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Yamaha MT-03 Service Manual

Other manuals for MT-03: Owner's Manual

Summary of MT-03

  • Page 1

    Mt-03 service manual 2006 5yk-f8197-e0 cn=lazarus, o=administrator, ou=mtoc, email=admin@mt oc.Org.Uk, c=gb.

  • Page 2

    Mt-03 (2006) service manual © 2006 by yamaha motor italia s.P.A. First edition, february 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor italia s.P.A. Is expressly prohibited. Printed in italy.

  • Page 3

    Eas00020 notice this manual was produced by the yamaha motor italia s.P.A. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yamaha...

  • Page 4

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

  • Page 5

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

  • Page 6: General Information

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

  • Page 8: General Information

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

  • Page 10: Identification

    1-1 identification identification eas00170 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas00180 model label the model label “1” is affixed to the frame un- der the passenger seat. This information will be needed to ord...

  • Page 11: Features

    1-2 features eas00019 features eas00896 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temper- ature. In a conventional carburetor s...

  • Page 12: Features

    1-3 features eas00897 fi system the fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fu- el pressure that is applied to the injector at 324 kpa (3.24 kg/cm 2 , 46.1 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal...

  • Page 13: Features

    1-4 features instrument functions eaub1392 multi-function meter unit ewa12421 warning be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer 2. Tachometer 3. Clock 4. Odometer/tripmeters/fuel reserve tripmeter 5. “select” button 6. “reset” butt...

  • Page 14: Features

    1-5 features odometer, tripmeter modes 1. “select” button 2. “reset” button pushing the “select” button switches the dis- play between the odometer mode “odo” and the tripmeter modes “trip 1” and “trip 2” in the following order: odo 6 trip 1 6 trip 2 6 odo if the fuel level warning light comes on, t...

  • Page 15: Features

    1-6 features self-diagnosis devices 1. Engine trouble warning light “u” 2. Immobilizer system indicator light “ ” this model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will start flashing. Refer t...

  • Page 16: Important Information

    1-7 important information 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 equipment. Refer to “special tools” on page 1-10. 3. When disassembl...

  • Page 17: Important Information

    1-8 important information 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

    1-9 checking the connections 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

    1-10 special tools eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or im- provised techniques. Special tools, part numbers...

  • Page 20: Special Tools

    1-11 special tools tool name/tool no. Illustration reference pages pressure gauge 90890-03153 fuel pressure adapter 90890-03176 radiator cap tester 90890-01325 radiator cap tester adaptor 90890-01352 radiator cap tester adapter 90890-01497 radiator tester adapter 90890-01496 thickness gauge 90890-03...

  • Page 21: Special Tools

    1-12 special tools tool name/tool no. Illustration reference pages slide hammer bolt 90890-01083 weight 90890-01084 piston pin puller set 90890-01304 valve guide remover (ø 6) 90890-04064 valve guide installer (ø 6) 90890-04065 valve guide reamer (ø 6) 90890-04066 valve lapper 90890-04101 flywheel p...

  • Page 22: Special Tools

    1-13 special tools tool name/tool no. Illustration reference pages universal clutch holder 90890-04086 crankcase separating tool 90890-01135 crankshaft installer pot 90890-01274 crankshaft installer bolt 90890-01275 adapter 90890-04130 spacer (crankshaft installer) 90890-04144 middle driven shaft be...

  • Page 23: Special Tools

    1-14 special tools tool name/tool no. Illustration reference pages t-handle 90890-01326 damper rod holder 90890-01460 fork seal driver weight 90890-01367 fork seal driver attachment (ø 43) 90890-01374 yamaha bond no. 1215 90890-85505 4-49, 4-51 4-51, 4-52 5-56, 5-63, 5-65, 6-10

  • Page 24: Specifications

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

  • Page 26: General Specifications

    2-1 general specifications general specifications model model code 5yk1 (europe) 5yk3 (mt-03 25kw) dimensions overall length 2070 mm (81.49 in) overall width 860 mm (33.85 in) overall height 1115 mm (43.89 in) seat height 805 mm (31.69 in) wheelbase 1420 mm (55.90 in) minimum ground clearance 200 mm...

