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Yamaha MT-01 T 2005 Service Manual

Other manuals for MT-01 T 2005: Service Manual

Summary of MT-01 T 2005

  • Page 1

    2005 service manual mt-01(t) 5yu1-ae1.

  • Page 2

    Eas20040 mt-01(t) 2005 service manual ©2004 by yamaha motor co., ltd. First edition, december 2004 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

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

  • Page 4: How to Use This Manual

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

  • Page 5: Symbols

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 lt new t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool ...

  • Page 6: Table of Contents

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

  • Page 7: Gen

    Gen info 1.

  • Page 8: 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 on the right side of the steering head pipe. Eas20150 model label the model label “1” is affixed to the lead holder under the seat. This information will be needed to or...

  • Page 11: Features

    Features 1-2 eas20170 features et5yu1009 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sy...

  • Page 12: Features

    Features 1-3 et5yu1010 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kpa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 13: Features

    Features 1-4 et5yu1011 instrument functions multifunction display warning ew5yu1005 be sure to stop the vehicle before making any setting changes to the multifunction dis- play. The multifunction display is equipped with the following: • a speedometer (which shows the riding speed) • a tachometer (w...

  • Page 14: Features

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

  • Page 15: Features

    Features 1-6 the brightness can be adjusted for the following: • the tachometer panel (item number “1”) • the lcd (item number “2”) • the tachometer needle (item number “3”) select the brightness control mode as follows. 1. Turn the key to “off”. 2. Push and hold the “select” button. 3. Turn the key...

  • Page 16: Important Information

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

  • Page 17: Important Information

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

  • Page 18: Checking The Connections

    Checking the connections 1-9 eas20250 checking the connections 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 sev- er...

  • 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 inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 20: Special Tools

    Special tools 1-11 compression gauge 90890-03081 engine compression tester yu-33223 3-10 extension 90890-04082 3-10 oil filter wrench 90890-01426 yu-38411 3-12 steering nut wrench 90890-01403 spanner wrench yu-33975 3-26, 4-59 vacuum/pressure pump gauge set 90890-06756 4-5, 6-9 fork spring compresso...

  • Page 21: Special Tools

    Special tools 1-12 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-53, 4-55 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-53, 4-55 ring nut wrench 90890-01268 spanner wrench yu-01268 4-59 pivot shaft wrench 90890-01485 frame moun...

  • Page 22: Special Tools

    Special tools 1-13 valve guide reamer (ø6) 90890-04066 valve guide reamer (6.0 mm) ym-04066 5-36 piston pin puller set 90890-01304 piston pin puller yu-01304 5-42 universal clutch holder 90890-04086 ym-91042 5-55, 5-58 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-55, 5-57, 5-68, 5-69...

  • Page 23: Special Tools

    Special tools 1-14 fuel pressure adapter 90890-03176 ym-03176 6-9 digital circuit tester 90890-03174 6-10 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 7-100 tool name/tool no. Illustration reference pages.

  • Page 24: Spec

    Spec 2.

  • Page 25: Specifications

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

  • Page 27: General Specifications

    General specifications 2-1 eas20280 general specifications model model 5yu1 (europe) 5yu2 (aus) dimensions overall length 2185 mm (86.0 in) overall width 790 mm (31.1 in) overall height 1160 mm (45.7 in) seat height 825 mm (32.5 in) wheelbase 1525 mm (60.0 in) ground clearance 143 mm (5.63 in) minim...

  • Page 28: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type air cooled 4-stroke, ohv displacement 1670.0 cm³ (101.90 cu.In) cylinder arrangement v-type 2 cylinders bore × stroke 97.0 × 113.0 mm (3.82 × 4.45 in) compression ratio 8.40 :1 standard compression pressure (at sea level) 12...

  • Page 29: Engine Specifications

    Engine specifications 2-3 spark plug (s) manufacturer/model ngk/dpr7ea-9 manufacturer/model denso/x22epr-u9 spark plug gap 0.8–0.9 mm (0.031–0.035 in) cylinder head volume 98.60–103.60 cm³ (6.02–6.32 cu.In) warpage limit* 0.03 mm (0.0012 in) camshaft drive system gear drive camshaft to crankcase cle...

  • Page 30: Engine Specifications

    Engine specifications 2-4 valve, valve seat, valve guide valve clearance (cold) intake 0.00–0.04 mm (0.0000–0.0016 in) exhaust 0.00–0.04 mm (0.0000–0.0016 in) valve dimensions valve head diameter a (intake) 33.90–34.10 mm (1.3346–1.3425 in) valve head diameter a (exhaust) 27.90–28.10 mm (1.0984–1.10...

  • Page 31: Engine Specifications

    Engine specifications 2-5 valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) limit 0.100 mm (0.0039 in) valve stem runout 0.010 mm (0.0004 in) valve spring inner spr...

  • Page 32: Engine Specifications

    Engine specifications 2-6 installed compression spring force (exhaust) 139.00–161.00 n (31.25–36.19 lb) (14.17– 16.42 kgf) spring tilt (intake) 2.5°/1.9 mm (2.5°/0.075 in) spring tilt (exhaust) 2.5°/1.9 mm (2.5°/0.075 in) winding direction (intake) clockwise winding direction (exhaust) clockwise val...

  • Page 33: Engine Specifications

    Engine specifications 2-7 piston ring top ring ring type barrel dimensions (b × t) 1.20 × 3.80 mm (0.05 × 0.15 in) end gap (installed) 0.30–0.50 mm (0.01–0.02 in) limit 0.70 mm (0.0276 in) ring side clearance 0.030–0.080 mm (0.0012–0.0032 in) limit 0.120 mm (0.0047 in) 2nd ring ring type taper dimen...

  • Page 34: Engine Specifications

    Engine specifications 2-8 crankshaft width a 132.80–133.20 mm (5.23–5.24 in) runout limit c 0.040 mm (0.0016 in) big end side clearance d 0.320–0.474 mm (0.0126–0.0187 in) big end radial clearance e 0.037–0.074 mm (0.0015–0.0029 in) limit 0.09 mm (0.0035 in) journal oil clearance (using plastigauge ...

  • Page 35: Engine Specifications

    Engine specifications 2-9 shifting mechanism shift mechanism type guide bar shift fork guide bar bending limit 0.025 mm (0.0010 in) shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in) air filter air filter element oil-coated paper element fuel pump pump type electrical model/manufacturer 5yu/denso ...

  • Page 36: Chassis Specifications

    Chassis specifications 2-10 eas20300 chassis specifications chassis frame type double cradle caster angle 25.00° trail 103.0 mm (4.06 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral...

  • Page 37: Chassis Specifications

    Chassis specifications 2-11 front brake type dual disc brake operation right hand operation front brake lever free play 7.0–19.0 mm (0.28–0.75 in) front disc brake disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) brake disc thickness limit 4.0 mm (0.16 in) brake disc deflection lim...

  • Page 38: Chassis Specifications

    Chassis specifications 2-12 front suspension type telescopic fork spring/shock absorber type coil spring/oil damper front fork travel 120.0 mm (4.72 in) fork spring free length 251.0 mm (9.88 in) limit 246.0 mm (9.69 in) collar length 100.8 mm (3.97 in) installed length 235.0 mm (9.25 in) spring rat...

  • Page 39: Chassis Specifications

    Chassis specifications 2-13 rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 50.0 mm (1.97 in) spring free length 159.5 mm (6.28 in) limit 156.0 mm (6.14 in) installed length 150.0 mm (5.91 in) spring rate k1 18...

  • Page 40: Electrical Specifications

    Electrical specifications 2-14 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) advancer type electric ignition timing (b.T.D.C.) 10.0°/900 r/min engine control unit model/manufacturer f8t83071/mitsubishi ignition c...

  • Page 41: Electrical Specifications

    Electrical specifications 2-15 bulb voltage, wattage × quantity low beam headlight 12 v, 51.0 w × 1 high beam headlight 12 v, 55.0 w × 1 auxiliary light 12 v, 5.0 w × 3 tail/brake light led front turn signal light 12 v, 10.0 w × 2 rear turn signal light 12 v, 10.0 w × 2 license plate light 12 v, 5.0...

  • Page 42: Electrical Specifications

    Electrical specifications 2-16 starting circuit cut-off relay model/manufacturer g8r-30y-u3/omron coil resistance 162–198 Ω headlight relay model/manufacturer acm33211m05/matsushita coil resistance 86.40–105.60 Ω fuel pump relay model/manufacturer g8r-30y-u3/omron coil resistance 162–198 Ω thermo un...

  • Page 43: Tightening Torques

    Tightening torques 2-17 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 44: Tightening Torques

    Tightening torques 2-18 eas20340 engine tightening torques item thread size q’ty tightening torque remarks oil tank: oil pipe bolt m6 11 13 nm (1.3 m·kg, 9.4 ft·lb) oil tank and oil tank bracket nut m6 1 13 nm (1.3 m·kg, 9.4 ft·lb) oil tank bolt m6 2 13 nm (1.3 m·kg, 9.4 ft·lb) oil tank and down tub...

  • Page 45: Tightening Torques

    Tightening torques 2-19 cylinder head cover bolt m6 24 10 nm (1.0 m·kg, 7.2 ft·lb) rocker arm base bolt m6 8 10 nm (1.0 m·kg, 7.2 ft·lb) rocker arm base bolt m8 4 24 nm (2.4 m·kg, 17 ft·lb) locknut (rocker arm adjusting screw) m7 4 20 nm (2.0 m·kg, 14 ft·lb) valve lifter case bolt m6 4 10 nm (1.0 m·...

  • Page 46: Tightening Torques

    Tightening torques 2-20 stopper lever bolt m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) generator and starter clutch: oil pipe 2 bolt m6 4 10 nm (1.0 m·kg, 7.2 ft·lb) generator cover bolt m6 11 10 nm (1.0 m·kg, 7.2 ft·lb) stator coil assembly lead holder screw m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) stator coil assemb...

  • Page 47: Tightening Torques

    Tightening torques 2-21 note: • tighten the connecting rod bolts to 15 nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 120°–150°. • install the crankcase stud bolts (m12) so that their installed length is 217.5 mm (8.56 in). • install the crankcase stud bolts (m10...

  • Page 48: Tightening Torques

    Tightening torques 2-22 oil tank tightening sequence: cylinder head tightening sequence: 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 a. Front cylinder b. Rear cylinder.

  • Page 49: Tightening Torques

    Tightening torques 2-23 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting: engine mounting bolt (left upper side) m10 2 53 nm (5.3 m·kg, 38 ft·lb) engine mounting bolt (right upper side) m10 1 53 nm (5.3 m·kg, 38 ft·lb) l=80 mm (3.15 in) engine mount...

  • Page 50: Tightening Torques

    Tightening torques 2-24 cylinder-#2 right ignition coil bracket bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder-#2 left ignition coil bracket bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) engine bracket (right upper side) and holder bolt m6 1 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank bolt m6 2 7 nm (0.7 m·kg, 5.1...

  • Page 51: Tightening Torques

    Tightening torques 2-25 shift arm bolt m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) left rider footrest assembly bolt m8 2 30 nm (3.0 m·kg, 22 ft·lb) right rider footrest assembly bolt m8 2 30 nm (3.0 m·kg, 22 ft·lb) footrest cover bracket m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) passenger footrest nut m10 2 28 nm (2.8 ...

  • Page 52: Tightening Torques

    Tightening torques 2-26 grip end m16 2 29 nm (2.9 m·kg, 21 ft·lb) clutch master cylinder holder bolt m6 2 13 nm (1.3 m·kg, 9.4 ft·lb) rearview mirror m10 2 14 nm (1.4 m·kg, 10 ft·lb) front fork and steering head: upper bracket pinch bolt m8 2 26 nm (2.6 m·kg, 19 ft·lb) steering stem nut m22 1 110 nm...

