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Yamaha FZS6W Service Manual

Other manuals for FZS6W: Service Manual

Summary of FZS6W

  • Page 1

    Fzs6w 4s8-28197-10 service manual lit-11616-20-60 fzs6wc.

  • Page 2

    Eas20050 fzs6w/fzs6wc service manual ©2006 by yamaha motor corporation, u.S.A. First edition, octover 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed inu.S.A. P/n lit-11616-20-60

  • Page 3

    Eas20070 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4

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

  • Page 5

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. El...

  • Page 7: Table of Contents

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

  • Page 9: General Information

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

  • Page 10: Identification

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

  • Page 11: Features

    Features 1-2 eas20170 features eas4s81003 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor s...

  • Page 12: Features

    Features 1-3 eas4s81004 fi system the fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kpa (2.5 kg/cm 2 ). Accordingly, when the energiz- ing signal from the ecu energizes the injector, the fue...

  • Page 13: Features

    Features 1-4 eas4s81005 instrument functions warning ewa4s81002 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a tachometer (which shows eng...

  • Page 14: Features

    Features 1-5 odometer and tripmeter modes push the “select” button to switch the dis- play between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” in the following order: “trip a” → “trip b” → “odo” → “trip a” when the fuel amount in the fuel tank decreases to 3.4 l (0.90 us ga...

  • Page 15: Features

    Features 1-6 note: • even if the air intake temperature is set to be displayed, the coolant temperature warning light comes on when the engine overheats. • when the key is turned to “on”, the coolant temperature is automatically displayed, even if the air intake temperature was displayed prior to tu...

  • Page 16: Important Information

    Important information 1-7 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to "special tools" on page 1-10. 3. When disassem...

  • Page 17: Important Information

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

  • Page 18: Checking The Connections

    Checking the connections 1-9 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect several...

  • Page 19: Special Tools

    Special tools 1-10 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 inappropri- ate tools or improvised techniques. Special tools, part numbers...

  • Page 20: Special Tools

    Special tools 1-11 steering nut wrench 90890-01403 spanner wrench yu-33975 3-26, 4-53 damper rod holder 90890-01294 damping rod holder set ym-01300 4-45, 4-47 t-handle 90890-01326 ym-01326 4-45, 4-47 oil filter wrench 90890-01426 yu-38411 3-13 fork seal driver weight 90890-01367 replacement hammer y...

  • Page 21: Special Tools

    Special tools 1-12 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-9, 5-38, 8-65, 8-66, 8-67, 8-71, 8-72, 8-73, 8-74, 8-75, 8-76, 8-77, 8-78, 8-79, 8-80, 8-81, 8-82 pressure gauge 90890-03153 yu-03153 3-14, 7-6 oil pressure adapter h 90890-03139 3-14 fuel pressure adapter 90890-03176 ym-...

  • Page 22: Special Tools

    Special tools 1-13 universal clutch holder 90890-04086 ym-91042 5-49, 5-51 valve lapper 90890-04101 valve lapping tool ym-a8998 3-5 valve guide remover (ø4) 90890-04111 valve guide remover (4.0 mm) ym-04111 5-23 valve guide installer (ø4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-23 valv...

  • Page 23: Specifications

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

  • Page 24: General Specifications

    General specifications 2-1 eas20280 general specifications model model 4s82 (u.S.A.) 4s83 (california) dimensions overall length 2095 mm (82.5 in) overall width 750 mm (29.5 in) overall height 1210 mm (47.6 in) seat height 795 mm (31.3 in) wheelbase 1440 mm (56.7 in) ground clearance 145 mm (5.71 in...

  • Page 25: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 600.0 cm³ 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 lev...

  • Page 26: Engine Specifications

    Engine specifications 2-3 water pump water pump type single suction centrifugal pump reduction ratio 86/44 × 31/31 (1.955) max. Impeller shaft tilt 0.15 mm (0.006 in) spark plug (s) manufacturer/model ngk/cr9ek spark plug gap 0.6–0.7 mm (0.024–0.028 in) cylinder head volume 10.33–10.93 cm³ (0.63–0.6...

  • Page 27: Engine Specifications

    Engine specifications 2-4 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 face width b (intake) 1.140–1.980 mm (0.0449–0.0780 in) valve face width b (exhaust) 1.140–1.980 mm (0.0449–0.0780 in) v...

  • Page 28: Engine Specifications

    Engine specifications 2-5 limit 1.6 mm (0.06 in) valve spring inner spring free length (intake) 37.04 mm (1.46 in) limit 35.20 mm (1.39 in) free length (exhaust) 41.79 mm (1.65 in) limit 39.70 mm (1.56 in) installed length (intake) 30.02 mm (1.18 in) installed length (exhaust) 36.12 mm (1.42 in) spr...

  • Page 29: Engine Specifications

    Engine specifications 2-6 offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) limit 16.043 mm (0.6316 in) piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) limit 15.971 mm (0.6288 in) piston-pin-to-piston-pin-bore ...

  • Page 30: Engine Specifications

    Engine specifications 2-7 crankshaft width a 51.850–52.550 mm (2.04–2.06 in) width b 268.80–270.00 mm (10.58–10.63 in) runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.160–0.262 mm (0.0063–0.0103 in) big end radial clearance 0.028–0.052 mm (0.0011–0.0020 in) small end free play 0.32–0....

  • Page 31: Engine Specifications

    Engine specifications 2-8 shifting mechanism shift mechanism type shift drum shift fork guide bar bending limit 0.050 mm (0.0020 in) shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) air filter air filter element oil-coated paper element fuel pump pump type electrical model/manufacturer 5vx/denso...

  • Page 32: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 25.00 ° trail 97.5 mm (3.84 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 33: Chassis Specifications

    Chassis specifications 2-10 front disc brake disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) brake disc thickness limit 4.5 mm (0.18 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thic...

  • Page 34: Chassis Specifications

    Chassis specifications 2-11 rear suspension type swingarm (monocross) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 50.0 mm (1.97 in) spring free length 185.0 mm (7.28 in) installed length 172.0 mm (6.77 in) spring rate k1 127.40 n/mm (727.45 lb/in) (12.99...

  • Page 35: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition system type dc. Tci advancer type digital ignition timing (b.T.D.C.) 5.0 °/1300 r/min engine control unit model/manufacturer f...

  • Page 36: Electrical Specifications

    Electrical specifications 2-13 indicator light neutral indicator light led turn signal indicator light led oil level warning light led high beam indicator light led coolant temperature warning light led engine trouble warning light led electric starting system system type constant mesh starter motor...

  • Page 37: Electrical Specifications

    Electrical specifications 2-14 fuel injection system relay model/manufacturer g8r-30y-r/omron resistance 162–198 Ω thermo unit model/manufacturer 8cc/mitsubishi resistance at 80 °c 290.0–354.0 Ω fuses main fuse 30.0 a headlight fuse 20.0 a taillight fuse 10.0 a signaling system fuse 10.0 a ignition ...

  • Page 38: Tightening Torques

    Tightening torques 2-15 eas20320 tightening torques eas20330 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each cha...

  • Page 39: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plugs m10 4 18 nm (1.8 m·kg, 13 ft·lb) cylinder head bolt m10 10 see note cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft caps bolt m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder...

  • Page 40: Tightening Torques

    Tightening torques 2-17 catalyst pipe and catalyst pipe stay bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) muffler joint bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) see note catalyst joint bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) see note exhaust pipe stay bolt m8 2 20 nm (2.0 m·kg, 14 ft·lb) catalyst pipe stay bolt m8...

  • Page 41: Tightening Torques

    Tightening torques 2-18 note: • cylinder head bolt 1. First, tighten the bolts to approximately 19 nm (1.9 m·kg, 14 ft·lb) with a torque wrench follow- ing the tightening order. 2. Retighten the bolts 50 nm (5.0 m·kg, 36 ft·lb) with a torque wrench. • crankcase bolt (main journal) 1. First, tighten ...

  • Page 42: Tightening Torques

    Tightening torques 2-19 cylinder head tightening sequence. Crankcase tightening sequence..