  • Page 27: Engine Specifications

    2-2 engine specifications engine specifications engine engine type liquid-cooled, 4-stroke, sohc displacement 660 cm 3 (40.27 cu·in) cylinder arrangement forward-inclined single cylinder bore x stroke 100.0 x 84.0 mm (3.94 x 3.31 in) compression ratio 10.00 : 1 standard compression pressure (at sea ...

  • Page 28: Engine Specifications

    2-3 engine specifications cooling system radiator capacity 1.00 l (1.06 us qt) (0.88 imp.Qt) radiator cap opening pressure 110.0-140.0 kpa (16.0-20.3 psi) (1.10-1.40 kg/cm 2 ) radiator core width 280.0 mm (11.02 in) height 158.0 mm (6.22 in) depth 23.0 mm (0.91 in) coolant reservoir capacity 0.25 l ...

  • Page 29: Engine Specifications

    2-4 engine specifications camshaft drive system chain drive (left) intake camshaft lobe dimensions measurement a 43.488-43.588 mm (1.7121-1.7161 in) limit 43.338 mm (1.7062 in) measurement b 36.959-37.059 mm (1.4551-1.4590 in) limit 36.859 mm (1.4511 in) exhaust camshaft lobe dimensions measurement ...

  • Page 30: Engine Specifications

    2-5 engine specifications valves, valve seats, valve guides valve clearance (cold) intake 0.09-0.13 mm (0.0035-0.0051 in) exhaust 0.16-0.20 mm (0.0063-0.0079 in) valve dimensions valve head diameter a (intake) 37.90-38.10 mm (1.4921-1.5000 in) valve head diameter a (exhaust) 31.90-32.10 mm (1.2559-1...

  • Page 31: Engine Specifications

    2-6 engine specifications limit 6.05 mm (0.2382 in) valve-stem to valve-guide clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in) limit 0.08 mm (0.0031 in) valve-stem to valve-guide clearance (exhaust) 0.025-0.052 mm (0.0010-0.0020 in) limit 0.10 mm (0.0039 in) valve stem runout 0.010 mm (0.0004 in...

  • Page 32: Engine Specifications

    2-7 engine specifications piston piston-to-cylinder clearance 0.030-0.055 mm (0.0012-0.0022 in) limit 0.13 mm (0.0051 in) diameter d 99.955-99.970 mm (3.9352-3.9358 in) height h 10.0 mm (0.39 in) piston pin bore (in the piston) diameter 23.004-23.015 mm (0.9057-0.9061 in) limit 23.045 mm (0.9073 in)...

  • Page 33: Engine Specifications

    2-8 engine specifications oil ring dimensions (b x t) 2.50 x 3.40 mm (0.098 x 0.134 in) end gap (installed) 0.20-0.70 mm (0.0079-0.0276 in) ring side clearance 0.060-0.150 mm (0.0024-0.0059 in) crankshaft width a 74.95-75.00 mm (2.9508-2.9528 in) maximum runout c 0.040 mm (0.0016 in) big end side cl...

  • Page 34: Engine Specifications

    2-9 engine specifications clutch plates thickness 1.50-1.70 mm (0.059-0.067 in) plate quantity 6 maximum warpage 0.20 mm (0.0079 in) clutch spring free length 55.60 mm (2.19 in) limit 52.82 mm (2.08 in) quantity 5 transmission transmission type constant mesh, 5-speed primary reduction system spur ge...

  • Page 35: Chassis Specifications

    2-10 chassis specifications chassis specifications frame frame type truss diamond caster angle 26° trail 97.0 mm (3.81 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 material aluminum wheel travel 130 mm (5.12 in) maximum radial wheel runout 1.0 mm (0.04 in) maximum lateral wheel runo...