  • Page 53: Tightening Torques

    Tightening torques 2-27 note: 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 23 nm (2.3 m·kg, 17 ft·lb) with a torque wrench. Drive chain guard bolt (swingarm side) m...

  • Page 54: 2-28

    Lubrication points and lubricant types 2-28 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head nuts and washers connecting rod small end and big end crankshaft journals piston surfaces piston pins connecting rod bo...

  • Page 55: 2-29

    Lubrication points and lubricant types 2-29 shift forks and shift fork guide bars shift drum shift shaft and shift shaft oil seal lip crankcase mating surface yamaha bond no.1215 stator coil lead grommet yamaha bond no.1215 crankshaft position sensor lead grommet yamaha bond no.1215 lubrication poin...

  • Page 56: 2-30

    Lubrication points and lubricant types 2-30 eas20380 chassis lubrication point lubricant down tube bolt (front and rear) steering bearings and upper bearing dust cover lip lower bearing dust seal lip steering ring nut thread (upper and lower) main switch bracket spacer outer surfaces front wheel oil...

  • Page 57: 2-31

    Lubrication system chart and diagrams 2-31 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 9 10 11 7 6 5 1 2 12 14 13 15 16 17 18 19 20 26 23 36 21 31 38 40 39 37 27 30 30 35 35 29 29 34 34 33 33 28 28 32 32 25 24 22 8 3 4 a.

  • Page 58: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil pan 2. Engine oil drain bolt (crankcase) 3. Oil strainer (crankcase) 4. Oil pump 5. Oil pump rotor 1 6. Oil pump rotor 2 7. Check ball 8. Relief valve 9. Oil tank 10. Oil strainer (oil tank) 11. Engine oil drain bolt (oil tank) 12. Drive axle 13. Dri...

  • Page 59: 2-33

    Lubrication system chart and diagrams 2-33 eas20410 lubrication diagrams 3 5 3 1 b-b d-d e-e a c e e 2 1 b b d d 4 2 a c.

  • Page 60: 2-34

    Lubrication system chart and diagrams 2-34 1. Oil delivery pipe 2. Push rod 3. Oil filter cartridge 4. Rocker arm shaft 5. Oil delivery pipe 2.

  • Page 61: 2-35

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

  • Page 62: 2-36

    Lubrication system chart and diagrams 2-36 1. Rocker arm shaft 2. Crankshaft 3. Valve lifter 4. Push rod.

  • Page 63: 2-37

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

  • Page 64: 2-38

    Lubrication system chart and diagrams 2-38 1. Oil pump 2. Oil strainer (crankcase) 3. Oil pipe 1.

  • Page 65: 2-39

    Lubrication system chart and diagrams 2-39 3 4 2 1 a.

  • Page 66: 2-40

    Lubrication system chart and diagrams 2-40 1. Main axle 2. Drive axle 3. Oil pump 4. Oil strainer (crankcase) a. To oil filter cartridge.

  • Page 67: Cable Routing

    Cable routing 2-41 eas20430 cable routing a 10 11 12 13 1 2 3 4 5 6 6 6 8 9 14 15 16 17 7 h d e g i j b c f.

  • Page 68: Cable Routing

    Cable routing 2-42 1. Air temperature sensor coupler 2. Sub-wire harness 3 coupler 3. Front turn signal light coupler 4. Headlight assembly coupler 5. Headlight coupler (low beam) 6. Wire harness 7. Clutch fluid reservoir hose 8. Left handlebar switch lead 9. Starter motor lead 10. Rectifier/regulat...

  • Page 69: Cable Routing

    Cable routing 2-43 d d c b b c 17 a b c d e f g h i j k l m m n o p q r s s t u v w x y z ac ab aa ae af ag ag ah ai ad ak al am an aj d-d c-c b-b a f e f a e 1 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 14 15 15 15 15 15 15 16 19 20 20 21 16 17 18.

  • Page 70: Cable Routing

    Cable routing 2-44 1. Meter assembly lead 2. Clutch hose 3. Left handlebar switch lead 4. Cylinder-#1 intake air pressure sensor 5. Cylinder-#1 intake air pressure sensor hose 6. Cylinder-#2 right spark plug lead 7. Cylinder-#2 right ignition coil 8. Cylinder-#2 right ignition coil lead 9. Cylinder-...

  • Page 71: Cable Routing

    Cable routing 2-45 a b c 1 29 z a b b c d e f g i h j k l m n q o p s t u y af ab aa ab ac ae ad d-d e c a b e d d 1 2 3 3 4 5 6 7 8 9 10 11 12 13 13 14 14 15 16 17 18 19 19 20 21 22 22 23 24 25 26 15 28 27 31 30 w v x r.

  • Page 72: Cable Routing

    Cable routing 2-46 1. Fuel pump lead 2. Cylinder-#1 right spark plug lead 3. Sub-wire harness 2 4. Cylinder-#2 left ignition coil lead 5. Sub-wire harness 2 coupler 6. Cylinder-#2 left ignition coil 7. Cylinder-#2 left spark plug lead 8. Cylinder-#2 intake air pressure sensor hose 9. Cylinder-#2 int...

  • Page 73: Cable Routing

    Cable routing 2-47 a a k l u a b c d e d f g h i j a 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 r q m n o p 24 25 s t u v w x af aa ab ac ad ae y z.

  • Page 74: Cable Routing

    Cable routing 2-48 1. Sub-wire harness 2 2. Intake solenoid lead 3. Isc (idle speed control) unit lead 4. Cylinder-#2 left ignition coil 5. Lean angle cut-off switch 6. Wire harness 7. Starter relay 8. Ecu (electronic control unit) 9. Rear turn signal light couplers 10. Muffler cooling fan temperatu...

  • Page 75: Cable Routing

    Cable routing 2-49 a a k l u a b c d e d f g h i j a 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 r q m n o p 24 25 s t u v w x af aa ab ac ad ae y z.

  • Page 76: Cable Routing

    Cable routing 2-50 ab.Route the starter motor lead and sub-wire harness 1 under the battery box, making sure that they are routed between the bolt holes in the battery box. Ac.Route the seat lock cable under the wire harness to the left of the battery box. Be sure not to pinch the seat lock cable wh...

  • Page 77: Cable Routing

    Cable routing 2-51 a a b d d e f g c 1 2 3 3 4 4 5 6 7 8 9.

  • Page 78: Cable Routing

    Cable routing 2-52 1. Fuel tank 2. Pressure regulator 3. Fuel return hose 4. Fuel hose 5. Fuel return pipe 6. Fuel return hose (fuel return pipe to fuel pump) 7. Fuel pump 8. Fuel pipe 9. Fuel hose (intake manifold assembly to pressure regulator) a. Face the ends of the hose clamps downward. B. Inst...

  • Page 79: Cable Routing

    Cable routing 2-53 a a a a a b c d d e f a a 1 1 2 2 5 3 6 8 10 10 11 a g h i k j 4 7 9 9 9.

  • Page 80: Cable Routing

    Cable routing 2-54 1. Fuel tank overflow hose 2. Fuel tank breather hose 3. Rollover valve hose 1 4. Rollover valve hose 2 5. Rollover valve 1 6. Rollover valve 2 7. Rollover valve hose 3 8. Rollover valve hose 4 9. Fuel tank breather/overflow hose 10. Oil tank 11. Bottom cover a. Face the ends of t...

  • Page 81: Cable Routing

    Cable routing 2-55 b a b a c c a a b c d e j 1 2 3 4 5 8 6 7 8 9 10 11 12 13 g h i k l m n f 14 15 16 17 10 e 3.

  • Page 82: Cable Routing

    Cable routing 2-56 1. Cylinder-#2 intake air pressure sensor 2. Cylinder-#2 isc (idle speed control) unit outlet hose 3. Isc (idle speed control) unit 4. Intake solenoid vacuum hose (one-way valve to throttle body) 5. Cylinder-#1 isc (idle speed control) unit outlet hose 6. Throttle position sensor ...

  • Page 83: Chk

    Chk adj 3.

  • Page 84

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance and lubrication chart ...................

  • Page 85

    Electrical system................................................................................. 3-33 checking and charging the battery ....................................... 3-33 checking the fuses ........................................................................ 3-33 replacing the headli...

  • Page 86: Periodic Maintenance

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

  • Page 87: Periodic Maintenance

    Periodic maintenance 3-2 eau36771 note: • air filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the air filter element needs to be replaced more frequently when riding in unusually wet or dus...

  • Page 88: Engine

    Engine 3-3 eas20470 engine eas20530 adjusting the valve clearance the following procedure applies to all of the valves. Note: • the valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times that the valve clearance needs to be ad- justed manually. If this is t...

  • Page 89: Engine

    Engine 3-4 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ piston #1 tdc (rear cylinder) a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark “a” on the crankshaft position sensor rotor with the pointer “b” on the clutch cover. C. Che...

  • Page 90: Engine

    Engine 3-5 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1” with the locknut wrench “2”. B. Insert a thickness gauge “3” between the end of the adjusting screw and the valve tip. C. Turn the adjusting screw “4” in direction “a” or “b” with the tappet adjusting tool “5” unt...

  • Page 91: Engine

    Engine 3-6 2. Remove: • seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 6-1. • air filter case refer to “general chassis” on page 4-1. 3. Disconnect: • intake solenoid vacuum hose (one-way valve to throttle body) “1” • cylinder-#1 intake air pressure sensor hose...

  • Page 92: Engine

    Engine 3-7 9. Install: • air filter case refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 6-1. • seat refer to “general chassis” on page 4-1. Eas20630 adjusting the throttle cable free play 1. Check: • throttle cable free play “a” out of specification → adjust. 2. Rem...

  • Page 93: Engine

    Engine 3-8 c. Tighten the locknut “1”. Warning ewa12910 after adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Instal...

  • Page 94: Engine

    Engine 3-9 1. Stand the vehicle on a level surface. 2. Remove: • air duct “1” • timing mark accessing screw “2” 3. Connect: • timing light “1” • digital tachometer 4. Check: • ignition timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine, warm it up for several min- utes, and...

  • Page 95: Engine

    Engine 3-10 5. Disconnect: • spark plug cap 6. Remove: • spark plug caution: eca13340 before removing the spark plugs, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinders. 7. Install: • compression gauge “1” • extension “2” 8...

  • Page 96: Engine

    Engine 3-11 eas20730 checking the engine oil level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Start the engine, warm it up for approximately 15 minutes until the oil temperature rises to 60 °c (140 °f), and then turn...

  • Page 97: Engine

    Engine 3-12 6. Remove: • engine oil drain bolt (crankcase) “1” 7. Drain: • engine oil (completely from the oil tank and crankcase) 8. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the rectifier/regulat...

  • Page 98: Engine

    Engine 3-13 note: pour the engine oil in two stages. First, pour in 2.5 l of oil, then start the engine and rev it 3 to 5 times. Stop the engine, and then pour in the re- mainder of the specified amount. Caution: ec5yu1004 when starting the engine make sure the dip- stick is securely fitted into the...

  • Page 99: Engine

    Engine 3-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas20890 checking the clutch fluid level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Check: • clutch fluid level below the minimum level mark “a” → add the...

  • Page 100: Engine

    Engine 3-15 d. Place the other end of the hose into a con- tainer. E. Slowly squeeze the clutch lever several times. F. Fully squeeze the clutch lever without releas- ing it. G. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip. H. Tighten...

  • Page 101: Engine

    Engine 3-16 eas21010 checking the throttle body joints 1. Remove: • seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 6-1. • air filter case refer to “general chassis” on page 4-1. 2. Check: • throttle body joints “1” cracks/damage → replace. 3. Install: • air fil...

  • Page 102: Engine

    Engine 3-17 • fuel tank refer to “fuel tank” on page 6-1. • seat refer to “general chassis” on page 4-1. Eas21060 checking the oil tank breather hose 1. Check: • oil tank breather hose “1” cracks/damage → replace. Loose connection → connect properly. Caution: eca14930 make sure the oil tank breather...