  • Page 43: Tightening Torques

    Tightening torques 2-20 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks upper bracket pinch bolt m8 2 30 nm (3.0 m·kg, 22 ft·lb) steering stem nut m22 1 110 nm (11 m·kg, 80 ft·lb) upper bracket and upper handle- bar holder m8 4 23 nm (2.3 m·kg, 17 ft·lb) lower bra...

  • Page 44: Tightening Torques

    Tightening torques 2-21 note: • lower ring nut 1. First, tighten the ring nut to approximately 52 nm (5.2 m·kg, 38 ft·lb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. • engine mount bolts and engine mount self locking nut refer to "inst...

  • Page 45

    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 lobes camshaft journals valv...

  • Page 46

    Lubrication points and lubricant types 2-23 eas20380 chassis lubrication point lubricant steering bearings and bearing races (upper and lower) front wheel oil seal (right and left) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surface rear brake pedal shaft sidestand ...

  • Page 47

    Lubrication points and lubricant types 2-24.

  • Page 48

    Lubrication system chart and diagrams 2-25 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 49

    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. Mission cooler 8. Drive axle 9. Main gallery 10.Piston cooler 11.Intake camshaft 12.Exhaust camshaft.

  • Page 50

    Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams.

  • Page 51

    Lubrication system chart and diagrams 2-28 1. Oil level switch 2. Oil cooler 3. Relief valve.

  • Page 52

    Lubrication system chart and diagrams 2-29.

  • Page 53

    Lubrication system chart and diagrams 2-30 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer.

  • Page 54

    Lubrication system chart and diagrams 2-31.

  • Page 55

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

  • Page 56

    Lubrication system chart and diagrams 2-33.

  • Page 57

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

  • Page 58

    Lubrication system chart and diagrams 2-35.

  • Page 59

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

  • Page 60

    Lubrication system chart and diagrams 2-37.

  • Page 61

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

  • Page 62: Cooling System Diagrams

    Cooling system diagrams 2-39 eas20420 cooling system diagrams.

  • Page 63: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Radiator 2. Oil cooler.

  • Page 64: Cooling System Diagrams

    Cooling system diagrams 2-41.

  • Page 65: Cooling System Diagrams

    Cooling system diagrams 2-42 1. Water pump 2. Oil cooler 3. Radiator.

  • Page 66: Cooling System Diagrams

    Cooling system diagrams 2-43.

  • Page 67: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Oil cooler 2. Water pump.

  • Page 68: Cooling System Diagrams

    Cooling system diagrams 2-45.

  • Page 69: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Radiator 2. Thermostat.

  • Page 70: Cable Routing

    Cable routing 2-47 eas20430 cable routing.

  • Page 71: Cable Routing

    Cable routing 2-48 1. Left handlebar switch lead 2. Main switch lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead a. Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebar. B. 70–90 mm (2.76–3.54 in) c. Clamp...

  • Page 72: Cable Routing

    Cable routing 2-49.

  • Page 73: Cable Routing

    Cable routing 2-50 1. Rear brake light switch lead 2. Neutral switch lead 3. Fuel tank breather hose 4. Crankshaft position sensor lead 5. Right handlebar switch lead 6. O 2 sensor lead 7. Bracket 8. Fuel tank drain hose 9. Rear brake reservoir hose a. Pass the fuel tank breather hose, fuel tank dra...

  • Page 74: Cable Routing

    Cable routing 2-51.

  • Page 75: Cable Routing

    Cable routing 2-52 1. Main switch lead 2. Stay assembly 3. Left handlebar switch lead 4. Clutch cable 5. Throttle cables 6. Battery negative lead coupler 7. Starter relay lead 8. Battery negative lead 9. Fuel tank drain hose 10.Rectifier/regulator 11.Turn signal relay 12.Radiator fan motor relay 13....

  • Page 76: Cable Routing

    Cable routing 2-53.

  • Page 77: Cable Routing

    Cable routing 2-54 1. Right handlebar switch lead 2. Throttle cables 3. Battery positive lead 4. Battery cover 5. Connector cover 6. Fuel tank breather hose 7. Lean angle sensor 8. Fuse box 9. Rear right turn signal light lead 10.License plate light lead 11.Rear left turn signal light lead 12.Seat l...

  • Page 78: Cable Routing

    Cable routing 2-55.

  • Page 79: Cable Routing

    Cable routing 2-56 1. Fuel pump assembly 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Fuel hose 5. Clip 6. Clamp 7. Fuel tank protector 8. Charge hose (fzs6wc) 9. Roll over valve (fzs6wc) a. Air opening. B. Install the o-ring with its lip pointed upward. C. Fuel tank breather hose has a whi...

  • Page 80: Cable Routing

    Cable routing 2-57 fzs6wc.

  • Page 81: Cable Routing

    Cable routing 2-58 1. Clip 2. Roll over valve assembly 3. Canister hose 4. Balance hose 5. Clamp 6. Canister assembly 7. Upper bracket 8. Hose 9. Canister bracket 10.Fuel tank drain hose 11.Roll over valve hose a. Front side b. Point the paint marking upward. C. Pass the canister hose outside, pass ...

  • Page 82: Cable Routing

    Cable routing 2-59.

  • Page 83

    3 periodic checks and adjustments periodic maintenance .........................................................................3-1 introduction ....................................................................................3-1 engine................................................................

  • Page 84

    Electrical system.............................................................................. 3-32 replacing the headlight bulbs............................................... 3-32 adjusting the headlight beams .............................................. 3-32.

  • Page 86: 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 longer service life and redu...

  • Page 87: Periodic Maintenance

    Periodic maintenance 3-2 4 * rear brake • check operation, fluid level, and for fluid leakage. • replace brake pads if neces- sary. √ √ √ √ √ √ 5 * brake hoses • check for cracks or damage. √ √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for damage. • replace if necessary. √ √ √ √ √...

  • Page 88: Periodic Maintenance

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

  • Page 89: Engine

    Engine 3-4 eas20470 engine eas20490 adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead ce...

  • Page 90: Engine

    Engine 3-5 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 note: • refer to "camshafts" on page 5-8. • when removing the timing...

  • Page 91: Engine

    Engine 3-6 • since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. C. Round off the original valve pad number according to the following table. Example: original valve pad number = 148 (thickness...

  • Page 92: Engine

    Engine 3-7 • air filter case refer to "general chassis" on page 4- 1. 3. Install: • vacuum gauge “1” (onto the synchronizing hose “2”) 4. Install: • air filter case refer to "general chassis" on page 4- 1. • fuel tank refer to "fuel tank" on page 7-1. 5. Start the engine and let it warm up for sev- ...

  • Page 93: Engine

    Engine 3-8 11. Install: • fuel tank refer to "fuel tank" on page 7-1. • seat refer to "general chassis" on page 4- 1. Eas20610 adjusting the engine idling speed note: prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element s...

  • Page 94: Engine

    Engine 3-9 b. Turn the adjusting nut “3” in direction “a” or “b” to take up any slack on the decelerator cable. C. Tighten the locknuts note: if the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. ▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 95: Engine

    Engine 3-10 caution: eca13320 before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: • spark plug type incorrect → change. 5. Check: • electrode “1” damage/wear → replace the spark plug. • i...

  • Page 96: Engine

    Engine 3-11 • battery refer to "general chassis" on page 4- 1 and "checking and charging the battery" on page 8-68. • battery box • battery box bracket refer to "general chassis" on page 4- 1. • heat protector plate • cover • ignition coils 4. Disconnect: • spark plug caps 5. Remove: • spark plugs c...

  • Page 97: Engine

    Engine 3-12 • heat protector plate • battery box bracket • battery box refer to "general chassis" on page 4- 1. • battery refer to "general chassis" on page 4- 1 and "checking and charging the battery" on page 8-68. • air filter case refer to "general chassis" on page 4- 1. • fuel tank refer to "fue...

  • Page 98: Engine

    Engine 3-13 4. Drain: • engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” of the new oil f...