  • Page 36: Chassis Specifications

    2-11 chassis specifications high-speed riding front 210 kpa (30 psi) (2.1 kgf/cm 2 ) (2.1 bar) rear 230 kpa (33 psi) (2.3 kgf/cm 2 ) (2.3 bar) front brakes brake type dual-disc brake operation right-hand operation recommended fluid dot 4 brake discs diameter x thickness 298.0 x 5.0 mm (11.73 x 0.20 ...

  • Page 37: Chassis Specifications

    2-12 chassis specifications front suspension suspension type telescopic fork front fork type coil spring/oil damper front fork travel 130.0 mm (5.12 in) spring free length 376.0 mm (14.80 in) limit 368.0 mm (14.48 in) installed length 365.0 mm (14.37 in) spring rate (k1) 7.38 n/mm (42.13 lb/in) (0.7...

  • Page 38: Electrical Specifications

    2-13 electrical specifications electrical specifications voltage system voltage 12 v ignition system ignition system type transistorized coil ignition (digital) ignition timing 9.0° btdc at 1400 r/min advancer type electrical crankshaft position sensor 192-288 Ω at 20 °c (68 °f)/ resistance/color bl...

  • Page 39: Electrical Specifications

    2-14 electrical specifications bulbs (voltage/wattage x quantity) headlight 12 v 55.0 w/60.0 w x 1 auxiliary light 12 v 3.0 w x 1 tail/brake light 12 v 5.0 w/21.0 w x 1 front turn signal light 12 v 10.0 w x 2 rear turn signal light 12 v 10.0 w x 2 meter lighting led (backlight) indicator light (volt...

  • Page 40: Electrical Specifications

    2-15 electrical specifications relay unit model/manufacturer g8r-30y-v4/omron coil resistance 162-198 Ω diode yes throttle position sensor model/manufacturer 5ps1/mikuni resistance 4.0-6.0 kΩ headlight relay model/manufacturer acm33211 m04/matsushita radiator fan model/manufacturer va31-a100-46a/spa...

  • Page 41: Tightening Torques

    2-16 tightening torques tightening torques eas00030 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of thi...

  • Page 42: Tightening Torques

    2-17 tightening torques engine tightening torques item thread q’ty tightening torque remarks size cylinder head stud bolts (exhaust pipe) m8 4 15 nm (1.5 m·kg, 11 ft·lb) cylinder head (left side) l=145 mm (5.71 in) m9 2 50 nm (5.0 m·kg, 36 ft·lb) cylinder head (right side) l=135 mm (5.31 in) m9 2 50...

  • Page 43: Tightening Torques

    2-18 tightening torques item thread q’ty tightening torque remarks size water jacket joint m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) crankcase cover (right) m6 9 10 nm (1.0 m·kg, 7.2 ft·lb) oil strainer m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) oil pump m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) oil baffle plate 2 m5 2 4 nm (0...

  • Page 44: Tightening Torques

    2-19 tightening torques item thread q’ty tightening torque remarks size a.C.Magneto cover m6 8 10 nm (1.0 m·kg, 7.2 ft·lb) a.C.Magneto rotor m16 1 80 nm (8.0 m·kg, 58 ft·lb) a.C.Magneto lead holder m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) crankcase (left side) m6 6 10 nm (1.0 m·kg, 7.2 ft·lb) crankcase (rig...

  • Page 45: Tightening Torques

    2-20 tightening torques item thread q’ty tightening torque remarks size engine mounting: engine front and stay engine m10 2 65 nm (6.5 m·kg, 47 ft·lb) stay engine (engine front) and frame m10 2 65 nm (6.5 m·kg, 47 ft·lb) engine rear under and frame m10 1 65 nm (6.5 m·kg, 47 ft·lb) stay engine (engin...

  • Page 46: Tightening Torques

    2-21 tightening torques item thread q’ty tightening torque remarks size union bolt and front master m10 1 30 nm (3.0 m·kg, 22 ft·lb) cylinder front fork under bracket and m10 2 28 nm (2.8 m·kg, 20 ft·lb) inner tube headlight stay 1, 2 (upper side) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) and handle crown hea...