  • Page 103: Engine

    Engine 3-18 4. Install: • seat refer to “general chassis” on page 4-1. Eas21100 adjusting the exup cables 1. Remove: • exup valve pulley cover “1” 2. Check: • exup system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the main switch to “on”. B. Check that the exup valve operate...

  • Page 104: Engine

    Engine 3-19 e. Tighten both locknuts and then slide the rub- ber cover to its original position. F. Remove the pin. G. Turn the main switch to “on”, check that the exup valve pulley contacts the stoppers (ful- ly-open and fully-closed positions), and then check that the notch in the exup valve pulle...

  • Page 105: Chassis

    Chassis 3-20 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 knob “1” until the brake lever is in the desired position. • be sure to a...

  • Page 106: Chassis

    Chassis 3-21 warning ew5yu1001 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 and could resu...

  • Page 107: Chassis

    Chassis 3-22 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 indicator grooves “1” almost disap- peared → replace the brake pads as a set. Refer to “rear brake” on page 4-31. Eas21280 checking the f...

  • Page 108: Chassis

    Chassis 3-23 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adjusting nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 109: Chassis

    Chassis 3-24 note: loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. H. Tighten the bleed screw and then release the brake lever or brake pedal. I. Repeat steps (e) to (h) until all of the air bub- bles ha...

  • Page 110: Chassis

    Chassis 3-25 note: measure the drive chain slack 85 mm (3.35 in) “b” from the end of the drive chain guide. 3. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle nut “1”. B. Loosen both locknuts “2”. C. Turn both adjusting bolts “3” in direction “a...

  • Page 111: Chassis

    Chassis 3-26 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. B. Loosen the lower ring nut “4”, and then tight- en it to the specified torque with a steering nut wrench “5”. Note: set a torque wrench at a right angle ...

  • Page 112: Chassis

    Chassis 3-27 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → repair. Refer to “front fork” on page 4-47. Eas21580 adjusting the front fork legs the fo...

  • Page 113: Chassis

    Chassis 3-28 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ compression damping caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression dampin...

  • Page 114: Chassis

    Chassis 3-29 c. Tighten the locknut to specification. Caution: eca13600 always tighten the locknut against the ad- justing nut and torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping caution: eca13590 never go beyond the maximum or minimum adjustment positio...

  • Page 115: Chassis

    Chassis 3-30 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21650 checking the tires the following procedure applies to both of the tires. 1. Check: • tire pressure out of specification → regulate. Warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperat...

  • Page 116: Chassis

    Chassis 3-31 warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure 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 ...

  • Page 117: Chassis

    Chassis 3-32 note: after a tire or wheel has been changed or re- placed, always balance the wheel. Eas21690 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Warning ewa13270 damaged outer cable may cause the cable to corrode and interfere wi...

  • Page 118: Electrical System

    Electrical system 3-33 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 7-85. Eas21770 checking the fuses refer to “electrical components” on page 7-85. Eas21790 replacing the headlight bulbs 1. Remove: • headlight assembly bolts “1” 2. R...

  • Page 119: Electrical System

    Electrical system 3-34 caution: eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth...

  • Page 120: Chas

    Chas 4.

  • Page 121: Chassis

    4 chassis general chassis....................................................................................... 4-1 checking the air filter case valve............................................ 4-5 front wheel............................................................................................

  • Page 122

    Handlebar ................................................................................................ 4-42 removing the handlebar.............................................................. 4-44 checking the handlebar .............................................................. 4-44 install...

  • Page 123: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 seat 1 2 lead holder 1 3 negative battery lead 1 disconnect. 4 positive battery lead 1 disconnect. 5 main fuse 1 6 battery band 1 7 battery 1 8 battery seat 1 9 battery box 1 for insta...

  • Page 124: General Chassis

    General chassis 4-2 removing the side covers and headlight assembly order job/parts to remove q’ty remarks 1 left side cover 1 2 right side cover 1 3 left side cover inner panel 1 4 right side cover inner panel 1 5 air duct 1 6 bottom cover 1 7 sub-wire harness 3 coupler (wire harness side) 1 discon...

  • Page 125: General Chassis

    General chassis 4-3 removing the tail/brake light assembly order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. 1 muffler cooling fan motor coupler 1 disconnect. 2 tail/brake light coupler 1 disconnect. 3 rear right turn signal light coupler 1 disconnect. 4 rear left t...

  • Page 126: General Chassis

    General chassis 4-4 removing the air filter case and oil catch tank order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. 1 air filter case cover 1 2 air filter element 1 3 cylinder head breather hose (air filter case to oil catch tank) 1 4 cylinder head breather hose (c...

  • Page 127: General Chassis

    General chassis 4-5 et5yu1013 checking the air filter case valve 1. Check: • air filter case valve operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the air filter case (with the air filter case valve). B. Connect the vacuum/pressure pump gauge set “1” to the air filter case valv...

  • Page 128: Front Wheel

    Front wheel 4-6 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 left front brake hose holder 1 2 right front brake hose holder 1 3 left front brake caliper 1 4 righ...

  • Page 129: Front Wheel

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

  • Page 130: Front Wheel

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

  • Page 131: Front Wheel

    Front wheel 4-9 • oil seals damage/wear → replace. Eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: ec5yu1001 do not contact the...

  • Page 132: Front Wheel

    Front wheel 4-10 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. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • fr...

  • Page 133: Front Wheel

    Front wheel 4-11 • front wheel axle pinch bolt caution: ec5yu1002 before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 6. Install: • front brake calipers warning ewa13500 make sure the brake hose is routed properly. Note: make...

  • Page 134: Rear Wheel

    Rear wheel 4-12 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the rear wheel is elevated. 1 rear brake caliper 1 2 drive chain adjusting locknut 2 loosen. 3 drive chain adjusting bolt 2 loosen. 4 rear wheel axle...

  • Page 135: Rear Wheel

    Rear wheel 4-13 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 (brake disc side) 1 4 collar (wheel sprocket side) 1 5 dust cover 2 6 oil seal 1 7 bearing 1 8 rear wheel drive hub 1 9 rear wheel drive hu...

  • Page 136: Rear Wheel

    Rear wheel 4-14 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 procedure. New 2 3 1 5 4 6 ls ls.

  • Page 137: Rear Wheel

    Rear wheel 4-15 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: • rear brake caliper “1” n...

  • Page 138: Rear Wheel

    Rear wheel 4-16 2. Replace: • rear wheel sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. B. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. C. Install the new rear wheel spro...

  • Page 139: Rear Wheel

    Rear wheel 4-17 • collar (brake disc side) “2” note: the collar (brake disc side) has marks “a” to dis- tinguish it from the collar (wheel sprocket side). 5. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-24. 6. Install: • rear brake caliper warning ewa13500 make su...

  • Page 140: Front Brake

    Front brake 4-18 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 front brake caliper 1 3 brake pad clip 2 4 brake pad pin 1 5 brake pad spring 1 6 front brake pad 2 ...

  • Page 141: Front Brake

    Front brake 4-19 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 3-23. 1 brake fluid reservoir cap holder 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid...

  • Page 142: Front Brake

    Front brake 4-20 *apply silicon grease 16 front brake master cylinder 1 for installation, reverse the removal procedure. Removing the front brake master cylinder order job/parts to remove q’ty remarks t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 14 nm (1.4 m...

  • Page 143: Front Brake

    Front brake 4-21 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 bleed screw 1 3 brake master cylinder body 1 for assembly, reverse the disassembly procedure..

  • Page 144: Front Brake

    Front brake 4-22 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. 1 front brake hose union bolt 1 2 copper washer 2 3 front bra...

  • Page 145: Front Brake

    Front brake 4-23 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 front brake pad 2 5 brake caliper piston 4 6 brake caliper piston seal 8 7 b...

  • Page 146: Front Brake

    Front brake 4-24 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 147: Front Brake

    Front brake 4-25 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 148: Front Brake

    Front brake 4-26 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • brake pad pin • brake pad clips • front brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on pa...

  • Page 149: Front Brake

    Front brake 4-27 b. Remove the brake caliper piston seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22390 checking the front brake calipers 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders “2” scratches/wear → replac...

  • Page 150: Front Brake

    Front brake 4-28 3. Install: • front brake pads • brake pad spring • brake pad pin • brake pad clips • front brake caliper refer to “replacing the front brake pads” on page 4-25. 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only...

  • Page 151: Front Brake

    Front brake 4-29 2. Check: • brake master cylinder kit damage/scratches/wear → replace. 3. Check: • brake fluid reservoir cracks/damage → replace. • brake fluid reservoir diaphragm cracks/damage → replace. 4. Check: • brake hoses cracks/damage/wear → replace. Eas22520 assembling the front brake mast...

  • Page 152: Front Brake

    Front brake 4-30 caution: eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system refer to “bleeding the hydraulic brake system” on page 3-23. 5. Check: • brake fluid level below the minimum level mark...

  • Page 153: Rear Brake

    Rear brake 4-31 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 2 5 brake pad insulator 2 6 rear brake pad 2 7 brake pad spring 2 for installation, reverse the removal procedure. T r . . ...

  • Page 154: Rear Brake

    Rear brake 4-32 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 3-23. Seat/battery box/lead holder refer to “general chassis” on page 4-1. Drive sprocket cover refer to “chain drive” on page 4-69...

  • Page 155: Rear Brake

    Rear brake 4-33 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake hose joint 1 3 bush 1 4 brake master cylinder body 1 for assembly, reverse the disassembly procedure..

  • Page 156: Rear Brake

    Rear brake 4-34 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 3-23. 1 rear brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 rear brake caliper 1 for installation, reverse the removal pro...

  • Page 157: Rear Brake

    Rear brake 4-35 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 shim 2 4 brake pad insulator 2 5 rear brake pad 2 6 brake pad spring 2 7 brake caliper piston 2 8 brake caliper piston seal 4 9 bleed screw 1 for assembly, reverse...

  • Page 158: Rear Brake

    Rear brake 4-36 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 159: Rear Brake

    Rear brake 4-37 note: always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw...

  • Page 160: Rear Brake

    Rear brake 4-38 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pistons 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 fr...

  • Page 161: Rear Brake

    Rear brake 4-39 eas22670 installing the rear brake caliper 1. Install: • rear brake caliper “1” (temporarily) • copper washers • rear brake hose “2” • rear brake hose union bolt “3” warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” o...

  • Page 162: Rear Brake

    Rear brake 4-40 eas22700 removing the rear brake master cylinder note: before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • rear brake hose union bolt “1” • copper washers “2” • rear brake hose “3” note: to collect any remaining brake flu...

  • Page 163: Rear Brake

    Rear brake 4-41 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 chem...

  • Page 164: Handlebar

    Handlebar 4-42 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 rearview mirror 2 2 front brake light switch connector 2 disconnect. 3 front brake master cylinder holder 1 4 front brake master cylinder assembly 1 5 right handlebar switch 1 6 throttle cable 2 disconn...

  • Page 165: Handlebar

    Handlebar 4-43 16 lower handlebar holder 2 for installation, reverse the removal procedure. Removing the handlebar order job/parts to remove q’ty remarks 1 2 4 3 16 ls t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 29 nm ...

  • Page 166: Handlebar

    Handlebar 4-44 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the left handlebar grip, and gradua...

  • Page 167: Handlebar

    Handlebar 4-45 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. B. Slide the handlebar grip over the left end of the handlebar. C. Wipe off any excess rubber adhesive with a clean rag. Warning ewa13700 do not touch the hand...

  • Page 168: Handlebar

    Handlebar 4-46 9. Install: • front brake master cylinder assembly • front brake master cylinder holder “1” note: • align the end of the brake master cylinder hold- er with the punch mark “a” on the handlebar. • first, tighten the upper bolt, then the lower bolt. 10.Adjust: • throttle cable free play...