  • Page 99: Engine

    Engine 3-14 caution: eca13410 when the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: • oil gallery bolt “1” warning ewa12980 the engine, muffler a...

  • Page 100: Engine

    Engine 3-15 2. Adjust: • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified clutch cable free play is obtained. Note: if the specified clutch cable free play cannot be obtained on the handlebar side of the c...

  • Page 101: Engine

    Engine 3-16 caution: eca4s81008 never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle bodies synchronization, leading to poor e...

  • Page 102: Engine

    Engine 3-17 caution: eca13450 make sure the crankcase breather hose is routed correctly. 3. Install: • fuel tank refer to "fuel tank" on page 7-1. • seat refer to "general chassis" on page 4- 1. Eas21080 checking the exhaust system the following procedure applies to all of the exhaust pipes and gask...

  • Page 103: Engine

    Engine 3-18 caution: eca13470 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, if dis- tilled water is not available, ...

  • Page 104: Engine

    Engine 3-19 3. Remove: • radiator cap lock bolt “1” • radiator cap “2” warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, o...

  • Page 105: Engine

    Engine 3-20 caution: eca13480 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, if dis- tilled water is not available, ...

  • Page 106: Chassis

    Chassis 3-21 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) note: • while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • be sure to a...

  • Page 107: Chassis

    Chassis 3-22 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. Caution: eca...

  • Page 108: Chassis

    Chassis 3-23 eas21260 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake pad wear indicators “b” almost touch the brake disc → replace the brake pads as a set. Refer to "rear brake" on page 4-27. Eas21280 checking the f...

  • Page 109: Chassis

    Chassis 3-24 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21340 bleeding the hydraulic brake sys- tem warning ewa13100 bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is fault...

  • Page 110: Chassis

    Chassis 3-25 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21370 adjusting the shift pedal 1. Check: • shift pedal position align the center of shift pedal “1” and cen- ter of footrest bracket bolt “2” in a straight line. Inc...

  • Page 111: Chassis

    Chassis 3-26 note: to maintain the proper wheel alignment, adjust both sides evenly. D. Tighten both locknuts to specification. E. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting parts. If t...

  • Page 112: Chassis

    Chassis 3-27 c. Loosen the lower ring nut “4” completely and then tighten it to specification with a steering nut wrench. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any bindi...

  • Page 113: Chassis

    Chassis 3-28 eas21530 checking the front fork 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Check: • inner tube “1” damage/scratches → replace. • oil seal “2” oil leakage → replace. 3. Hold the vehicle upright...

  • Page 114: Chassis

    Chassis 3-29 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, rider, passenger and accessories) and the antic...

  • Page 115: Chassis

    Chassis 3-30 warning ewa14080 • do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • when using a tube tire, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. • to avoid pinc...

  • Page 116: Chassis

    Chassis 3-31 eas21670 checking the wheels the following procedure applies to both of the wheels. 1. Check: • wheel damage/out-of-round → replace. Warning ewa13260 never attempt to make any repairs to the wheel. Note: after a tire or wheel has been changed or replaced, always balance the wheel. Eas21...

  • Page 117: Electrical System

    Electrical system 3-32 eas21750 electrical system eas21790 replacing the headlight bulbs the following procedure applies to both of 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”...

  • Page 118: Electrical System

    Electrical system 3-33.

  • Page 119: Chassis

    4 chassis general chassis....................................................................................4-1 front wheel ............................................................................................4-5 removing the front wheel .........................................................

  • Page 120

    Installing the handlebar .......................................................... 4-40 front fork ............................................................................................. 4-43 removing the front fork legs ............................................... 4-45 disassembling the f...

  • Page 122: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat order job/parts to remove q’ty remarks 1 seat 1 for installation, reverse the removal proce- dure..

  • Page 123: General Chassis

    General chassis 4-2 removing the cowlings order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. 1 left front cowling inner panel (with cowling) 1 2 right front cowling inner panel (with cowling) 1 3 front turn signal light coupler 2 disconnect. 4 front cowling 1 5 front...

  • Page 124: General Chassis

    General chassis 4-3 removing the air filter case and battery order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Fuel tank re...

  • Page 125: General Chassis

    General chassis 4-4 removing the battery box order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tan...

  • Page 126: Front Wheel

    Front wheel 4-5 eas21880 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 brake hose holder 1 2 reflector stay 2 3 reflector 2 4 front brake caliper 2 5 front wheel axle pinch bolt 1 loosen. 6 front wheel axle 1 7 collar 2 8 front wheel 1 9 front brake di...

  • Page 127: Front Wheel

    Front wheel 4-6 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..

  • Page 128: Front Wheel

    Front wheel 4-7 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. Note: place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • r...

  • Page 129: Front Wheel

    Front wheel 4-8 c. Remove the wheel bearings “3” with a gen- eral bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: eca14130 do not contact the wheel bearing inner race “4” or balls “5”. Contact should be made only with the outer race “6”. ...

  • Page 130: Front Wheel

    Front wheel 4-9 note: 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 balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 131: Rear Wheel

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

  • Page 132: Rear Wheel

    Rear wheel 4-11 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 2 4 oil seal 2 5 bearing 2 6 rear wheel drive hub 1 7 rear wheel drive hub damper 6 8 rear wheel 1 for installation, reverse the removal pr...

  • Page 133: Rear Wheel

    Rear wheel 4-12 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 134: Rear Wheel

    Rear wheel 4-13 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. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper “1” note: ...

  • Page 135: Rear Wheel

    Rear wheel 4-14 eas22120 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the rear wheel sprocket. Bent teeth → replace the rear wheel sprocket. 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-lo...

  • Page 136: Front Brake

    Front brake 4-15 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks 1 brake hose holder 1 2 reflector stay 1 3 reflector 1 4 front brake caliper 1 5 brake pad clip 2 6 brake pad pin 1 7 brake pad spring 1 8 brake pad 2 9 bleed screw 1 for installation, reverse ...

  • Page 137: Front Brake

    Front brake 4-16 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 3-24. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm holder 1 3 brake master cylinder reserv...

  • Page 138: Front Brake

    Front brake 4-17 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 master cylinder kit 1 4 spring 1 5 master cylinder 1 6 push rod 1 for assembly, reverse the disassembly pro- cedure..

  • Page 139: Front Brake

    Front brake 4-18 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 3-24. 1 union bolt 2 2 copper washer 5 3 brake hose 2 4 reflector stay 1 5 reflector 1 6 brake caliper 1 for installation, reverse the r...

  • Page 140: Front Brake

    Front brake 4-19 disassembling the front brake calipers order job/parts to remove q’ty remarks 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston seal 8 7 bleed screw 1 for assembly, reverse the disassembly pro- cedure..

  • Page 141: Front Brake

    Front brake 4-20 eas22220 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...

  • Page 142: Front Brake

    Front brake 4-21 d. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment 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 143: Front Brake

    Front brake 4-22 below the minimum level mark “c” → add the recommended brake fluid to the proper level. Refer to "checking the brake fluid level" on page 3-22. 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3...

  • Page 144: Front Brake

    Front brake 4-23 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders “2” scratches/wear → replace the brake cali- per assembly. • brake caliper body “3” cracks/damage → replace the brake cali- per assembly. • brake fluid delivery p...

  • Page 145: Front Brake

    Front brake 4-24 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful che...

  • Page 146: Front Brake

    Front brake 4-25 2. Check: • brake master cylinder kit “1” damage/scratches/wear → replace. 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 a...

  • Page 147: Front Brake

    Front brake 4-26 caution: eca4s81013 when installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection “b” on the brake master cylinder. Note: • while holding the brake hose, tighten the union bolt as shown. • turn the handlebar to the left and right...

  • Page 148: Rear Brake

    Rear brake 4-27 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 shim 4 5 brake pad 2 6 brake screw 1 7 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 149: Rear Brake

    Rear brake 4-28 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 3-24. 1 brake fluid reservoir cap 1 2 rear brake fluid reservoir diaphragm holder 1 3 rear brake fluid reservoir diaphragm 1 4 brak...

