fuel Injection System

    Fuel injection system 8-32 the ecu takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ecu directly operates an actuator. Details on the fail-safe actions are given in the table below..

  • Page 348: Fuel Injection System

    Fuel injection system 8-33 eas20s1002 trouble shooting chart * operated when the engine trouble warning light is on. Fault code number displayed fault code number not displayed ok ng ok ok ok ng the engine trouble warning light comes on. Repairs completed malfunction of en- gine defective sensor or ...

  • Page 349: Fuel Injection System

    Fuel injection system 8-34 eas27411 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch t...

  • Page 350: Fuel Injection System

    Fuel injection system 8-35 eas27451 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 351: Fuel Injection System

    Fuel injection system 8-36 5 crankshaft position sen- sor malfunction replace if defective. Refer to “checking the crankshaft position sensor” on page 8-87. Crank the engine, and check the fault code indi- cation. No fault code indicated. ⇒ recovered. Fault code indicated. ⇒ check the next step. 6 e...

  • Page 352: Fuel Injection System

    Fuel injection system 8-37 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 13 symptom open or short circuit of intake air pressure sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitoring co...

  • Page 353: Fuel Injection System

    Fuel injection system 8-38 5 intake air pressure sen- sor malfunction check in the diagnostic mode (code no. D03). When engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa 1000 m above sea level: approx. 90 kpa 200...

  • Page 354: Fuel Injection System

    Fuel injection system 8-39 if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 14 symptom the intake air pressure sensor has failed (due to clogging of hole or sensor disconnection). Fail-safe action engine startup: possible ridin...

  • Page 355: Fuel Injection System

    Fuel injection system 8-40 fault code no. 15 symptom open or short circuit of throttle position sensor lead fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. 01 meter display display the throttle opening (betwe...

  • Page 356: Fuel Injection System

    Fuel injection system 8-41 6 supply voltage of throttle position sensor lead check the supply volt- age. (black/blue – yellow) refer to “checking the throttle posi- tion sensor” on page 8-92. Repair/replace the wire harness, or replace the ecu (common to sepa- rate and integration mod- els). Line di...

  • Page 357: Fuel Injection System

    Fuel injection system 8-42 fault code no. 16 symptom open or short circuit of throttle position sensor lead fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. 01 meter display display the throttle opening (betwe...

  • Page 358: Fuel Injection System

    Fuel injection system 8-43 fault code no. 19 symptom open or short circuit of ecu input line (blue/yellow lead) fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 20 meter display sidestand retracted: on indication sidestand extended: off indication checkin...

  • Page 359: Fuel Injection System

    Fuel injection system 8-44 5 sidestand switch mal- function diagnostic mode (code no. D20) sidestand retracted: on indication sidestand extended: off indication indication is incorrect. ⇒ replace the sidestand switch. Refer to “checking the switches” on page 8-75 . Place the main switch to the on po...

  • Page 360: Fuel Injection System

    Fuel injection system 8-45 2 connection of main har- ness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- ing, wear, or locking). Poor connection ⇒ con- nect it securely, or repair/ replace the wire harness. Place the main switch to the on...

  • Page 361: Fuel Injection System

    Fuel injection system 8-46 *check the sensor only when the engine is cold. Fault code no. 22 symptom open or short circuit of intake air temperature sensor lead fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 05 meter display -30 to 120 °°°° c during cold st...

  • Page 362: Fuel Injection System

    Fuel injection system 8-47 5 intake air temperature sensor malfunction check in the diagnostic mode (code no. D05). During cold starting: a temperature close to the ambient temperature is indicated. Indication is incorrect. ⇒ replace the intake air temperature sensor. Refer to “checking the intake a...

  • Page 363: Fuel Injection System

    Fuel injection system 8-48 fault code no. 30 symptom turnover of vehicle fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 08 meter display the lean angle sensor value is indicated. 0 to 5.0 v the vehicle is in a vertical position: 0.4 – 1.4 v the vehicle ...

  • Page 364: Fuel Injection System

    Fuel injection system 8-49 fault code no. 33 symptom ignition coil primary lead malfunction fail-safe action engine startup: possible (depending on the number of failed cylinders) riding: possible (depending on the number of failed cylinders) diagnostic monitoring code no. 30 meter display each igni...