  • Page 169: Front Fork

    Front fork 4-47 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-6. 1 front fork guard 2 2 front fender 1 3 cap bolt 1 loosen. 4 upper bracket pinch bol...

  • Page 170: Front Fork

    Front fork 4-48 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 washer 1 4 damper adjusting rod 1 5 spacer 1 6 nut 1 7 upper spring seat 1 8 fork spring 1 9 lower spring seat 1 10 outer...

  • Page 171: Front Fork

    Front fork 4-49 16 inner tube 1 for assembly, reverse the disassembly procedure. Disassembling the front fork legs order job/parts to remove q’ty remarks t r . . 35 nm (3.5 m • kg, 25 ft • ib) 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 ls new new new t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 25 nm ...

  • Page 172: Front Fork

    Front fork 4-50 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 173: Front Fork

    Front fork 4-51 d. Remove the cap bolt. E. Remove the rod holder and fork spring com- pressor. F. Remove the spacer and nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Drain: • fork oil note: stroke the damper rod “1” several times while draining the fork oil. 4. Remove: • damper rod assem...

  • Page 174: Front Fork

    Front fork 4-52 caution: eca14200 • the front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • when disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter th...

  • Page 175: Front Fork

    Front fork 4-53 • lubricate the outer surface of the inner tube with fork oil. • before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 5. Install: • outer tube (to the inner tube) 6. Install: • washer • oil seal “1” (with ...

  • Page 176: Front Fork

    Front fork 4-54 10.Fully compress the front fork leg. 11.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) caution: eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling ...

  • Page 177: Front Fork

    Front fork 4-55 d. Install the upper spring seat and nut. E. Reinstall the rod puller attachment. F. Install the spacer. G. Press down on the spacer with the fork spring compressor “9”. H. Pull up the rod puller and install the rod holder “10” between the nut “4” and the spacer “5”. Note: use the si...

  • Page 178: Front Fork

    Front fork 4-56 eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg temporarily tighten the upper and lower bracket pinch bolts. Note: make sure the outer tube is flush with the top of the handlebar holder. 2. Tighten: ...

  • Page 179: Steering Head

    Steering head 4-57 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks air filter case/headlight assembly refer to “general chassis” on page 4-1. Lower handlebar holder refer to “handlebar” on page 4-42. Front fork leg refer to “front fork” on page 4-47. 1 meter ...

  • Page 180: Steering Head

    Steering head 4-58 13 lower bracket 1 14 washer 1 15 lower bearing 1 16 lower bearing dust seal 1 17 lower bearing inner race 1 18 upper bearing cover 1 19 upper bearing inner race 1 20 upper bearing 1 21 bearing outer race 2 for installation, reverse the removal procedure. Removing the lower bracke...

  • Page 181: Steering Head

    Steering head 4-59 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut “1” • rubber washer • lower ring nut “2” • lower bracket warning ewa13730 securely ...

  • Page 182: Steering Head

    Steering head 4-60 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to “checking and adjusting the steering head” on page 3-25. 3. Install: • front brake hose joint bracket “1” • front brake hose joint “2” note: make sure that the tab “a” on the front...

  • Page 183: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-61 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks 1 self-locking nut/bolt 1/1 2 self-locking nut/bolt/spacer 1/1/1 3 self-locking nut/bolt 1/1 4 rear shock absorber assembly 1 5 collar/spacer/oil s...

  • Page 184: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-62 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 185: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 • oil seals damage/pitting → replace. 3. Check: • collars • spacers damage/scratches → replace. Eas23270 installing the connecting arm and relay arm 1. Lubricate: • spacers • bearings 2. Install: • bearing “1” (to the relay arm) • bearings “2” (to the connecting arm...

  • Page 186: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-64 eas23310 installing the rear shock absorber assembly 1. Lubricate: • spacers • bearings 2. Install: • relay arm (to the swingarm) note: when installing the relay arm, lift up the swing- arm. 3. Tighten: • rear shock absorber assembly nut (front side) • relay arm nut...

  • Page 187: Swingarm

    Swingarm 4-65 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “general chassis” on page 4-1. Rear shock absorber refer to “rear shock absorber assembly” on page 4-61. Drive chain guard (drive sprocket side) refer to “chain drive” on page 4-69. 1 foo...

  • Page 188: Swingarm

    Swingarm 4-66 13 rear fender 1 14 drive chain guide 1 15 swingarm 1 16 spacer 1 17 oil seal 1 18 oil seal 1 19 oil seal 2 20 circlip 1 21 bearing 1 22 bearing 1 23 bearing 1 24 oil seal 2 25 bearing 1 for installation, reverse the removal procedure. Removing the swingarm order job/parts to remove q’...

  • Page 189: Swingarm

    Swingarm 4-67 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swinga...

  • Page 190: Swingarm

    Swingarm 4-68 • bearing “3” • oil seal “4” 3. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-24. Installed depth of bearing “a” 6.3 mm (0.25 in) installed depth of bearing “b” 5.7 mm (0.22 in) installed depth of oil seal “c” 0.5–1.0 mm (0.02–0.04 in) installed depth...

  • Page 191: Chain Drive

    Chain drive 4-69 eas23400 chain drive removing the drive sprocket and drive chain order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. 1 drive sprocket cover 1 2 clutch pipe union bolt cap 1 3 clutch pipe union bolt 1 4 copper washer...

  • Page 192: Chain Drive

    Chain drive 4-70 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 193: Chain Drive

    Chain drive 4-71 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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...

  • Page 194: Chain Drive

    Chain drive 4-72 3. Install: • clutch release cylinder refer to “installing the clutch re- lease cylinder” on page 5-62. A 1 2 3 new b.

  • Page 195: Eng

    Eng 5.

  • Page 196: Engine

    5 engine engine removal ........................................................................................ 5-1 checking the oil pipes ..................................................................... 5-2 checking the oil strainer ...............................................................

  • Page 197

    Clutch ........................................................................................................ 5-46 removing the clutch ..................................................................... 5-55 removing the primary drive gear ............................................ 5-55 checki...

  • Page 198

    Oil pump...................................................................................................... 5-81 checking the oil pump ................................................................... 5-84 checking the relief valve ........................................................... 5-8...

  • Page 200: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the oil tank order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Air duct refer to “general chassis” on page 4-1. 1 oil tank breather hose 1 disconnect. 2 dipstick 1 3 oil tank inlet pipe 1 4 oi...

  • Page 201: Engine Removal

    Engine removal 5-2 et5yu1027 checking the oil pipes 1. Check: • oil pipes damage → replace. Obstruction → wash and blow out with com- pressed air. Et5yu1028 checking the oil strainer 1. Check: • oil strainer (oil tank) damage → replace. Contaminants → clean with engine oil. Et5yu1019 installing the ...

  • Page 202: Engine Removal

    Engine removal 5-3 removing the exhaust pipe order job/parts to remove q’ty remarks seat refer to “general chassis” on page 4-1. 1 exup valve pulley cover 1 2 exup cable 2 disconnect. 3 o 2 sensor cover 1 4 o 2 sensor 1 5 muffler end cover 2 6 muffler end cover plate 2 7 muffler cover 2 8 muffler 2 ...

  • Page 203: Engine Removal

    Engine removal 5-4 et5yu1029 removing the muffler end covers 1. Remove: • muffler end covers “1” note: before removing a muffler end cover, turn it in the direction of the arrow shown in the illustra- tion. Et5yu1030 installing the muffler end covers 1. Install: • muffler covers “1” • muffler end co...

  • Page 204: Engine Removal

    Engine removal 5-5 removing the exup servo motor and rear exhaust pipe joint order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case/oil catch tank/air duct refer to “general chassis” on page 4-1. Throttle body/intake manifold/rollover valve bracket refer t...

  • Page 205: Engine Removal

    Engine removal 5-6 5 horn connector 2 disconnect. 6 horn 1 7 oil pump outlet pipe 1 8 oil pump inlet pipe 1 9 sidestand switch coupler 1 disconnect. 10 shift rod 1 11 left rider footrest assembly 1 12 sidestand assembly 1 13 right rider footrest assembly 1 14 drive sprocket case assembly 1 15 left s...

  • Page 206: Engine Removal

    Engine removal 5-7 22 rear exhaust pipe joint cover 1 23 rear exhaust pipe joint 1 24 gasket 1 for installation, reverse the removal procedure. Removing the exup servo motor and rear exhaust pipe joint order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m ...

  • Page 207: Engine Removal

    Engine removal 5-8 removing the leads order job/parts to remove q’ty remarks 1 stator coil assembly lead 1 2 horn lead 1 3 wire harness 1 4 decompression solenoid coupler 2 disconnect. 5 speed sensor coupler 1 disconnect. 6 starter motor connector 1 7 starter motor lead 1 8 crankshaft position senso...

  • Page 208: Engine Removal

    Engine removal 5-9 removing the down tube order job/parts to remove q’ty remarks note: place a suitable stand under the frame and engine. 1 engine mounting bolt (right upper side) 1 l = 65 mm (2.56 in) 2 engine mounting bolt (right upper side) 1 l = 80 mm (3.15 in) 3 engine mounting bolt (left upper...

  • Page 209: Engine Removal

    Engine removal 5-10 15 down tube nut (front side) 2 16 down tube spacer bolt 2 loosen. 17 down tube bolt (front side) 2 18 engine mounting nut (front lower side) 1 19 engine mounting bolt (front lower side) 1 20 down tube 1 for installation, reverse the removal procedure. Removing the down tube orde...

  • Page 210: Engine Removal

    Engine removal 5-11 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the frame and engine. 1 engine mounting nut (rear upper side) 1 2 engine mounting spacer bolt (rear upper side) 1 loosen. 3 engine mounting bolt (rear upper side) 1 4 engine bracket nut ...

  • Page 211: Engine Removal

    Engine removal 5-12 14 engine bracket (rear upper side) 1 for installation, reverse the removal procedure. Removing the engine order job/parts to remove q’ty remarks t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 53 nm (5....

  • Page 212: Engine Removal

    Engine removal 5-13 et5yu1031 removing the engine note: pass a suitable rod through the hole in the swin- garm pivot shaft and secure the rod to support the vehicle. 1. Loosen: • down tube spacer bolts • engine mounting spacer bolt (rear upper side) • engine mounting spacer bolt (rear lower side) no...

  • Page 213: Engine Removal

    Engine removal 5-14 note: do not fully tighten the bolts and nuts. 7. Tighten: • down tube nut (front side) “14” • engine mounting nut (rear lower side) “15” • engine mounting nut (rear upper side) “16” • engine bracket nuts (rear upper side) “17” 8. Install: • engine brackets (front upper side) “18...

  • Page 214: Engine Removal

    Engine removal 5-15 25 10 11 28 26 12 29 27 14 30 26 24 2 21 19 18 18 19 23 22 20 9 13.

  • Page 215: Camshafts

    Camshafts 5-16 eas23750 camshafts removing the camshaft sprocket cover order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. 1 spark plug 4 2 timing mark accessing screw 1 3 crankshaft end cover 1 4 decompression solenoid cover 1 5 camshaft sprocket cover 1 6 camshaft ...

  • Page 216: Camshafts

    Camshafts 5-17 removing cylinder head covers order job/parts to remove q’ty remarks 1 tappet cover bolt 4 2 tappet cover 2 3 o-ring 2 4 cylinder head cover bolt 4 l = 60 mm (2.36 in) 5 cylinder head cover bolt 2 l = 50 mm (1.97 in) 6 cylinder head cover bolt 10 l = 50 mm (1.97 in) 7 cylinder head co...

  • Page 217: Camshafts

    Camshafts 5-18 removing the push rods and rocker arms order job/parts to remove q’ty remarks 1 rear rocker arm base assembly 1 2 front rocker arm base assembly 1 3 rocker arm base gasket 2 4 dowel pin 4 5 push rod 1 3 l = 288.5 mm (11.358 in) green painting 6 push rod 2 1 l = 290.5 mm (11.437 in) ye...