  • Page 150: Rear Brake

    Rear brake 4-29 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 spring 1 5 brake master cylinder body 1 for installation, reverse the removal proce- dure..

  • Page 151: Rear Brake

    Rear brake 4-30 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 3-24. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 152: Rear Brake

    Rear brake 4-31 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 shim 4 5 brake pad spring 1 6 brake caliper piston 1 7 brake caliper piston seal 2 8 bleed screw 1 for assembly, reverse the disassembly pro- cedure..

  • Page 153: Rear Brake

    Rear brake 4-32 eas22560 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the enti...

  • Page 154: Rear Brake

    Rear brake 4-33 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. D. Install a new brake pad shim “3” onto each new brake pad “4”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • brake caliper • brake pad pin • screw plug 4...

  • Page 155: Rear Brake

    Rear brake 4-34 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. Warning ewa13550 • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper...

  • Page 156: Rear Brake

    Rear brake 4-35 1. Install: • brake caliper seals • brake caliper piston eas22670 installing the rear brake caliper 1. Install: • brake caliper “1” (temporarily) • copper washers • brake hose “2” • union bolt “3” warning ewa13530 proper brake hose routing is essential to insure safe vehicle operatio...

  • Page 157: Rear Brake

    Rear brake 4-36 7. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-24. Eas22700 removing the rear brake master cylinder 1. Remove: • union bolt “1” • copper washers “2” • brake hose “3” note: to collect any rema...

  • Page 158: Rear Brake

    Rear brake 4-37 eas22730 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components. 1. Install: • master cylinder kit • circlip ea...

  • Page 159: Rear Brake

    Rear brake 4-38 6. Adjust: • rear brake light operation timing refer to "adjusting the rear brake light switch" on page 3-23. Brake pedal position 25.8 mm (1.02 in).

  • Page 160: Handlebar

    Handlebar 4-39 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 1 disconnect. 4 left handlebar switch 1 5 clutch cable 1 6 clutch lever 1 7 right handlebar switch 1 8 throttle grip 1 9 throttle cable 2 10 front...

  • Page 161: Handlebar

    Handlebar 4-40 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” note: blow compressed air between the left handle- bar and the handlebar grip, and gra...

  • Page 162: Handlebar

    Handlebar 4-41 2. Install: • handlebar “1” • upper handlebar holders “2” • upper handlebar holder caps “3” (stan- dard) caution: 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 ...

  • Page 163: Handlebar

    Handlebar 4-42 note: align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 7. Install: • handlebar grip • grip end ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. B. Slide the handlebar grip over the left ...

  • Page 164: Front Fork

    Front fork 4-43 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-5. Front brake calipers refer to "front brake" on page 4-15. 1 front fender 1 2 cap bolt 1 loosen. 3 upper bracket pinch bolt 1 loosen. 4 under bracket...

  • Page 165: Front Fork

    Front fork 4-44 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 washer 1 5 front fork spring 1 6 dust seal 1 7 oil seal clip 1 8 damper rod assembly bolt 1 9 copper washer 1 10 damper rod assembly 1 11 oil seal 1 12 washer 1 13 inner tube...

  • Page 166: Front Fork

    Front fork 4-45 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. Note: place the vehicle on a suitable stand so t...

  • Page 167: Front Fork

    Front fork 4-46 caution: 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 the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2301...

  • Page 168: Front Fork

    Front fork 4-47 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. Note: • when assembling th...

  • Page 169: Front Fork

    Front fork 4-48 5. Install: • washer • oil seal “1” (with the fork seal driver and adapter) caution: eca14220 make sure the numbered side of the oil seal faces up. Note: • before installing the oil seal, lubricate its lips with lithium soap base grease. • lubricate the outer surface of the inner tub...

  • Page 170: Front Fork

    Front fork 4-49 9. Measure: • front fork leg oil level “a” out of specification → correct. Note: • while filling the front fork leg, keep it upright. • after filling, slowly pump the front fork leg up and down to distribute the fork oil. 10. Install: • spring “1” • spring seat “2” • spacer “3” • cap...

  • Page 171: Front Fork

    Front fork 4-50

  • Page 172: Steering Head

    Steering head 4-51 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-5. Front fender refer to "front fork" on page 4-43. Front fork refer to "front fork" on page 4-43. Handlebar refer to "handlebar" on page 4-39. Fro...

  • Page 173: Steering Head

    Steering head 4-52 13 upper bearing 1 14 lower bearing 1 15 dust seal 1 16 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks.

  • Page 174: 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 • upper ring nut • lock washer • rubber washer • lower ring nut “1” (wi...

  • Page 175: 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 “1” • rubber washer “2” • upper ...

  • Page 176: 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 seat refer to "general chassis" on page 4-1. Side cover refer to "general chassis" on page 4-1. Rear brake caliper refer to "rear brake" on page 4-...

  • Page 177: 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 informa- tion. The manufacturer cannot be held respo...

  • Page 178: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-57 • bushings damage/wear → replace. • dust seals damage/wear → replace. • bolts bends/damage/wear → replace. Eas23300 installing the rear shock absorber assembly 1. Lubricate: • collar • bearings • oil seals 2. Install: • rear shock absorber assembly note: when instal...

  • Page 179: Swingarm

    Swingarm 4-58 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks muffler assembly refer to "engine removal" on page 5-1. Catalyst assembly refer to "engine removal" on page 5-1. Exhaust pipe assembly refer to "engine removal" on page 5-1. Rear brake caliper refer to "rear...

  • Page 180: Swingarm

    Swingarm 4-59 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks.

  • Page 181: Swingarm

    Swingarm 4-60 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. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swinga...

  • Page 182: Swingarm

    Swingarm 4-61 eas23380 installing the swingarm 1. Lubricate: • bearings • spacers • dust covers • pivot shaft “1” 2. Install: • swingarm • pivot shaft nut “2” 3. Install: • rear shock absorber assembly refer to "installing the rear shock absorber assembly" on page 4-57. • rear wheel refer to "instal...

  • Page 183: Chain Drive

    Chain drive 4-62 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket cover refer to "engine removal" on page 5-1. Swingarm refer to "removing the swingarm" on page 4-60. 1 rear fender 1 2 drive chain 1 3 chain protector 1 for installation, reverse the ...

  • Page 184: Chain Drive

    Chain drive 4-63 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. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain (with the ...

  • Page 185: Chain Drive

    Chain drive 4-64 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 b...

  • Page 186: Chain Drive

    Chain drive 4-65.

  • Page 187: Engine

    5 engine engine removal ......................................................................................5-1 installing the engine ....................................................................5-6 camshafts......................................................................................

  • Page 188

    Checking the oil nozzles .......................................................... 5-44 assembling the oil pump ............................................................ 5-44 installing the oil pump ............................................................... 5-45 installing the oil strainer ...

  • Page 190: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen refer to "adjusting the shift pedal" on page 3-25. 1 locknut 1 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive sprocket nut 1 6 lock washer 1 7 drive sprocket...

  • Page 191: Engine Removal

    Engine removal 5-2 removing the exhaust pipe order job/parts to remove q’ty remarks 1 exhaust pipe assembly 1 2 exhaust pipe gasket 4 3 catalytic converter pipe 1 4 muffler cover 1 5 muffler 1 for installation, reverse the removal proce- dure..

  • Page 192: Engine Removal

    Engine removal 5-3 disconnecting the leads and hoses order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Fuel tank refer to "...

  • Page 193: Engine Removal

    Engine removal 5-4 5 starter motor lead 1 disconnect. 6 stator coil assembly coupler 1 disconnect. 7 oil level switch connector 1 disconnect. 8 neutral switch coupler 1 disconnect. 9 speed sensor coupler 1 disconnect. For assembly, reverse the removal proce- dure. Disconnecting the leads and hoses o...

  • Page 194: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks 1 right front engine mounting bolt 1 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..