  • Page 47: Tightening Torques

    2-22 tightening torques item thread q’ty tightening torque remarks size starter relay and wire (+)/ m6 2 8 nm (0.8 m·kg, 5.8 ft·lb) starting motor cord pressure sensor and frame m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) lead wire (+/-) and battery m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) front and rear wheel: front wh...

  • Page 48

    2-23 lubrication points and lubricant types lubrication point lubricant oil seal lips o-rings bearings cylinder head tightening bolts cylinder tightening bolts crankshaft pin timing chain sprocket inner surface connecting rod big end thrust surface piston pin piston and ring groove balancer weight t...

  • Page 49

    2-24 lubrication points and lubricant types lubrication point lubricant shift shaft spacer crankcase mating surface yamaha bond no.1215 a.C. Magnet lead grommet (a.C. Magneto cover) yamaha bond no.1215 oil seal holder tightening bolt yamaha bond no.1215 oil delivery hose 2 tightening bolt yamaha bon...

  • Page 50

    2-25 lubrication points and lubricant types lubrication point lubricant front wheel oil seal lips (left and right) rear wheel oil seal lips (left and right) rear wheel drive hub contact surface rear arm pivot shaft outer surface and bush outer surface and oil seal lip dust cover thrust surface rear ...

  • Page 51: Cooling System Diagrams

    2-26 cooling system diagrams eas00033 cooling system diagrams 5vk 5vk00 a 4 a b 4 3 2 1 2 3 1 a a a.

  • Page 52: Cooling System Diagrams

    2-27 cooling system diagrams 1. Water jacket joint 2. Water pump outlet hose 3. Water pump outlet pipe 4. Water pump a. From the radiator b. To the cylinder.

  • Page 53: Cooling System Diagrams

    2-28 cooling system diagrams 1 2 3 4 5 6 7 8 9 5 10 11 a b c.

  • Page 54: Cooling System Diagrams

    2-29 cooling system diagrams 1. Fast idle plunger outlet hose 2. Coolant reservoir hose 3. Coolant reservoir breather hose 4. Radiator cap 5. Radiator 6. Coolant reservoir cap 7. Coolant reservoir 8. Radiator outlet hose 9. Water pump 10. Radiator fan 11. Radiator inlet hose a. From the fast idle pl...

  • Page 55: Lubrication Chart

    2-30 lubrication chart lubrication chart oil strainer oil pump rotor 2 check ball oil filter cylinder head drive axle crankshaft camshaft oil tank main axle oil pan oil pump rotor 1 connecting rod.

  • Page 56: Lubrication Chart

    2-31 lubrication chart : pressure feed : splashed scavenge.

  • Page 57: Lubrication Diagrams

    2-32 lubrication diagrams lubrication diagrams a a 1 3 2 2 4 a-a a-a.

  • Page 58: Lubrication Diagrams

    2-33 lubrication diagrams 1. Oil delivery hose 2 2. Oil strainer 3. Oil delivery hose 1 4. Oil tank.

  • Page 59: Lubrication Diagrams

    2-34 lubrication diagrams a-a a a 3 1 2 3 4.

  • Page 60: Lubrication Diagrams

    2-35 lubrication diagrams 1. Oil delivery pipe 2 2. Oil delivery pipe 1 3. Oil filter 4. Oil pump.

  • Page 61: Lubrication Diagrams

    2-36 lubrication diagrams 1 7 2 3 4 5 6 a.

  • Page 62: Lubrication Diagrams

    2-37 lubrication diagrams 1. Oil delivery hose 2 2. Oil delivery pipe 2 3. Oil filter 4. Oil pump rotor 1 5. Oil pump rotor 2 6. Main axle 7. Oil delivery pipe 3 a. To oil tank.

  • Page 63: Lubrication Diagrams

    2-38 lubrication diagrams 1 6 5 4 3 2.