  • Page 218: Camshafts

    Camshafts 5-19 removing the valve lifters order job/parts to remove q’ty remarks front cylinder refer to “cylinders and pistons” on page 5-41. 1 push rod cover 2 2 o-ring 4 3 seal 2 4 rear valve lifter case 1 5 front valve lifter case 1 6 valve lifter 4 for installation, reverse the removal procedur...

  • Page 219: Camshafts

    Camshafts 5-20 removing the camshafts order job/parts to remove q’ty remarks 1 decompression solenoid 1 2 long decompression push rod 1 92 mm (3.6 in) 3 short decompression push rod 1 78 mm (3.1 in) 4 camshaft drive gear 1 5 straight key 1 6 camshaft driven gear 1 7 straight key 1 8 front cylinder c...

  • Page 220: Camshafts

    Camshafts 5-21 eas23790 removing the rocker arms, push rods and valve lifters 1. Align: • tdc mark “a” on the crankshaft position sen- sor rotor (with the pointer “b” on the clutch cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is ...

  • Page 221: Camshafts

    Camshafts 5-22 3. Remove: • camshaft drive gear “1” • camshaft driven gear “2” • straight keys • front cylinder camshaft end cover note: cover the crankcase hole with a clean rag “3” to prevent the straight keys from falling into the crankcase. 4. Remove: • oil delivery pipe “1” • camshaft cover “2”...

  • Page 222: Camshafts

    Camshafts 5-23 3. Measure: • camshaft journal diameter (crankcase side) “a” out of specification → replace the camshaft. 4. Measure: • camshaft journal diameter (camshaft cover side) “a” out of specification → replace the camshaft. 5. Measure: • crankcase hole inside diameter “a” out of specificatio...

  • Page 223: Camshafts

    Camshafts 5-24 note: calculate the clearance by subtracting the cam- shaft journal diameter (camshaft cover side) from the camshaft cover hole inside diameter. 9. Check: • camshaft drive gears • camshaft driven gears chips/pitting/roughness/wear → replace the defective part(s). Eas23890 checking the...

  • Page 224: Camshafts

    Camshafts 5-25 eas23920 checking the valve lifters and valve lifter cases 1. Check: • valve lifter blue discoloration/excessive wear/pitting/ scratches → replace and check the lubrica- tion system. 2. Check: • valve lifter case “1” damage/wear → replace the valve lifter case. • seal “2” • o-ring “3”...

  • Page 225: Camshafts

    Camshafts 5-26 • o-ring damage/wear → replace the oil seal and o- ring as a set. Eas23980 checking the decompression system 1. Check: • decompression system note: • check the decompression system while the decompression push rod is installed in the camshaft. • check that the decompression pin “1” pr...

  • Page 226: Camshafts

    Camshafts 5-27 • align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the cam- shaft driven gear “2”. • insert a cross-headed screwdriver into one of the holes in the outer camshaft driven gear and rotate the gear until the teeth of both driven gears are aligned. The te...

  • Page 227: Camshafts

    Camshafts 5-28 caution: eca14630 • do not pump the valve lifter excessively. • kerosene is highly flammable. B. Install the valve lifter into the engine. Caution: eca14650 be sure to install the valve lifter in its appro- priate position. C. Start the engine and warm it up. D. Stop the engine. E. Re...

  • Page 228: Camshafts

    Camshafts 5-29 i. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lift- er to bleed. J. If necessary, repeat steps (h) and (i) to bleed other valve lifters. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24060 installing the valve lifters 1. Install: • fro...

  • Page 229: Camshafts

    Camshafts 5-30 c. Install the rocker arm base bolts (m6) “1”, “2” and the rocker arm base bolts (m8) “3”. Note: tighten the rocker arm base bolts in stages and in a crisscross pattern. Bolts “1”: l = 36 mm (1.42 in) bolts “2”: l = 40 mm (1.57 in) ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas...

  • Page 230: Cylinder Heads

    Cylinder heads 5-31 eas24110 cylinder heads removing the cylinder heads order job/parts to remove q’ty remarks cylinder head covers/rocker arms refer to “camshafts” on page 5-16. 1 front exhaust pipe joint 1 2 front exhaust pipe joint gasket 1 3 oil pipe 1 1 from crankcase to cylinder heads. 4 coppe...

  • Page 231: Cylinder Heads

    Cylinder heads 5-32 eas24140 removing the cylinder heads 1. Remove: • cylinder head nuts note: • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas24170 checking the cylinder heads the following proce...

  • Page 232: Cylinder Heads

    Cylinder heads 5-33 eas24250 installing the cylinder heads 1. Tighten: • cylinder head nuts (m12) “1”–“4” • cylinder head nuts (m10) “5”, “6” note: • lubricate the cylinder head nuts with engine oil. • tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two s...

  • Page 233: Valves and Valve Springs

    Valves and valve springs 5-34 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks the following procedure applies to both cylinders. Cylinder heads refer to “cylinder heads” on page 5-31. 1 valve cotter 8 2 upper spring seat 4 3 outer valve ...

  • Page 234: Valves and Valve Springs

    Valves and valve springs 5-35 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve seal...

  • Page 235: Valves and Valve Springs

    Valves and valve springs 5-36 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide remover ...

  • Page 236: Valves and Valve Springs

    Valves and valve springs 5-37 6. Measure: • valve stem runout out of specification → replace the valve. Note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always re- place the oil seal. Eas24300 checking the valve seats the following procedure...

  • Page 237: Valves and Valve Springs

    Valves and valve springs 5-38 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Caution: eca13790 do not let the lapping compound enter the gap between the valve stem and the valve guide. B. Apply molybdenum disulfide oil onto the valve stem....

  • Page 238: Valves and Valve Springs

    Valves and valve springs 5-39 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24340 installing the valves the following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem “1...

  • Page 239: Valves and Valve Springs

    Valves and valve springs 5-40 • upper spring seat “7” (into the cylinder head) note: install the valve springs with the larger pitch “a” facing up. 4. Install: • valve cotters note: install the valve cotters by compressing the valve springs with the valve spring compressor set “1”. 5. To secure the ...

  • Page 240: Cylinders and Pistons

    Cylinders and pistons 5-41 eas24360 cylinders and pistons removing the cylinders and pistons order job/parts to remove q’ty remarks cylinder head refer to “cylinder heads” on page 5-31. 1 front cylinder 1 2 rear cylinder 1 3 cylinder gasket 2 4 dowel pin 4 5 piston pin clip 4 6 piston pin 2 7 piston...

  • Page 241: Cylinders and Pistons

    Cylinders and pistons 5-42 eas24380 removing the pistons the following procedure applies to all of the pis- tons. 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” caution: eca13810 do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the ...

  • Page 242: Cylinders and Pistons

    Cylinders and pistons 5-43 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cy...

  • Page 243: Cylinders and Pistons

    Cylinders and pistons 5-44 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 gap is exces- sive, replace all three piston rings. Eas24440 checking the piston pins the following pro...

  • Page 244: Cylinders and Pistons

    Cylinders and pistons 5-45 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” note: • apply engine oil onto the piston pin. • make sure the arrow mark “a” on the piston fac- es towards the front of the vehicle. • before installing the piston pin clip, cover the crankcase opening with a...

  • Page 245: Clutch

    Clutch 5-46 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Battery box/air duct refer to “general chassis” on page 4-1. Oil tank/shift rod refer to “engine removal” on page 5-1. 1 crankshaft position...

  • Page 246: Clutch

    Clutch 5-47 removing the crankshaft position sensor order job/parts to remove q’ty remarks 1 oil seal 1 2 bearing 1 3 crankshaft position sensor lead holder 3 4 crankshaft position sensor 1 for installation, reverse the removal procedure. 2 1 3 3 3 4 lt lt lt lt lt lt lt ls t r . . 10 nm (1.0 m • kg...

  • Page 247: Clutch

    Clutch 5-48 removing the clutch order job/parts to remove q’ty remarks 1 clutch spring plate retainer 1 2 clutch spring plate 1 3 clutch spring plate seat 1 4 pressure plate 1 5 short clutch push rod 1 6 friction plate 1 9 7 clutch plate 8 8 conical spring washer 1 9 wire circlip 1 10 clutch plate 1...

  • Page 248: Clutch

    Clutch 5-49 18 washer 1 19 circlip 1 20 oil pump drive gear 1 21 dowel pin 1 22 collar 1 23 thrust washer 2 1 24 ball 1 25 long clutch push rod 1 26 spacer 1 27 crankshaft position sensor rotor 1 28 primary drive gear 1 29 straight key 1 for installation, reverse the removal procedure. Removing the ...

  • Page 249: Clutch

    Clutch 5-50 removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-14. 1 clutch fluid reservoir cap holder 1 2 clutch fluid reservoir cap 1 3 clutch fluid reservoir diaphragm holder 1 4 clutch fluid res...

  • Page 250: Clutch

    Clutch 5-51 16 clutch master cylinder holder 1 17 clutch master cylinder 1 for installation, reverse the removal procedure. Removing the clutch master cylinder order job/parts to remove q’ty remarks t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 30 nm (3.0 m •...

  • Page 251: Clutch

    Clutch 5-52 disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 clutch master cylinder kit 1 3 dust seal 1 4 circlip 1 5 clutch fluid reservoir hose joint 1 6 o-ring 1 7 clutch master cylinder body 1 for assembly, reverse the disassem...

  • Page 252: Clutch

    Clutch 5-53 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-14. 1 clutch pipe union bolt cap 1 2 clutch pipe union bolt 1 3 copper washer 2 4 clutch pipe 1 5 clutch release cylinder 1 6 dowel pi...

  • Page 253: Clutch

    Clutch 5-54 disassembling the clutch release cylinder order job/parts to remove q’ty remarks 1 boots 1 2 clutch release cylinder piston 1 3 clutch release cylinder spring 1 4 clutch release cylinder piston seal 1 5 bleed screw 1 for assembly, reverse the disassembly procedure. Ls ls 1 2 4 3 5 new t ...

  • Page 254: Clutch

    Clutch 5-55 eas25080 removing the clutch 1. Loosen: • clutch boss nut “1” note: while holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. 2. Remove: • clutch boss nut “1” • washer “2” • clutch boss assembly “3” note: there is a built-in damper between the ...

  • Page 255: Clutch

    Clutch 5-56 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 256: Clutch

    Clutch 5-57 eas25190 checking the clutch push rods 1. Check: • o-ring • short clutch push rod • long clutch push rod • ball cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • long clutch push rod bending limit out of specification → replace the defective part(s). Eas25200 checking t...

  • Page 257: Clutch

    Clutch 5-58 eas25260 installing the clutch 1. Install: • clutch housing • thrust washer note: • lubricate the clutch housing bearings with en- gine oil. • make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • make sure that the oil pump drive gear teeth and oil ...

  • Page 258: Clutch

    Clutch 5-59 6. Install: • clutch spring plate “1” • clutch spring plate retainer “2” note: tighten the clutch spring bolts in stages and in a crisscross pattern. 7. Install: • shift arm “1” note: install the shift arm “1” with its punch mark “a” aligned with the notch “b” in end of the shift shaft. ...

  • Page 259: Clutch

    Clutch 5-60 eas25290 checking the clutch master cylinder 1. Check: • clutch master cylinder body cracks/damage → replace the clutch mas- ter cylinder. • clutch fluid delivery passage (clutch master cylinder body) obstruction → blow out with compressed air. 2. Check: • clutch master cylinder kit rust...

  • Page 260: Clutch

    Clutch 5-61 3. Fill: • clutch fluid reservoir (with the specified amount of the recom- mended clutch fluid) warning ewa13370 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the same type...