  • Page 365: Fuel Injection System

    Fuel injection system 8-50 5 ignition coil malfunction (check the resistance of primary coil.) replace if defective. Refer to “checking the ignition coil” on page 8-86. Start and idle the engine for approximately 5 sec- onds. Then, check the fault code indication. No fault code indicated. ⇒ recovere...

  • Page 366: Fuel Injection System

    Fuel injection system 8-51 fault code no. 34 symptom ignition coil primary lead malfunction fail-safe action engine startup: possible (depending on the number of failed cylinders) riding: possible (depending on the number of failed cylinders) diagnostic monitoring code no. 31 meter display each igni...

  • Page 367: Fuel Injection System

    Fuel injection system 8-52 5 ignition coil malfunction (check the resistance of primary coil.) replace if defective. Refer to “checking the ignition coil” on page 8-86. Start and idle the engine for approximately 5 sec- onds. Then, check the fault code indication. No fault code indicated. ⇒ recovere...

  • Page 368: Fuel Injection System

    Fuel injection system 8-53 fault code no. 41 symptom open or short circuit of lean angle sensor lead fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. 08 meter display the lean angle sensor value is indicated. 0 to 5.0 v the vehicle is in a vertical positi...

  • Page 369: Fuel Injection System

    Fuel injection system 8-54 fault code no. 42 symptom a. Normal signals are not received from the speed sensor. B. Open or short circuit of neutral switch lead fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 07 (speed sensor) 21 meter display vehicle speed pu...

  • Page 370: Fuel Injection System

    Fuel injection system 8-55 a. Speed sensor system malfunction order item/components and probable cause check or maintenance job sensor inspection procedure 1 connection of speed sensor (meter) coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- in...

  • Page 371: Fuel Injection System

    Fuel injection system 8-56 b. Neutral switch system malfunction order item/components and probable cause check or maintenance job sensor inspection procedure 1 connection of neutral switch coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bend- ing, w...

  • Page 372: Fuel Injection System

    Fuel injection system 8-57 fault code no. 43 symptom incorrect voltage supplied to the fuel injector and fuel pump fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 50 meter display the relay turns on or off 5 times per second. The engine warning light flashes...

  • Page 373: Fuel Injection System

    Fuel injection system 8-58 fault code no. 44 symptom an error is detected while reading or writing on eep-rom fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. 60 meter display the in self diagnostic code 44 detected eep-rom errors are indicated. If there are ...

  • Page 374: Fuel Injection System

    Fuel injection system 8-59 fault code no. 46 symptom incorrect voltage is supplied to the ecu. Fail-safe action engine startup: possible riding: possible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspec...

  • Page 375: Fuel Injection System

    Fuel injection system 8-60 fault code no. 50 symptom ecu memory malfunction fail-safe action engine startup: possible under certain conditions riding: possible under certain conditions diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check o...

  • Page 376: Fuel Injection System

    Fuel injection system 8-61 fault code no. Er-1 symptom no signal is received from the ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspec...

  • Page 377: Fuel Injection System

    Fuel injection system 8-62 fault code no. Er-2 symptom no signal is sent from ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sensor inspection pro...

  • Page 378: Fuel Injection System

    Fuel injection system 8-63 fault code no. Er-3 symptom correct data cannot be received from the ecu. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or maintenance job sen...

  • Page 379: Fuel Injection System

    Fuel injection system 8-64 fault code no. Er-4 symptom no registration data can be received from the meter unit. Fail-safe action engine startup: impossible riding: impossible diagnostic monitoring code no. — meter display — checking method — order item/components and probable cause check or mainten...

  • Page 380: Fuel Injection System

    Fuel injection system 8-65 eas20s18001 other diagnostic monitoring codes this table shows diagnostic monitoring codes which are not linked to the fault code symptoms. Diagnostic code table diagnos tic code no. Item meter display checking method 09 fuel system voltage (battery voltage) approximately ...

  • Page 381: Fuel Injection System

    Fuel injection system 8-66 63 malfunction code reinstate ● no malfunction code 00 — ● malfunction code exists fault code 24 ● (if more than one code number is detected, the display changes every two seconds to show all the detected code num- bers are shown, the dis- play repeats.) to reinstate, set ...