  • Page 195: Engine Removal

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

  • Page 196: Engine Removal

    Engine removal 5-7 note: • before installing, make sure to align the punch mark “a” of the shift shaft with the punch mark “b” of the shift arm. • align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket..

  • Page 197: Camshafts

    Camshafts 5-8 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks battery refer to "general chassis" on page 4-1. Air filter case refer to "general chassis" on page 4-1. Battery box refer to "fuel tank" on page 7-1. Battery box bracket refer to "general chassis...

  • Page 198: 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 timing chain guide (exhaust side) 1 5 intake camshaft cap 3 6 dowel pin 6 7 e...

  • Page 199: 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 th...

  • Page 200: Camshafts

    Camshafts 5-11 8. Remove: • camshaft sprockets eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out o...

  • Page 201: Camshafts

    Camshafts 5-12 note: • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the plastigauge®. D. Remove the camshaft caps and then mea- sure the width of ...

  • Page 202: Camshafts

    Camshafts 5-13 • timing chain guide (top side) “3” damage/wear → replace the defective part(s). Eas23970 checking the timing chain ten- sioner 1. Check: • timing chain tensioner cracks/damage → replace. 2. Check: • one-way cam rough movement → replace the timing chain tensioner assembly. ▼▼▼▼▼▼▼▼▼▼▼...

  • Page 203: Camshafts

    Camshafts 5-14 3. Install: • dowel pins • intake camshaft caps • exhaust camshaft caps note: • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “i1”, “i2”: intake side camshaft cap mark “e1”, “e2”: exhaust side camshaft cap mark • make sur...

  • Page 204: Camshafts

    Camshafts 5-15 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Turn: • crankshaft (several full turns clockwise) 8. Check: • “t” mark “a” make sure the “t” mark on the pickup rotor is aligned with the crankcase mating sure face “b”. • camshaft sprocket match mark “c” make sure the match marks on the cam- shaft sp...

  • Page 205: Cylinder Head

    Cylinder head 5-16 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks intake camshaft refer to "camshafts" on page 5-8. Exhaust camshaft refer to "camshafts" on page 5-8. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the remo...

  • Page 206: Cylinder Head

    Cylinder head 5-17 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts note: • 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: • c...

  • Page 207: Cylinder Head

    Cylinder head 5-18 note: pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head bolts “1” – “10” • cylinder head bolts “11” “12” note: • lubricate the cylinder head bolts with engine oil. • tighten the cylinder head bolts in the proper tightening sequence as shown and tor...

  • Page 208: Valves and Valve Springs

    Valves and valve springs 5-19 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 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve upper spring seat 8 5...

  • Page 209: Valves and Valve Springs

    Valves and valve springs 5-20 for installation, reverse the removal proce- dure. Removing the valves and valve springs order job/parts to remove q’ty remarks.

  • Page 210: 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. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve l...

  • Page 211: Valves and Valve Springs

    Valves and valve springs 5-22 eas24290 checking the valves and valve guides the following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide rem...

  • Page 212: 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. Mea...

  • Page 213: Valves and Valve Springs

    Valves and valve springs 5-24 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. 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 impression. D. Measure the valve seat width. N...

  • Page 214: Valves and Valve Springs

    Valves and valve springs 5-25 h. Install the valve into the cylinder head. I. Press the valve through the valve guide and onto the valve seat to make a clear impression. J. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲▲▲▲▲...

  • Page 215: Valves and Valve Springs

    Valves and valve springs 5-26 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head....

  • Page 216: Valves and Valve Springs

    Valves and valve springs 5-27 4. Install: • valve cotters “1” note: install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attach- ment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a so...

  • Page 217: 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 seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Coolant drain refer to "changing the coolant" on page 3-...

  • Page 218: Generator and Starter Clutch

    Generator and starter clutch 5-29 11 idler gear shaft 1 12 idler gear 1 13 starter clutch drive gear 1 for installation, reverse the removal proce- dure. Removing the generator and starter clutch order job/parts to remove q’ty remarks.

  • Page 219: Generator and Starter Clutch

    Generator and starter clutch 5-30 eas24490 removing the generator 1. Remove: • seat refer to "general chassis" on page 4- 1. • fuel tank refer to "fuel tank" on page 7-1. 2. Drain: • coolant refer to "changing the coolant" on page 3-18. • engine oil refer to "changing the engine oil" on page 3-12. 3...

  • Page 220: Generator and Starter Clutch

    Generator and starter clutch 5-31 eas24570 checking the starter clutch 1. Check: • starter clutch rollers “1” damage/wear → replace. 2. Check: • starter clutch idle gear “1” • starter clutch drive gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s ...

  • Page 221: Generator and Starter Clutch

    Generator and starter clutch 5-32 eas24500 installing the generator 1. Install: • generator rotor • washer • generator rotor bolt note: • clean the tapered portion of the crankshaft and the generator rotor hub. • replace the washer with a new one. 2. Tighten: • generator rotor bolt “1” note: • while...

  • Page 222: Pickup Rotor

    Pickup rotor 5-33 eas4s81015 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Fuel ...

  • Page 223: Pickup Rotor

    Pickup rotor 5-34 eas4s81041 removing the pickup rotor 1. Remove: • pickup rotor cover “1” note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3”...

  • Page 224: Pickup Rotor

    Pickup rotor 5-35 3. Apply: • sealant (onto the crankshaft position sensor lead grommet) 4. Install: • pickup rotor cover gasket • pickup rotor cover note: • when installing the pickup rotor cover, align the timing chain guide (intake side) pin “1” with the hole “2” in the pickup rotor cover. • tigh...

  • Page 225: Electric Starter

    Electric starter 5-36 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1...

  • Page 226: 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 o-ring 2 10 brush holder 1 11 armature assembly 1 12 starter mot...

  • Page 227: 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 228: 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 seat “1” 2. Install: • armature “2” • o-ring “3” note: align the tab “a” on the brush sea...

  • Page 229: Oil Pump

    Oil pump 5-40 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-12. Coolant drain. Refer to "changing the coolant" on page 3-18. Exhaust pipe assembly refer to "engine removal" on page 5-1. Water ...

  • Page 230: Oil Pump

    Oil pump 5-41 13 relief valve assembly 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks.

  • Page 231: 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..

  • Page 232: Oil Pump

    Oil pump 5-43 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan gasket • dowel pins note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas24960 checking the oil pump 1. C...

  • Page 233: 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 compressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas4s810...

  • Page 234: Oil Pump

    Oil pump 5-45 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 • gear cover • oil pump • oil pump bolts caution: eca4s81018 after tightening the bolts, make sure the oil pump turns smoothly. Eas25040 ins...

  • Page 235: Clutch

    Clutch 5-46 eas25060 clutch * yamaha bond no.1215 (three bond no.1215®) removing the clutch cover order job/parts to remove q’ty remarks engine oil drain refer to "changing the engine oil" on page 3-12. Coolant drain refer to "changing the coolant" on page 3-18. 1 coolant hose 1 2 clutch cable 1 3 c...

  • Page 236: Clutch

    Clutch 5-47 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 2 2 washer 1 3 pull lever 1 4 pull lever spring 1 5 washer 1 6 oil seal 1 7 bearing 2 8 pull lever shaft 1 9 washer 1 for installation, reverse the removal proce- dure..

  • Page 237: Clutch

    Clutch 5-48 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 6 6 clutch plate 1 7 7 friction plate 2 2 8 clutch plate 2 1 9 clutch boss nut 1 10 lock washer 1 11 clutch boss 1 12 thrust plate 1 for assemb...

  • Page 238: Clutch

    Clutch 5-49 eas25070 removing the clutch 1. Remove: • clutch cable holder “1” • clutch cover “2” • gasket note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compres...

  • Page 239: Clutch

    Clutch 5-50 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 240: Clutch

    Clutch 5-51 note: pitting on the clutch boss splines will cause erratic clutch operation. Eas25170 checking the pressure plate 1. Check: • pressure plate “1” cracks/damage → replace. • bearing “2” damage/wear → replace. Eas25220 checking the pull lever shaft and pull rod 1. Check: • pull lever shaft...