  • Page 261: Clutch

    Clutch 5-62 1. Check: • clutch release cylinder body cracks/damage → replace the clutch re- lease cylinder. 2. Check: • clutch release cylinder • clutch release cylinder piston rust/scratches/wear → replace the clutch release cylinder and clutch release cylinder piston as a set. Eas25340 assembling ...

  • Page 262: Clutch

    Clutch 5-63 5. Check: • clutch lever operation soft or spongy feeling → bleed the clutch system. Refer to “bleeding the hydraulic clutch system” on page 3-14. A.

  • Page 263: Shift Shaft

    Shift shaft 5-64 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-46. 1 shift shaft 1 2 circlip 2 3 shift shaft spring 1 4 shift shaft spring stopper 1 5 washer 1 6 stopper lever 1 7 stopper lever spring...

  • Page 264: Shift Shaft

    Shift shaft 5-65 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • stopper lever ...

  • Page 265: Generator and Starter Clutch

    Generator and starter clutch 5-66 eas24480 generator and starter clutch removing the stator coil assembly order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Oil tank/front exhaust pipe refer to “engine removal” on page 5-1. 1 stator coil assembl...

  • Page 266: Generator and Starter Clutch

    Generator and starter clutch 5-67 removing the generator rotor order job/parts to remove q’ty remarks 1 starter clutch idle gear shaft #2 1 2 starter clutch idle gear shaft #1 1 3 starter clutch idle gear #2 1 4 starter clutch idle gear #1 1 5 generator rotor 1 6 woodruff key 1 7 starter clutch gear...

  • Page 267: Generator and Starter Clutch

    Generator and starter clutch 5-68 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer note: while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the rotor puller “2”) • woodruff key eas245...

  • Page 268: Generator and Starter Clutch

    Generator and starter clutch 5-69 2. Tighten: • generator rotor bolt “1” note: tighten the generator rotor bolt “1” while holding the generator rotor “2” with a sheave holder “3”. 3. Apply: • sealant (onto the stator coil assembly lead grommet) t r . . Generator rotor bolt 80 nm (8.0 m·kg, 58 ft·lb)...

  • Page 269: Electric Starter

    Electric starter 5-70 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks oil tank refer to “engine removal” on page 5-1. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal procedure. 2 1.

  • Page 270: Electric Starter

    Electric starter 5-71 disassembling the starter motor order job/parts to remove q’ty remarks 1 circlip 1 2 starter motor gear 1 3 starter motor rear cover 1 4 bearing 1 5 oil seal 1 6 circlip 1 7 starter motor front cover 1 8 brush 2 9 brush holder (along with the brushes) 1 10 brush seat (along wit...

  • Page 271: Electric Starter

    Electric starter 5-72 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 272: Electric Starter

    Electric starter 5-73 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” note: align the slot “a” on the brush seat with the tab “b” in the starter motor...

  • Page 273: Crankcase

    Crankcase 5-74 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Camshafts refer to “camshafts” on page 5-16. Pistons refer to “cylinders and pistons” on page 5-41. Shift shaft refer to “shift shaft” on page 5-64. Generat...

  • Page 274: Crankcase

    Crankcase 5-75 10 right crankcase 1 for installation, reverse the removal procedure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 275: Crankcase

    Crankcase 5-76 removing the oil baffle plate and bearings order job/parts to remove q’ty remarks oil pump refer to “oil pump” on page 5-81. Crankshaft refer to “crankshaft” on page 5-86. Transmission refer to “transmission” on page 5-92. 1 oil baffle plate 1 2 bearing retainer 1 3 bearing retainer 1...

  • Page 276: Crankcase

    Crankcase 5-77 eas25570 disassembling the crankcase note: loosen the generator shaft bolt before removing the generator rotor. 1. Loosen: • generator shaft bolt “1” note: while the holding the generator rotor “2” with the primary sheave holder “3”, loosen the generator shaft bolt. 2. Remove: • crank...

  • Page 277: Crankcase

    Crankcase 5-78 • tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crank- case mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. Eas25580 checking the crankcase 1. Thoroughly wash the cr...

  • Page 278: Crankcase

    Crankcase 5-79 • tap lightly on the left crankcase with a soft- face hammer. 4. Install: • crankcase bolts (m8) • crankcase bolts (m6) note: • lubricate the bolt threads with engine oil. • tighten each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. • tighten the bolts in nume...

  • Page 279: Crankcase

    Crankcase 5-80

  • Page 280: Oil Pump

    Oil pump 5-81 eas24910 oil pump removing the oil pump order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. 1 oil strainer (crankcase) 1 2 oil pump assembly 1 for installation, reverse the removal procedure..

  • Page 281: Oil Pump

    Oil pump 5-82 disassembling the oil pump order job/parts to remove q’ty remarks 1 spring retainer 1 2 spring 1 3 relief valve 1 4 oil pump housing cover 1 1 5 pin 2 6 spring 1 7 collar 1 8 ball 1 9 oil pump outer rotor 1 1 10 oil pump inner rotor 1 1 11 pin 1 12 oil pump housing cover 2 1 13 pin 2 1...

  • Page 282: Oil Pump

    Oil pump 5-83 18 oil seal 2 19 oil pump housing 1 for assembly, reverse the disassembly procedure. Disassembling the oil pump order job/parts to remove q’ty remarks.

  • Page 283: Oil Pump

    Oil pump 5-84 eas24960 checking the oil pump 1. Check: • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-housing-to-inner-rotor-and-ou...

  • Page 284: Oil Pump

    Oil pump 5-85 • oil pump shaft “6” • pins “7” • oil pump housing cover 2 “8” • pin “9” • oil pump inner rotor 1 “10” • oil pump outer rotor 1 “11” • ball “12” • collar “13” • spring “14” • pins “15” • oil pump housing cover 1 “16” • relief valve “17” • spring “18” • spring retainer “19” note: when i...

  • Page 285: Crankshaft

    Crankshaft 5-86 eas25960 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. 1 crankshaft 1 2 generator shaft 1 3 connecting rod cap 2 4 big end lower bearing 2 5 connecting rod 2 6 big end upper bearing 2 for installation,...

  • Page 286: Crankshaft

    Crankshaft 5-87 eas26010 removing the connecting rods the following procedure applies to all of the con- necting rods. 1. Remove: • connecting rod caps “1” • connecting rod • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place. Eas...

  • Page 287: Crankshaft

    Crankshaft 5-88 c. Put a piece of plastigauge ® “1” on the crank- shaft pin. D. Assemble the connecting rod halves. Note: • do not move the connecting rod or crankshaft until the clearance measurement has been completed. • lubricate the bolts threads and nut seats with molybdenum disulfide grease. •...

  • Page 288: Crankshaft

    Crankshaft 5-89 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Select: • big end bearings (“p 1 ”–“p 2 ”) note: • the numbers “a” stamped into the crankshaft web and the numbers “b” on the connecting rods are used to determine the replacement big end bearing sizes. • “p 1 ”–“p 2 ” refer to the...

  • Page 289: Crankshaft

    Crankshaft 5-90 7. Calculate: • crankshaft journal-to-crankshaft journal bearing clearance out of specification → replace the crank- shaft and crankshaft journal bearings as a set. Note: calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside...

  • Page 290: Crankshaft

    Crankshaft 5-91 a. Tighten the connecting rod bolts to the spec- ified torque. B. Put a mark “1” on the connecting rod bolts “2” and the connecting rod cap “3”. C. Tighten the connecting rod bolts further to reach the specified angle 120°–150°. Warning ewa12900 when the bolts are tightened more than...

  • Page 291: Transmission

    Transmission 5-92 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-74. 1 shift fork guide bar 2 2 shift drum assembly 1 3 shift fork-l 1 4 shift fork-r 1 5 shift fork-c 1 6 ...

  • Page 292: Transmission

    Transmission 5-93 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 5th pinion gear 1 4 collar 1 5 washer 1 6 2nd/3rd pinion gear 1 7 circlip 1 8 washer 1 9 4th pinion gear 1 10 collar 1 11 main axle/1st pinion gear 1 for assembly, reverse the disas...

  • Page 293: Transmission

    Transmission 5-94 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 5th wheel gear 1 2 circlip 1 3 washer 1 4 2nd wheel gear 1 5 collar 1 6 circlip 1 7 washer 1 8 1st wheel gear 1 9 collar 1 10 washer 1 11 4th wheel gear 1 12 circlip 1 13 washer 1 14 3rd wheel gear 1 15 ...

  • Page 294: Transmission

    Transmission 5-95 eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • shift fork pawl “2” bends/damage/scoring/wear → replace the shift fork. 2. Check: • shift fork guide bar roll the shift fork guide bar on a flat su...

  • Page 295: Transmission

    Transmission 5-96 • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmission axle assemblies. 5. Check: • transmission gear movement rough movem...

  • Page 296: Fuel

    Fuel 6.

  • Page 297: Fuel System

    6 fuel system fuel tank..................................................................................................... 6-1 removing the fuel tank .................................................................. 6-2 removing the fuel pump .........................................................

  • Page 299: Fuel Tank

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

  • Page 300: Fuel Tank

    Fuel tank 6-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Disconnect: • fuel hose • fuel return hose caution: ec5yu1029 although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be...

  • Page 301: Fuel Tank

    Fuel tank 6-3 caution: ec5yu1017 when installing the fuel hose and the fuel re- turn hose, make sure that they are securely connected, and that the fuel hose connector cover on the fuel hose is in the correct posi- tion, otherwise the fuel hose will not be prop- erly installed. Note: • install the f...

  • Page 302: Throttle Bodies

    Throttle bodies 6-4 eas26970 throttle bodies removing the pressure regulator and rollover valves order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air duct refer to “general chassis” on page 4-1. 1 pressure regulator cover 1 2 fuel hose (intake manifold assembly to p...

  • Page 303: Throttle Bodies

    Throttle bodies 6-5 14 rollover valve 2 1 15 rollover valve bracket 1 for installation, reverse the removal procedure. Removing the pressure regulator and rollover valves order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 9 nm...

  • Page 304: Throttle Bodies

    Throttle bodies 6-6 removing the throttle bodies order job/parts to remove q’ty remarks seat/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. 1 throttle position sensor coupler 1 disconnect. 2 cylinder-#1 intake air pressure sensor hose 1 disconnect...

  • Page 305: Throttle Bodies

    Throttle bodies 6-7 removing the intake manifolds order job/parts to remove q’ty remarks 1 fuel hose 1 2 fuel hose (intake manifold assembly to pressure regulator) 1 3 cylinder-#2 isc (idle speed control) unit outlet hose 1 4 cylinder-#1 isc (idle speed control) unit outlet hose 1 5 intake manifold ...

  • Page 306: Throttle Bodies

    Throttle bodies 6-8 removing the injectors order job/parts to remove q’ty remarks 1 fuel pipe 1 2 injector joint 1 1 3 injector joint 2 1 4 injector 2 5 intake manifold 2 for installation, reverse the removal procedure. 2 4 3 4 1 t r . . 30 nm (3.0 m • kg, 22 ft • ib) new new new new new new new new...

  • Page 307: Throttle Bodies

    Throttle bodies 6-9 eas26980 checking the injectors 1. Check: • injectors damage → replace. Eas26990 checking the throttle bodies 1. Check: • throttle bodies cracks/damage → replace the throttle bod- ies as a set. 2. Check: • fuel passages obstructions → clean. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 308: Throttle Bodies

    Throttle bodies 6-10 h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. Note: the vacuum pressure should not exceed 100 kpa (760 mm hg). Faulty → replace the pressure regulator. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ...

  • Page 309: 6-11

    Isc (idle speed control) unit 6-11 et5yu1012 isc (idle speed control) unit removing the isc (idle speed control) unit and intake solenoid order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. 1 isc (idle speed contr...

  • Page 310: 6-12

    Isc (idle speed control) unit 6-12 12 isc (idle speed control) unit coupler 1 disconnect. 13 cylinder-#1 isc (idle speed control) unit outlet hose 1 disconnect. 14 cylinder-#2 isc (idle speed control) unit outlet hose 1 disconnect. 15 isc (idle speed control) unit inlet hose 1 16 isc (idle speed con...