  • Page 382: Fuel Pump System

    Fuel pump system 8-67 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 383: Fuel Pump System

    Fuel pump system 8-68 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 13. Relay unit 15. Fuel injection system relay 21. Engine stop switch 23. Fuel pump 32. Ecu (engine control unit) 65. Ignition fuse.

  • Page 384: Fuel Pump System

    Fuel pump system 8-69 eas27570 troubleshooting if the fuel pump fails to operate. Tip ● before troubleshooting, remove the following part(s): 1.Passenger seat/rider seat 2.Fuel tank 1. Check the fuses. (main, ignition and fuel injection sys- tem) refer to “checking the fuses” on page 8-79 . Ng → rep...

  • Page 385: Fuel Pump System

    Fuel pump system 8-70

  • Page 386: Electrical Components

    Electrical components 8-71 eas27970 electrical components 2 1 3 4 5 6 10 8 9 11 7 12 13 14 15.

  • Page 387: Electrical Components

    Electrical components 8-72 1. Front brake light switch 2. Clutch switch 3. Air induction system solenoid 4. Battery 5. Starter relay 6. Fuse box 7. Neutral switch 8. Rear brake light switch 9. Sidestand switch 10. Speed sensor 11. Oil level switch 12. Radiator fan motor 13. Horn 14. Ignition coil 15...

  • Page 388: Electrical Components

    Electrical components 8-73 2 1 3 4 5 6 10 8 9 7 11 12 13.

  • Page 389: Electrical Components

    Electrical components 8-74 1. Fuel injector 2. Intake air temperature sensor 3. Fuel pump 4. Intake air pressure sensor 5. Lean angle sensor 6. Relay unit 7. Turn signal relay 8. Radiator fan motor relay 9. Headlight relay 10. Ecu (engine control unit) 11. Rectifier/regulator 12. Coolant temperature...

  • Page 390: Electrical Components

    Electrical components 8-75 eas27980 checking the switches 7 8 9 12 11 14 10 4 1 2 3 5 6 13.

  • Page 391: Electrical Components

    Electrical components 8-76 1. Main switch 2. Horn switch 3. Turn signal switch 4. Dimmer switch 5. Clutch switch 6. Sidestand switch 7. Start switch 8. Engine stop switch 9. Front brake light switch 10. Oil level switch 11. Neutral switch 12. Rear brake light switch 13. Left handlebar switch lead co...

  • Page 392: Electrical Components

    Electrical components 8-77 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes ...

  • Page 393: Electrical Components

    Electrical components 8-78 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or ...

  • Page 394: Electrical Components

    Electrical components 8-79 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: ● bulb socket (for continuity) (with the digital circuit tester) no continuity → replace. Tip check each bulb socket for contin...

  • Page 395: Electrical Components

    Electrical components 8-80 4. Install: ● passenger seat/rider seat refer to “general chassis” on page 4-1. Eas28030 checking and charging the battery this model is equipped with a vrla (valve regulated lead acid) battery. There is no need to check the electrolyte or to add distilled water. However, ...

  • Page 396: Electrical Components

    Electrical components 8-81 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: ● battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Notice eca20s1011 ● never remove the vrla battery sealing caps. ● do not use a high-rate battery charger since it forces a high-...

  • Page 397: Electrical Components

    Electrical components 8-82 tip set the charging voltage to 16 – 17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be over-charged. C. Make sure that the current is higher than the standard charging current written on the bat- tery. Tip if the current is lo...

  • Page 398: Electrical Components

    Electrical components 8-83 eas28040 checking the relays check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect the relay from the wire harness. 2. Connect the digital circuit tester and battery (12 v) to the relay ...

  • Page 399: Electrical Components

    Electrical components 8-84 radiator fan motor relay eas4b51020 checking the turn signal relay 1. Check: ● turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal relay cou- pler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 400: Electrical Components

    Electrical components 8-85 eas28050 checking the relay unit (diode) 1. Check: ● relay unit (diode) out of specification → replace. Tip the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from ...