  • Page 241: Clutch

    Clutch 5-52 5. Install: • friction plates • clutch plates note: first, install a friction plate and then alternate between a clutch plate and a friction plate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a install the clutch plate and friction plate as shown in the illustration. Clutch plate “1”: t=2.3 mm (0.09 ...

  • Page 242: Shift Shaft

    Shift shaft 5-53 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks drive sprocket cover refer to "engine removal" on page 5-1. 1 shift shaft cover 1 2 shift shaft cover gasket 1 3 dowel pin 2 4 oil seal 1 5 shift shaft 1 6 shift shaft spring 1 7 c...

  • Page 243: Shift Shaft

    Shift shaft 5-54 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace the stopper lever. Eas2...

  • Page 244: Crankcase

    Crankcase 5-55 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. Generator refer to "generator and starter clutch" on page 5-28. Starter clutch refer to "generator and ...

  • Page 245: Crankcase

    Crankcase 5-56 8 plate 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 246: Crankcase

    Crankcase 5-57 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerica...

  • Page 247: Crankcase

    Crankcase 5-58 eas25660 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) 2. Apply: • sealant (onto the crankcase mating surfaces) note: do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not app...

  • Page 248: Crankcase

    Crankcase 5-59.

  • Page 249: Crankshaft

    Crankshaft 5-60 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to "crankcase" on page 5-55. 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 250: Crankshaft

    Crankshaft 5-61 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to "crankcase" on page 5-55. Connecting rods caps refer to "crankshaft" on page 5-60. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft journal upper bearing 5 for installation, re...

  • Page 251: Crankshaft

    Crankshaft 5-62 eas26030 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap “1” • big end bearings note: identify the position of each bigend bearing so that it can be reinstalled in its original place. ...

  • Page 252: Crankshaft

    Crankshaft 5-63 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 t...

  • Page 253: Crankshaft

    Crankshaft 5-64 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s...

  • Page 254: Crankshaft

    Crankshaft 5-65 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 clear- ance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼...

  • Page 255: Crankshaft

    Crankshaft 5-66 e. Tighten the connecting rod bolts. Note: install by carrying out the following procedures in order to assemble in the most suitable con- dition. • connecting rod bolts f. Replace the connecting rod bolts with new ones. G. Clean the connecting rod bolts. H. After installing the big ...

  • Page 256: Crankshaft

    Crankshaft 5-67 p. After the installation, check that the section show “a” is flush with each other by touch- ing the surface. • side machined face “a” warning ewa4s81014 • when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a...

  • Page 257: Crankshaft

    Crankshaft 5-68 eas26190 installing the connecting rod and piston the following procedure applies to all of the connecting 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” note: be sure to install the piston rings...

  • Page 258: Crankshaft

    Crankshaft 5-69 6. Install: • big end bearings • connecting rod cap (onto the connecting rod) note: • align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • make sure that the characters “a” on both the connecting rod and connecting rod cap a...

  • Page 259: Crankshaft

    Crankshaft 5-70 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ caution: eca14980 tighten the connecting rod bolts using the plastic-region tightening angle method. A. Clean the connecting rod bolts. B. Tighten the connecting rod bolts. C. Put a mark “1” on the corner of the con- necting rod bolt “2” and the connect...

  • Page 260: Crankshaft

    Crankshaft 5-71 caution: eca4s81028 do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal- to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 261: Crankshaft

    Crankshaft 5-72 g. Remove the lower crankcase and the crankshaft journal lower bearings. H. Measure the compressed plastigauge® width “c” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, select replacement crankshaft journal b...

  • Page 262: Crankshaft

    Crankshaft 5-73 • be sure to install each crankshaft journal upper bearing in its original place. 2. Install: • crankshaft 3. Install: • lower crankcase refer to "crankcase" on page 5-55..

  • Page 263: Transmission

    Transmission 5-74 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase 1 refer to "crankcase" on page 5-55. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 shift drum retainer 1 6 shift fork guide ...

  • Page 264: Transmission

    Transmission 5-75 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 bearing 1 2 2nd pinion gear 1 3 toothed lock washer 1 4 toothed lock washer retainer 1 5 6th pinion gear 1 6 collar 1 7 washer 1 8 circlip 1 9 3rd pinion gear 1 10 circlip 1 11 washer 1 12 5th pinion gear...

  • Page 265: Transmission

    Transmission 5-76 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 collar 1 8 3rd wheel gear 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 266: Transmission

    Transmission 5-77 for installation, reverse the removal proce- dure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks.

  • Page 267: Transmission

    Transmission 5-78 eas26250 removing the transmission 1. Remove: • 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 the bolts until they conta...

  • Page 268: Transmission

    Transmission 5-79 • shift drum bearing “2” damage/pitting → replace the shift drum assembly. 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 ...

  • Page 269: Transmission

    Transmission 5-80 • install shift fork-c into the groove in the 3rd and 4th pinion gear on the main axle. 3. Install: • shift fork-r “1” • shift fork-l “2” • drive axle “3” • shift fork guide bar • shift drum retainer note: • install shift fork-l into the groove in the 6th wheel gear and shift fork-...

  • Page 270: Transmission

    Transmission 5-81.

  • Page 271: Cooling System

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

  • Page 272: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Fuel tank refer to "...

  • Page 273: Radiator

    Radiator 6-2 13 coolant reservoir drain hose 1 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to remove q’ty remarks.

  • Page 274: Radiator

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

  • Page 275: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks radiator assembly refer to "radiator" on page 6-1. Coolant reservoir refer to "radiator" on page 6-1. Engine oil drain. Refer to "changing the engine oil" on page 3-12. 1 oil cooler outlet hose 1 2 unio...

  • Page 276: 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 277: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. Fuel tank refe...

  • Page 278: 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 water. D. Whi...

  • Page 279: Thermostat

    Thermostat 6-8 5. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to "checking the radiator" on page 6-3..

  • Page 280: 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 3-18. 1 radiator outlet ...

  • Page 281: 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 impeller shaft 1 4 circlip 1 5 water pump seal 1 6 oil seal 1 7 bearing 1 8 water pump housing 1 9 o-ring 1 10 copper washer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 282: 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” note: 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) note...

  • Page 283: Water Pump

    Water pump 6-12 3. Check: • water pump outlet pipe • radiator outlet hose cracks/damage/wear → replace. Eas26560 assembling the water pump 1. Install: • bearing • oil seal “1” (into the water pump housing “2”) note: • before installing the oil seal, apply tap water or coolant onto its out surface. •...

  • Page 284: Water Pump

    Water pump 6-13 5. Install: • impeller shaft • circlip • o-ring • water pump cover eas26590 installing the water pump 1. Install: • o-ring • copper washer • water pump assembly “1” note: • align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft. • lubricate the o-ring ...

  • Page 285: Fuel System

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

  • Page 286: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1. 1 fuel hose 1 2 f...

  • Page 287: 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 return hose • fuel hose caution: eca4s81003 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel...

  • Page 288: Fuel Tank

    Fuel tank 7-3 eas4s81001 installing the fuel tank 1. Install: • fuel hose caution: eca4s81001 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed. Note: install th...

  • Page 289: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel refer to "general chassis" on page 4-1. Right front cowling inner panel refer to "general chassis" on page 4-1....

  • Page 290: Throttle Bodies

    Throttle bodies 7-5 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 cylinder #1 injector coupler 1 disconnect. 4 cylinder #2 injector coupler 1 disconnect. 5 cylinder #3 injector coupl...

  • Page 291: Throttle Bodies

    Throttle bodies 7-6 eas26980 checking the injectors 1. Check: • injectors damage → replace. Eas26990 checking the throttle bodies 1. Check: • throttle bodies cracks/damage → replace the throttle bodies as a set. 2. Check: • fuel passages obstructions → clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash t...

  • Page 292: Throttle Bodies

    Throttle bodies 7-7 c. Measure the throttle position sensor volt- age. D. Adjust the throttle position sensor angle so that the voltage is within the specified range. E. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • ...