  • Page 311: 6-13

    Isc (idle speed control) unit 6-13 et5yu1015 checking the isc (idle speed control) system 1. Check: • hoses loose connections → connect properly. Cracks/damage → replace. 2. Check: • surge tank cracks/damage → replace. 3. Check: • one-way valve cracks/damage/faulty → replace. Note: check that air fl...

  • Page 313: Elec

    Elec 7 – +.

  • Page 314: Electrical System

    7 electrical system ignition system ......................................................................................... 7-1 circuit diagram .................................................................................. 7-1 troubleshooting ......................................................

  • Page 315

    Electrical components...................................................................... 7-85 checking the switches ................................................................. 7-89 checking the bulbs and bulb sockets ................................... 7-92 checking the fuses .................

  • Page 316: Ignition System

    Ignition system 7-1 eas27090 ignition system eas27110 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch sb /w r /l l/ w1 l /y l /g sb l /r b /r b /y l r b1 b2 b1 b2 b b2 lg r /w y /l r /g r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y ...

  • Page 317: Ignition System

    Ignition system 7-2 3. Main switch 4. Battery 8. Main fuse 10.Ecu fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.Ecu (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34...

  • Page 318: Ignition System

    Ignition system 7-3 eas27150 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. Air filter case 4. Battery box 5. Engine ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok...

  • Page 319: Ignition System

    Ignition system 7-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 7-89. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 7...

  • Page 320: Electric Starting System

    Electric starting system 7-5 eas27160 electric starting system eas27170 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch sb /w r /l l/ w1 l /y l /g sb l /r b /r b /y l r b1 b2 b1 b2 r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y l r /...

  • Page 321: Electric Starting System

    Electric starting system 7-6 3. Main switch 4. Battery 6. Starter relay 7. Starter motor 8. Main fuse 10.Ecu fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 29.Ecu (electronic control unit) 38.Decompression solenoid 56.Clutch switch 70.Auto decompression fu...

  • Page 322: Electric Starting System

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

  • Page 323: Electric Starting System

    Electric starting system 7-8 a. When the transmission is in neutral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Relay unit (starting circuit cut-off relay) 7. Relay unit (diode) 8. Clutch...

  • Page 324: Electric Starting System

    Electric starting system 7-9 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Oil tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ig...

  • Page 325: Electric Starting System

    Electric starting system 7-10 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 7-89. Replace the right handlebar switch. 9. Check the neutral switch. Refer to “checking the switches” on page 7-89. Replace ...

  • Page 326: Charging System

    Charging system 7-11 eas27200 charging system eas27210 circuit diagram b1 b2 b1 b2 r /g b2 lg y /l r /w b b b on off b b b r r b b y l b g l /g l /g b (blue) l /g b (blue) (dark green) b b w l b l w /y b /l b b l b /l b g b r /l b /l gy1 gy b l b /l w /y l b /l b /l br /y br /w p /w (bla ck) (bla ck...

  • Page 327: Charging System

    Charging system 7-12 1. Ac magneto 2. Rectifier/regulator 4. Battery 8. Main fuse.

  • Page 328: Charging System

    Charging system 7-13 eas27220 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fuses” on page 7-93. Replace the fuse. 2. Check the...

  • Page 329: Charging System

    Charging system 7-14.

  • Page 330: Lighting System

    Lighting system 7-15 eas27240 lighting system eas27250 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y l r /w r /g lg b b on off b b b r r b b y l b g l /g l /g b (blue) l /g...

  • Page 331: Lighting System

    Lighting system 7-16 3. Main switch 4. Battery 8. Main fuse 10.Ecu fuse 29.Ecu (electronic control unit) 47.High beam indicator light 50.Meter light 54.Headlight relay 57.Pass switch 58.Dimmer switch 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 75.Tail/brake light 76.License p...

  • Page 332: Lighting System

    Lighting system 7-17 eas27260 troubleshooting any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank...

  • Page 333: Lighting System

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

  • Page 334: Signaling System

    Signaling system 7-19 eas27270 signaling system eas27280 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y l r /w r /g lg b b on off b b b r r b b y l b g l /g l /g b (blue) l ...

  • Page 335: Signaling System

    Signaling system 7-20 3. Main switch 4. Battery 8. Main fuse 10.Ecu fuse 12.Backup fuse (odometer, clock and immobilizer system) 13.Relay unit 16.Neutral switch 18.Fuel sender 25.Speed sensor 29.Ecu (electronic control unit) 42.Fuel level warning light 43.Neutral indicator light 44.Multi-function me...

  • Page 336: Signaling System

    Signaling system 7-21 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. • the speedometer fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case...

  • Page 337: Signaling System

    Signaling system 7-22 ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the entire signaling system wiring. Refer to “circuit diagram” on page 7-19....

  • Page 338: Signaling System

    Signaling system 7-23 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 5. Check the entire signaling system wiring. Refer to “circuit diagram” on page 7...

  • Page 339: Signaling System

    Signaling system 7-24.

  • Page 340: Fuel Injection System

    Fuel injection system 7-25 eas27330 fuel injection system eas27340 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y l r /w r /g lg b b on off b b b r r b b y l b g l /g l /g b...

  • Page 341: Fuel Injection System

    Fuel injection system 7-26 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.Ecu fuse 15.Fuel pump relay 16.Neutral switch 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Throttle position sensor 22.Cylinder-#1 intake air pressure sensor 23.Cylinder-#2 intake ...

  • Page 342: Fuel Injection System

    Fuel injection system 7-27 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 343: Fuel Injection System

    Fuel injection system 7-28 eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the ...

  • Page 344: Fuel Injection System

    Fuel injection system 7-29 24 o 2 sensor no normal signal is received from the o 2 sensor. Able able 25 cylinder-#2 intake air pressure sensor (open or short circuit) cylinder-#2 intake air pressure sensor: open or short circuit detected. Able able 26 cylinder-#2 intake air pressure sensor (hose sys...

  • Page 345: Fuel Injection System

    Fuel injection system 7-30 communication error with the meter 42 speed sensor no normal signals are received from the speed sensor. Able able neutral switch open or short circuit is detected in the neutral switch. 43 fuel system voltage (monitoring voltage) the ecu is unable to monitor the battery v...

  • Page 346: Fuel Injection System

    Fuel injection system 7-31 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 faulty s...

  • Page 347: Fuel Injection System

    Fuel injection system 7-32 note: • all displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays. • “diag” appears on the odometer/trip meter/fuel reserve trip meter lcd. 4. Press the “select” button to select the diagnostic mode “diag”. 5. After selec...

  • Page 348: Fuel Injection System

    Fuel injection system 7-33 14 cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). • cylinder-#1 intake air pressure sensor hose is detached, clogged, kinked, or pinched. • malfunction in ecu. 03 15 throttle position sensor: open or short circuit detected. • op...

  • Page 349: Fuel Injection System

    Fuel injection system 7-34 33 malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. • open or short circuit in wire sub lead. • open or short circuit in wire harness. • malfunction in cylinder-#1 left or right ignition coil. • malfunction in ecu. • malfunction in a...

  • Page 350: Fuel Injection System

    Fuel injection system 7-35 42 no normal signals are received from the speed sensor. Open circuit is detected in the neutral switch. • open circuit in wire harness. • defective speed sensor. • malfunction in vehicle speed sensor detected. • defective neutral switch. • malfunction in the engine side o...

  • Page 351: Fuel Injection System

    Fuel injection system 7-36 sensor operation table er-4 non-registered data has been received from the meter. • improper connection in wire harness. • malfunction in meter. • malfunction in ecu. — diag- nostic code no. Item meter display checking method 01 throttle angle • fully closed position 15–20...

  • Page 352: Fuel Injection System

    Fuel injection system 7-37 11 engine temperature displays the engine temperature. Compare the actually measured engine temperature with the meter display value. 12 muffler cooling fan temperature displays the muffler cooling fan temperature. Compare the actually measured muffler cooling fan temperat...

  • Page 353: Fuel Injection System

    Fuel injection system 7-38 actuator operation table 63 stopping the flashing of the engine trouble warning light (erasing the muffler cooling fan temperature sensor fault code) 00 to stop the flashing of the engine trouble warning light, set the engine stop switch to “ ”. 70 control number 0–255 — d...

  • Page 354: Fuel Injection System

    Fuel injection system 7-39 eas27460 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 355: Fuel Injection System

    Fuel injection system 7-40 code number displayed on the meter when the engine failed to work normally. Refer to “self-diagnos- tic function table”. Diagnostic code no.: diagnostic code number to be used when the diagnostic mode is operated. Refer to “diagnostic mode” on page 7-31. Fault code no. 12 ...

  • Page 356: Fuel Injection System

    Fuel injection system 7-41 fault code no. 13 symptom cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 357: Fuel Injection System

    Fuel injection system 7-42 fault code no. 14 symptom cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 358: Fuel Injection System

    Fuel injection system 7-43 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 reinstatement method 1 installed condition of throttle position sensor. • c...

  • Page 359: Fuel Injection System

    Fuel injection system 7-44 fault code no. 17 symptom exup servo motor circuit: open or short circuit detected. Diagnostic code no. 53 exup servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness e...

  • Page 360: Fuel Injection System

    Fuel injection system 7-45 fault code no. 19 symptom a break or disconnection of the blue/yellow lead of the ecu is detected. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler •...

  • Page 361: Fuel Injection System

    Fuel injection system 7-46 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed state of o 2 sensor. Check for looseness or pinching. Starting the engine ...

  • Page 362: Fuel Injection System

    Fuel injection system 7-47 fault code no. 25 symptom cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 363: Fuel Injection System

    Fuel injection system 7-48 fault code no. 26 symptom cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 364: Fuel Injection System

    Fuel injection system 7-49 fault code no. 28 symptom engine temperature sensor: open or short circuit detect- ed. Diagnostic code no. 11 engine temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed state of engine temperature sensor. Ch...

  • Page 365: Fuel Injection System

    Fuel injection system 7-50 fault code no. 29 symptom decompression solenoid (thermistor): open or short cir- cuit detected. Diagnostic code no. 55 decompression solenoid order item/components and probable cause check or maintenance job reinstatement method 1 installed state of decompression solenoid...

  • Page 366: Fuel Injection System

    Fuel injection system 7-51 fault code no. 33 symptom malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code no. 30, 32 cylinder-#1 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 367: Fuel Injection System

    Fuel injection system 7-52 fault code no. 34 symptom malfunction detected in the primary wire of the cylinder-#2 left ignition coil. Diagnostic code no. 31 cylinder-#2 left ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#...

  • Page 368: Fuel Injection System

    Fuel injection system 7-53 fault code no. 35 symptom malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code no. 30, 32 cylinder-#1 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 369: Fuel Injection System

    Fuel injection system 7-54 fault code no. 36 symptom malfunction detected in the primary wire of the cylinder-#2 right ignition coil. Diagnostic code no. 33 cylinder-#2 right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 370: Fuel Injection System

    Fuel injection system 7-55 fault code no. 37 symptom engine speed is high when the engine is idling. Diagnostic code no. 54 isc valve order item/components and probable cause check or maintenance job reinstatement method 1 ecu fuse is blown. • check the ecu fuse. Refer to “checking the fuses” on pag...

  • Page 371: Fuel Injection System

    Fuel injection system 7-56 fault code no. 38 symptom decompression solenoid: open or short circuit detected. Diagnostic code no. 55 decompression solenoid order item/components and probable cause check or maintenance job reinstatement method 1 installed state of decompression solenoid. Check for loo...

  • Page 372: Fuel Injection System

    Fuel injection system 7-57 fault code no. 41 symptom lean angle cut-off switch: open or short circuit detected. Diagnostic code no. 08 lean angle cut-off switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle cut-off switch coupler • ...