  • Page 401: Electrical Components

    Electrical components 8-86 c. Turn the main switch to “on” and set the en- gine stop switch to “ ”. D. Measure the ignition spark gap “a”. E. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap un- til a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28070 chec...

  • Page 402: Electrical Components

    Electrical components 8-87 2. Check: ● secondary coil resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. Connect the digital circuit tester ( Ω × 1k) to the ignition coil as shown. C. Measure the secondary coil re...

  • Page 403: Electrical Components

    Electrical components 8-88 c. Set the main switch to “on”. D. Turn the lean angle sensor 65 ° . E. Measure the lean angle sensor output volt- age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28940 checking the starter motor operation 1. Check: ● starter motor operation does not operate → perform the electri...

  • Page 404: Electrical Components

    Electrical components 8-89 b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28170 checking the rectifier/regulator 1. Check: ● rectifier/regulator output voltage out of specification → replace the rectifier/ regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tach...

  • Page 405: Electrical Components

    Electrical components 8-90 ● engine oil level gauge (from the oil pan) 3. Check: ● engine oil level gauge resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester ( Ω × 100) to the engine oil level gauge terminal as shown. B. Measure the picku...

  • Page 406: Electrical Components

    Electrical components 8-91 assembly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester ( Ω × 10) to the fuel pump terminals as shown. B. Move the fuel sender float to empty fuel tank position “3” and full fuel tank position “4” level position. C. Measure the fuel sender resistan...

  • Page 407: Electrical Components

    Electrical components 8-92 from the wire harness. B. Connect the battery (dc 12 v) as shown. C. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28260 checking the coolant temperature sensor 1. Remove: ● coolant temperature sensor refer to “cylinder head” on page 5-16. Wa...

  • Page 408: Electrical Components

    Electrical components 8-93 b. Measure the throttle position sensor maxi- mum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: ● throttle position sensor tip when installing the throttle position sensor, ad- just its angle properly. Refer to “adjusting the throttle position sensor” on page 7-...

  • Page 409: Electrical Components

    Electrical components 8-94 b. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ● positive tester probe black/blue “1” ● negative tester probe brown/white “2” 1 2.

  • Page 410: Electrical Components

    Electrical components 8-95.

  • Page 411: Troubleshooting

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

  • Page 412: Troubleshooting

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

  • Page 413: Troubleshooting

    Troubleshooting 9-2 ● faulty battery 2. Spark plug(s) ● incorrect spark plug gap ● incorrect spark plug heat range ● fouled spark plug ● worn or damaged electrode ● worn or damaged insulator ● faulty spark plug cap 3. Ignition coil(s) ● broken or shorted primary or secondary coils ● faulty spark plu...

  • Page 414: Troubleshooting

    Troubleshooting 9-3 ● hose(s) and pipe(s) ● damaged hose ● improperly connected hose ● damaged pipe ● improperly connected pipe fuel system 1. Throttle body(-ies) ● damaged or loose throttle body joint 2. Air filter ● clogged air filter element chassis 1. Brake(s) ● dragging brake electrical system ...

  • Page 415: Troubleshooting

    Troubleshooting 9-4 ● incorrect connection ● improperly grounded circuit ● poor contacts (main or light switch) ● burnt-out headlight bulb headlight bulb burnt out ● wrong headlight bulb ● faulty battery ● faulty rectifier/regulator ● improperly grounded circuit ● faulty main switch ● faulty light s...

  • Page 416

    Eas28740 wiring diagram fz6ry(c) 2009 1.Ac magneto 2.Rectifier/regulator 3.Battery 4.Main fuse 5.Starter relay 6.Starter motor 7.Fuel injection system fuse 8.Backup fuse 9.Radiator fan fuse 10.Main switch 11.Radiator fan motor relay 12.Radiator fan motor 13.Relay unit 14.Starting circuit cut-off rel...

  • Page 418

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 419

    Fz6ry(c) 2009 wiring diagram xj6n 2009 schÉma de cblage fz6ry(c)̲a̲w.D 09.1.22 9:55 ページ 1.

  • Page 420

    Fz6ry(c) 2009 wiring diagram xj6n 2009 schÉma de cblage fz6ry(c)̲a̲w.D 09.1.22 9:55 ページ 2.