  • Page 293: Throttle Bodies

    Throttle bodies 7-8.

  • Page 294: Air Induction System

    Air induction system 7-9 eas27040 air induction system.

  • Page 295: Air Induction System

    Air induction system 7-10 1. Air cut-off valve 2. Reed valve 3. To air filter case a. To cylinder #1 and #2 b. To cylinder #3 and #4.

  • Page 296: Air Induction System

    Air induction system 7-11 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer t...

  • Page 297: Air Induction System

    Air induction system 7-12 eas27060 checking the air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the r...

  • Page 298: Air Induction System

    Air induction system 7-13.

  • Page 299: Electrical System

    8 electrical system ignition system.......................................................................................8-1 circuit diagram................................................................................8-1 troubleshooting ..............................................................

  • Page 300

    Checking the relay unit (diode) .............................................. 8-72 checking the spark plug caps ................................................ 8-73 checking the ignition coils ...................................................... 8-74 checking the crankshaft position sensor ........

  • Page 302: Ignition System

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

  • Page 303: Ignition System

    Ignition system 8-2 1. Main switch 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 17.Lean angle sensor 18.Crankshaft position sensor 21.Ecu (engine control unit) 28.Cylinder-#1/#4 ignition coil 29.Cylinder-#2/#3 ignition coil 30.Spark plug 46.Engine s...

  • Page 304: Ignition System

    Ignition system 8-3 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the f...

  • Page 305: Ignition System

    Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the engine stop switch. Refer to "checking the switches" on page 8-63. Replace the right handlebar switch. 9. Check the neutral switch. Refer to "checking the switches" on page 8-63. Replace the neutra...

  • Page 306: Electric Starting System

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

  • Page 307: Electric Starting System

    Electric starting system 8-6 1. Main switch 6. Main fuse 7. Starter relay 8. Starter motor 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 46.Engine stop switch 47.Start switch 53.Ignition fuse 60.Clutch switch.

  • Page 308: 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 309: Electric Starting System

    Electric starting system 8-8 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Left side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the...

  • Page 310: Electric Starting System

    Electric starting system 8-9 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the neutral switch. Refer to "checking the switches" on page 8-63. Replace the neutral switch. 9. Check the sidestand switch. Refer to "checking the switches" on page 8-63. Replace the sidestand switch. 10.Check ...

  • Page 311: Electric Starting System

    Electric starting system 8-10

  • Page 312: Charging System

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

  • Page 313: Charging System

    Charging system 8-12 2. Ac magneto 3. Rectifier/regulator 6. Main fuse 9. Battery.

  • Page 314: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to "checking the fuses" on...

  • Page 315: Charging System

    Charging system 8-14.

  • Page 316: Lighting System

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

  • Page 317: Lighting System

    Lighting system 8-16 1. Main switch 6. Main fuse 9. Battery 21.Ecu (engine control unit) 39.High beam indicator light 52.Headlight fuse 54.Tail fuse 57.License plate light 58.Tail/brake light 61.Dimmer switch 66.Headlight relay 67.Headlight (high beam) 68.Headlight (low beam).

  • Page 318: 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. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Side cover ng → ok ↓ ng ...

  • Page 319: Lighting System

    Lighting system 8-18 ng → ok ↓ 7. Check the entire lighting system’s wiring. Refer to "circuit diagram" on page 8-15. Properly connect or repair the lighting system’s wiring. This circuit is ok..

  • Page 320: Signaling System

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

  • Page 321: Signaling System

    Signaling system 8-20 1. Main switch 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 12.Neutral switch 13.Fuel pump 21.Ecu (engine control unit) 32.Fuel level warning light 33.Oil level warning light 34.Neutral indicator light 35.Tachometer 36.Multi-function meter 40.Left turn signal indic...

  • Page 322: 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. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Side cover ng → ok ...

  • Page 323: Signaling System

    Signaling system 8-22 ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to "circuit diagram" on page 8-19. Properl...

  • Page 324: Signaling System

    Signaling system 8-23 ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the hazard switch. Refer to "checking the switches" on page 8-63. Replace the left handlebar switch. 4. Check the turn signal/hazard relay. Refer to "checking the rel...

  • Page 325: Signaling System

    Signaling system 8-24 ng → ok ↓ the oil level warning light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come. Ng → ok ↓ ng → ok ↓ 4. Check the entire signaling system’s wiring. Refer to "circuit diagram" on page 8-19. Properly connect or repair the signal- ing ...

  • Page 326: Signaling System

    Signaling system 8-25 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ note: repair or replace if there is an open or short circuit. • between ecu coupler and meter assembly. (yellow/blue-yellow/blue) 3. Check the entire signaling system’s wiring. Refer to "circuit diagram" on page 8-...

  • Page 327: Signaling System

    Signaling system 8-26.

  • Page 328: Cooling System

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

  • Page 329: Cooling System

    Cooling system 8-28 1. Main switch 6. Main fuse 9. Battery 20.Coolant temperature sensor 21.Ecu (engine control unit) 36.Multi-function meter 48.Radiator fan motor fuse 49.Radiator fan motor relay 50.Radiator fan motor 53.Ignition fuse.

  • Page 330: Cooling System

    Cooling system 8-29 eas27320 troubleshooting note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and radiator fan motor)...

  • Page 331: Cooling System

    Cooling system 8-30

  • Page 332: Fuel Injection System

    Fuel injection system 8-31 eas27330 fuel injection system eas27340 circuit diagram.

  • Page 333: Fuel Injection System

    Fuel injection system 8-32 1. Main switch 5. Fuel injection system fuse 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 13.Fuel pump 14.Throttle position sensor 15.Intake air pressure sensor 16.O 2 sensor 17.Lean angle sensor 18.Crankshaft position sen...

  • Page 334: Fuel Injection System

    Fuel injection system 8-33 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 engine under substitute char...

  • Page 335: Fuel Injection System

    Fuel injection system 8-34 eas27362 fail-safe actions (substitute characteristics operation control) if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc-...

  • Page 336: Fuel Injection System

    Fuel injection system 8-35 communication error with the meter 34 ignition coil (#2, #3) (faulty ignition) malfunction detected in the pri- mary wire of the ignition coil (#2, #3). Able (depending on the num- ber of faulty cylinders) able (depending on the num- ber of faulty cylinders) 41 lean angle ...

  • Page 337: Fuel Injection System

    Fuel injection system 8-36 eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the system with the malfunction...

  • Page 338: Fuel Injection System

    Fuel injection system 8-37 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 339: Fuel Injection System

    Fuel injection system 8-38 note: if the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “off” to cancel the diagnostic mode. Diagnostic code table fault code no. Symptom probable cause of malfunction diagnostic code no. 12 no normal signals a...

  • Page 340: Fuel Injection System

    Fuel injection system 8-39 30 latch up detected. No normal signal is received from the lean angle sensor. • the vehicle has overturned. • defective lean angle sensor. • malfunction in ecu. • improperly installed lean angle sensor. 08 33 malfunction detected in the primary wire of the ignition coil (...

  • Page 341: Fuel Injection System

    Fuel injection system 8-40 sensor operation table er-3 data from the ecu cannot be received correctly. • open or short circuit in communication line. • malfunction in meter unit. • malfunction in ecu. — er-4 non-registered data has been received from the meter. • open or short circuit in communicati...

  • Page 342: Fuel Injection System

    Fuel injection system 8-41 * if it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference). 60 eeprom fault code display — • not fault 00 • fault detected 01 to 02 (fault detection cyl- inder) 01: #1 and #4 02: #2 and #3 • (if...

  • Page 343: Fuel Injection System

    Fuel injection system 8-42 actuator operation table diag- nostic code no. Item actuation checking method 30 ignition coil #1/#4 actuates the ignition coils #1, #4 for five times every sec- ond. Illuminates the engine trou- ble warning light. Check the spark five times. • connect an ignition checker....

  • Page 344: Fuel Injection System

    Fuel injection system 8-43 eas27451 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfu...