  • Page 373: Fuel Injection System

    Fuel injection system 7-58 fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open 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 reinstatement m...

  • Page 374: Fuel Injection System

    Fuel injection system 7-59 b-1 connections • neutral switch coupler • main wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. Starting the engine, and...

  • Page 375: Fuel Injection System

    Fuel injection system 7-60 fault code no. 43 symptom the ecu is unable to monitor the battery voltage (an open or short circuit in the line to the ecu). Diagnostic code no. 09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • r...

  • Page 376: Fuel Injection System

    Fuel injection system 7-61 fault code no. 46 symptom power supply to the fuel injection system is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • check the coupler for any pins ...

  • Page 377: Fuel Injection System

    Fuel injection system 7-62 fault code no. 62 symptom muffler cooling fan temperature sensor: open or short cir- cuit detected. Diagnostic code no. 12 muffler cooling fan temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of...

  • Page 378: Fuel Injection System

    Fuel injection system 7-63 fault code no. 63 symptom engine trouble warning light is flashing. (abnormally high temperature is detected by muffler cooling fan tempera- ture sensor.) diagnostic code no. 12 51 63 muffler cooling fan temperature sensor muffler cooling fan motor relay stopping the flash...

  • Page 379: Fuel Injection System

    Fuel injection system 7-64 fault code no. Er-2 symptom no signals are received from the ecu within the specified duration. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness ...

  • Page 380: Fuel Injection System

    Fuel injection system 7-65 fault code no. Er-4 symptom non-registered data has been received from the meter. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly...

  • Page 381: Fuel Injection System

    Fuel injection system 7-66.

  • Page 382: Fuel Pump System

    Fuel pump system 7-67 eas27550 fuel pump system eas27560 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b on off b b b r r b b y l b g l /g l /g b (blue) l /g b (blue) (dark green) b b b3 b3 w l b l w /y b /l b b l b /...

  • Page 383: Fuel Pump System

    Fuel pump system 7-68 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.Ecu fuse 15.Fuel pump relay 17.Fuel pump 29.Ecu (electronic control unit) 73.Engine stop switch 81.Ignition fuse.

  • Page 384: Fuel Pump System

    Fuel pump system 7-69 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, fuel inje...

  • Page 385: Fuel Pump System

    Fuel pump system 7-70

  • Page 386: Muffler Cooling System

    Muffler cooling system 7-71 et5yu1002 muffler cooling system et5yu1003 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b on off b b b r r b b y l b g l /g l /g b (blue) l /g b (blue) (dark green) b b b3 b3 w l b l w /y ...

  • Page 387: Muffler Cooling System

    Muffler cooling system 7-72 4. Battery 8. Main fuse 9. Muffler cover fan fuse 10.Ecu fuse 26.Muffler cooling fan temperature sensor 29.Ecu (electronic control unit) 78.Muffler cooling fan motor 79.Muffler cooling fan motor relay.

  • Page 388: Muffler Cooling System

    Muffler cooling system 7-73 et5yu1004 troubleshooting the muffler cooling fan motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, muffler cover fan, and ecu) refer to “checki...

  • Page 389: Muffler Cooling System

    Muffler cooling system 7-74.

  • Page 390: Immobilizer System

    Immobilizer system 7-75 eas27640 immobilizer system eas27650 circuit diagram br /w b l /b r /y b /y pg y b dg ch br /w l /y g /l r /y b /y b g y b dg ch b1 b2 b1 b2 r /g b2 lg y /l r /w b b b l g g sb /w r /g lg dg r /w ch y /l y /l y l r /w r /g lg b b on off b b b r r b b y l b g l /g l /g b (blue...

  • Page 391: Immobilizer System

    Immobilizer system 7-76 3. Main switch 4. Battery 8. Main fuse 10.Ecu fuse 11.Immobilizer unit 12.Backup fuse (odometer, clock and immobilizer system) 29.Ecu (electronic control unit) 44.Multi-function meter 46.Immobilizer system indicator light 81.Ignition fuse.

  • Page 392: Immobilizer System

    Immobilizer system 7-77 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 393: Immobilizer System

    Immobilizer system 7-78 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with ...

  • Page 394: Immobilizer System

    Immobilizer system 7-79 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a standa...

  • Page 395: Immobilizer System

    Immobilizer system 7-80 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost sta...

  • Page 396: Immobilizer System

    Immobilizer system 7-81 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number ...

  • Page 397: Immobilizer System

    Immobilizer system 7-82 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. 52 immobilizer unit codes between the key and immobilizer unit do not match. 1. Signal rece...

  • Page 398: Immobilizer System

    Immobilizer system 7-83 example: fault code 52 a b a. Light on b. Light off.

  • Page 399: Immobilizer System

    Immobilizer system 7-84.

  • Page 400: Electrical Components

    Electrical components 7-85 eas27970 electrical components 4 3 5 7 6 8 9 10 12 13 14 15 1 2 11.

  • Page 401: Electrical Components

    Electrical components 7-86 1. Air temperature sensor 2. Cylinder-#2 left ignition coil 3. Cylinder-#2 right ignition coil 4. Isc (idle speed control) unit 5. Intake solenoid 6. Cylinder-#1 right ignition coil 7. Cylinder-#1 left ignition coil 8. Muffler cooling fan temperature sensor 9. Muffler cool...

  • Page 402: Electrical Components

    Electrical components 7-87 3 4 6 5 8 7 9 11 12 13 14 15 16 17 18 1 2 10

  • Page 403: Electrical Components

    Electrical components 7-88 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor 3. Immobilizer unit 4. Throttle position sensor 5. Main fuse 6. Fuse box 7. Muffler cooling fan motor relay 8. Ecu (electronic control unit) 9. Headlight relay 10.Relay unit 11.Turn signal/...

  • Page 404: Electrical Components

    Electrical components 7-89 eas27980 checking the switches br/w b l/b r/y b/y p g y b dg ch b b (black) r/w l/w r/b b b/y b (blue) (brown) b b (blue) b b b b b 11 12 13 8 5 6 9 10 1 2 7 3 b b r/y y y l/b g dg br/w ch dg br/w ch p b/y b b r/w r/b l/w b/y r br/l br/r 4 r br/l br/r on off l/w b/y.

  • Page 405: Electrical Components

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

  • Page 406: Electrical Components

    Electrical components 7-91 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 407: Electrical Components

    Electrical components 7-92 eas27990 checking the bulbs and bulb sockets note: do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or ...

  • Page 408: Electrical Components

    Electrical components 7-93 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 409: Electrical Components

    Electrical components 7-94 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • lead holder • seat refer to “general chassis” on page 4-1. Eas28030 checking and charging the battery warning...

  • Page 410: Electrical Components

    Electrical components 7-95 b. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Caution: eca13670 • never...

  • Page 411: Electrical Components

    Electrical components 7-96 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a constant volt- age charger a. Measure the open-circuit voltage prior to charging. Note: voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat-...

  • Page 412: Electrical Components

    Electrical components 7-97 relay unit (starting circuit cut-off relay) relay unit (fuel pump relay) headlight relay muffler cooling fan motor relay et5yu1021 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the ma...

  • Page 413: Electrical Components

    Electrical components 7-98 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay input voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • turn signal/hazard relay output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a...

  • Page 414: Electrical Components

    Electrical components 7-99 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 c...

  • Page 415: Electrical Components

    Electrical components 7-100 c. Measure the secondary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et5yu1032 checking the ignition spark gap 1. Check: • ignition spark gap out of specification → perform the ignition system troubleshooting, starting with step 5. Refer to “trouble...

  • Page 416: Electrical Components

    Electrical components 7-101 2. Check: • lean angle cut-off switch output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the lean angle cut-off switch coupler to the lean angle cut-off switch. B. Connect the pocket tester (dc 20 v) to the lean ang...

  • Page 417: Electrical Components

    Electrical components 7-102 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead. B. Connect the pocket tester (dc 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run at appro...

  • Page 418: Electrical Components

    Electrical components 7-103 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the en- gine temperature sensor terminal as shown. B. Immerse the engine temperature sensor “1” in a container filled with water “2”. Note: make sure that the engine temperature se...

  • Page 419: Electrical Components

    Electrical components 7-104 b. Turn the main switch to “on”. C. Elevate the rear wheel and slowly rotate it. D. Measure the voltage of white/yellow and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 420: Electrical Components

    Electrical components 7-105 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert a plug “1” into the fuel return hose end. B. Fill the fuel tank. C. Put the end of the fuel hose “2” into an open container. D. Connect the battery (dc 12 v) to the fuel pump terminal as shown. E. Check the fuel ...

  • Page 421: Electrical Components

    Electrical components 7-106 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the decompression solenoid cou- plers from the wire harness. B. Connect the pocket tester ( Ω × 10) to the de- compression solenoid coupler as shown. C. Measure the decompression solenoid (ther- mistor) resis...

  • Page 422: Electrical Components

    Electrical components 7-107 et5yu1007 checking the air temperature sensor 1. Remove: • air temperature sensor warning ew5yu1002 • handle the air temperature sensor with special care. • never subject the air temperature sensor to strong shocks. If the air temperature sen- sor is dropped, replace it. ...

  • Page 423: Electrical Components

    Electrical components 7-108 c. Check the muffler cooling fan motor move- ment. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et5yu1006 checking the muffler cooling fan temperature sensor 1. Remove: • muffler cooling fan temperature sensor warning ew5yu1003 • handle the muffler cooling fan temper...

  • Page 424: Trbl

    Trbl shtg 8.

  • Page 425: Troubleshooting

    8 troubleshooting troubleshooting..................................................................................... 8-1 general information ....................................................................... 8-1 starting failures...................................................................

  • Page 427: Troubleshooting

    Troubleshooting 8-1 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 trouble- shooting. Refer to the relative procedure in this manual for checks, ...

  • Page 428: Troubleshooting

    Troubleshooting 8-2 electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator • faulty spark plug cap 3. Ignition coil(s) • broken or sho...

  • Page 429: Troubleshooting

    Troubleshooting 8-3 eas28590 overheating engine 1. Cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality fuel system 1. Throttle body(-ies) • faulty throttle body(-ies) • damaged or loose throttle body joint 2. Air ...

  • Page 430: Troubleshooting

    Troubleshooting 8-4 • incorrect connection • improperly grounded circuit • poor contacts (main or light switch) • burnt-out headlight bulb headlight bulb burnt out • wrong headlight bulb • faulty battery • faulty rectifier/regulator • improperly grounded circuit • faulty main switch • faulty light s...

  • Page 431: Wiring Diagram

    Eas28740 wiring diagram mt-01(t) 2005 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Battery 5. Fuel injection system fuse 6. Starter relay 7. Starter motor 8. Main fuse 9. Muffler cover fan fuse 10. Ecu fuse 11. Immobilizer unit 12. Backup fuse (odometer, clock and immobilizer sys- tem) 13....

  • Page 432

    L/b blue/black l/g blue/green l/r blue/red l/w blue/white l/y blue/yellow p/l pink/blue p/w pink/white p/y pink/yellow r/b red/black r/g red/green r/l red/blue r/w red/white r/y red/yellow sb/w sky blue/white w/b white/black w/g white/green w/r white/red w/y white/yellow y/b yellow/black y/g yellow/...

  • Page 434

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

  • Page 435: Mt-01(T) 2005 Wiring Diagram

    Mt-01(t) 2005 wiring diagram br/w b l/b r/y b/y p g y b dg ch br/w l/y g/l r/y b/y b g y b dg ch sb/w r/l l/w1 l/y l/g sb l/r b/r b/y l r b1 b2 b1 b2 b b2 lg r/w y/l r/g r/g b2 lg y/l r/w b b b l g g sb/w r/g lg dg r/w ch y/l y/l y l r/w r/g lg b b on off b b b r r b b y l b g l/g l/g b (blue) l/g b...