  • Page 345: Fuel Injection System

    Fuel injection system 8-44 2 open or short circuit in wire harness and/or sub lead. • repair or replace if there is an open or short circuit. • between intake air pressure sensor coupler and ecu cou- pler (black/blue–black/blue) (pink/white–pink/white) (blue–blue) turning the main switch on. 3 defec...

  • Page 346: Fuel Injection System

    Fuel injection system 8-45 fault code no. 15 symptom throttle position sensor-open or short circuit detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 installed condition of throttle position sensor. Ch...

  • Page 347: Fuel Injection System

    Fuel injection system 8-46 fault code no. 19 symptom open circuit is detected in the input line from the side- stand switch to the ecu. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • ma...

  • Page 348: Fuel Injection System

    Fuel injection system 8-47 fault code no. 22 symptom intake air temperature sensor-open or short circuit detected. Diagnostic code no. 05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 installed condition of intake air tem- pe...

  • Page 349: Fuel Injection System

    Fuel injection system 8-48 fault code no. 30 symptom latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 the vehicle has overturned. Raise the v...

  • Page 350: Fuel Injection System

    Fuel injection system 8-49 fault code no. 34 symptom malfunction detected in the primary wire of the ignition coil (#2/#3). Diagnostic code no. 31 ignition coil (#2/#3) order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • ignition ...

  • Page 351: Fuel Injection System

    Fuel injection system 8-50 fault code no. 42 symptom ano normal signals are received from the speed sensor. Bopen or short circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or maintenance job reinstate-...

  • Page 352: Fuel Injection System

    Fuel injection system 8-51 fault code no. 43 symptom the ecu is unable to monitor the battery voltage. Diagnostic code no. 50 fuel injection system relay order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • fuel injection system re...

  • Page 353: Fuel Injection System

    Fuel injection system 8-52 fault code no. 46 symptom power supply to the fi system relay is not normal. Diagnostic monitor- ing code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector. • main wire harness ecu coupler • chec...

  • Page 354: Fuel Injection System

    Fuel injection system 8-53 fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • main wire harness ecu coupler • main wire harness meter coupl...

  • Page 355: Fuel Injection System

    Fuel injection system 8-54 fault code no. Er-3 symptom data from the ecu cannot be received correctly. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • main wire harness ecu coupler • main wire harness m...

  • Page 356: Fuel Pump System

    Fuel pump system 8-55 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 357: Fuel Pump System

    Fuel pump system 8-56 1. Main switch 5. Fuel injection system fuse 7. Main fuse 9. Battery 10.Starting circuit cut-off relay 13.Fuel pump 21.Ecu (engine control unit) 46.Engine stop switch 53.Ignition fuse.

  • Page 358: Fuel Pump System

    Fuel pump system 8-57 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel3 3. Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition...

  • Page 359: Fuel Pump System

    Fuel pump system 8-58.

  • Page 360: Electrical Components

    Electrical components 8-59 eas27970 electrical components.

  • Page 361: Electrical Components

    Electrical components 8-60 1. Main switch 2. Front brake light switch 3. Starter relay 4. Battery 5. Fuse box 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Radiator fan motor 11.Horn 12.Ignition coil.

  • Page 362: Electrical Components

    Electrical components 8-61.

  • Page 363: Electrical Components

    Electrical components 8-62 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air temperature sensor 4. Fuel pump 5. Intake air pressure sensor 6. Ecu (engine control unit) 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Dimmer relay 10.Radiator fan motor relay 11.Turn sig...

  • Page 364: Electrical Components

    Electrical components 8-63 eas27980 checking the switches.

  • Page 365: Electrical Components

    Electrical components 8-64 1. Main switch 2. Horn switch 3. Dimmer switch 4. Turn signal switch 5. Hazard switch 6. Clutch switch 7. Sidestand switch 8. Engine stop switch 9. Front brake light switch 10.Start switch 11.Oil level switch 12.Neutral switch 13.Rear brake light switch 14.Fuse 15.Left han...

  • Page 366: Electrical Components

    Electrical components 8-65 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. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 367: Electrical Components

    Electrical components 8-66 eas27990 checking the bulbs and bulb sock- ets check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. N...

  • Page 368: Electrical Components

    Electrical components 8-67 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in ...

  • Page 369: Electrical Components

    Electrical components 8-68 d. If the fuse immediately blows again, check the electrical circuit. Warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, caus...

  • Page 370: Electrical Components

    Electrical components 8-69 2. Disconnect: • battery leads (from the battery terminals) caution: eca13640 first, disconnect the negative battery lead “1”, and then positive battery lead “2”. 3. Remove: • battery 4. Check: • battery charge ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to t...

  • Page 371: Electrical Components

    Electrical components 8-70 note: voltage should be measured 30 minutes after the machine is stopped. B. Connect a charged and amp meter to the battery and start charging. Note: set the charging voltage at 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery wil...

  • Page 372: Electrical Components

    Electrical components 8-71 9. Lubricate: • battery terminals 10. Install: • fuel tank • front cowling inner panel • seat eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect the relay from the...

  • Page 373: Electrical Components

    Electrical components 8-72 radiator fan motor eas4s81032 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/haz- ard relay coupler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 374: Electrical Components

    Electrical components 8-73 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continu- ity. ▲▲▲▲▲▲...

  • Page 375: Electrical Components

    Electrical components 8-74 eas28100 checking the ignition coils the following procedure applies to all of the ignition coils. 1. Check: • primary coil resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals...

  • Page 376: Electrical Components

    Electrical components 8-75 e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28120 checking the crankshaft position sensor 1. Disconnect: • crankshaft position sensor coupler (from the wire harness) 2. Che...

  • Page 377: Electrical Components

    Electrical components 8-76 • this check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. B. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • stator coil resistance out of specification → replace the stator coil. Eas28150 che...

  • Page 378: Electrical Components

    Electrical components 8-77 eas28180 checking the horn 1. Check: • horn resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn terminals. B. Connect the pocket tester ( Ω × 1) to the horn terminals. C. Measure the horn resistance. ▲▲▲▲▲▲▲▲...

  • Page 379: Electrical Components

    Electrical components 8-78 b. Measure the pickup coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28230 checking the fuel sender 1. Remove: • fuel tank 2. Disconnect: • fuel pump coupler • fuel sender coupler (from the wire harness) 3. Remove: • fuel pump (from the fuel tank) 4. Check: • fuel send...

  • Page 380: Electrical Components

    Electrical components 8-79 eas28250 checking the radiator fan motor 1. Check: • radiator fan motor faulty/rough movement → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. B. Connect the battery (dc 12 v) as shown. C. Measure the radiator fa...

  • Page 381: Electrical Components

    Electrical components 8-80 b. Check the throttle position sensor maxi- mum resistance. Out of specification → replace the throttle position sensor. C. Connect the pocket tester ( Ω × 1k) to the throttle position sensor as shown. D. While slowly turning the throttle position sensor shaft, check that ...

  • Page 382: Electrical Components

    Electrical components 8-81 b. Measure the fuel pump resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air induction system so...

  • Page 383: Electrical Components

    Electrical components 8-82 2. Check: • intake air temperature sensor resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. B. Measure the intake air temperature sensor resistance. ▲▲▲▲...

  • Page 384: Electrical Components

    Electrical components 8-83.

  • Page 385: Troubleshooting

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

  • Page 386: Troubleshooting

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

  • Page 387: Troubleshooting

    Troubleshooting 9-2 • improper throttle cable free play • flooded throttle body • faulty air induction system electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electro...

  • Page 388: Troubleshooting

    Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump • thermos...

  • Page 389: Troubleshooting

    Troubleshooting 9-4 • faulty rear shock absorber spring • leaking oil or gas 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose wheel axle • excessive whe...

  • Page 390

    Eas28740 wiring diagram fzs6w/fzs6wc 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Main fuse 7. Starter relay 8. Starter motor 9. Battery 10. Starting circuit cut-off relay 11. Sidestand switch 12. Neutral switch 13. Fuel pump 14. Throttle positi...

  • Page 392

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

  • Page 393

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