  • Page 64: Lubrication Diagrams

    2-39 lubrication diagrams 1. Camshaft 2. Oil delivery pipe 1 3. Oil filter 4. Main axle 5. Drive axle 6. Crankshaft.

  • Page 65: Cable Routing

    2-40 cable routing cable routing.

  • Page 66: Cable Routing

    2-41 cable routing warning proper cable and lead routing are essential to insure safe motorcycle operation. 1. Clutch cable 2. Throttle cables 3. Front brake hose 4. Front brake light switch lead 5. Plastic band 6. Right handlebar switch lead 7. Piece connecting and plastic band 8. Clutch switch lea...

  • Page 67: Cable Routing

    2-42 cable routing.

  • Page 68: Cable Routing

    2-43 cable routing 1. Plastic band 2. Front brake light switch lead 3. Meter assembly lead 4. Piece connecting and plastic band 5. Clutch cable 6. Clutch switch lead 7. Left handlebar switch lead 8. Front turn signal light coupler (left) 9. Auxiliary light coupler 10. Front brake hose holder 11. Hea...

  • Page 69: Cable Routing

    2-44 cable routing.

  • Page 70: Cable Routing

    2-45 cable routing 1. Front brake hose holder 2. Front brake hose 3. Front fork under bracket 4. Front brake caliper (left) 5. Front brake caliper (right) 6. Brake caliper projection 7. Front mud guard a. When installing the brake hose onto the brake caliper, make sure that the brake pipe touches th...

  • Page 71: Cable Routing

    2-46 cable routing.

  • Page 72: Cable Routing

    2-47 cable routing 1. Main switch 2. Front brake light switch lead 3. Plastic band 4. Rear brake light switch coupler 5. Spark plug lead 6. Clutch cable 7. Coolant temperature sensor lead 8. Plastic band 9. Intake air temperature sensor lead 10. Intake air pressure sensor 11. Throttle position senso...

  • Page 73: Cable Routing

    2-48 cable routing.

  • Page 74: Cable Routing

    2-49 cable routing 1. Plastic band 2. Clutch cable 3. Starter motor 4. Negative battery lead 5. Starter negative lead 6. Rear brake pedal 7. Rear brake light switch 8. Rear brake master cylinder 9. Rear brake hose 10. Rear brake hose holder 11. Rear brake caliper.

  • Page 75: Cable Routing

    2-50 cable routing.

  • Page 76: Cable Routing

    2-51 cable routing 1. Main switch 2. Positive battery lead 3. Battery 4. Battery cover 5. Relay unit 6. Starter relay 7. Speed sensor lead 8. Intake air pressure sensor 9. Positive starter lead 10. Horn lead 11. Throttle cables 12. Reserve fuse 13. Main fuse 14. Left handlebar switch lead 15. Right ...

  • Page 77: Cable Routing

    2-52 cable routing.

  • Page 78: Cable Routing

    2-53 cable routing 1. Throttle cables 2. Ecu 3. Lean angle cut-off switch 4. Starter negative lead 5. A.C. Magneto lead 6. Speed sensor 7. Plastic band 8. Rubber protection 9. Rectifier/regulator 10. Sidestand switch lead 11. Neutral switch lead 12. Starter motor 13. Hose holder 14. Main wire harnes...

  • Page 79: Cable Routing

    2-54 cable routing.

  • Page 80: Cable Routing

    2-55 cable routing 1. Throttle cables 2. Ecu 3. Lean angle cut-off switch 4. Starter negative lead 5. A.C. Magneto lead 6. Speed sensor 7. Plastic band 8. Rubber protection 9. Rectifier/regulator 10. Sidestand switch lead 11. Neutral switch lead 12. Starter motor 13. Hose holder 14. Main wire harnes...

  • Page 81: Cable Routing

    2-56 cable routing.

  • Page 82: Cable Routing

    2-57 cable routing 1. Battery cover 2. Plastic band 3. Plastic locking tie 4. Wire harness 5. Speed sensor coupler 6. Ecu 7. Fuel pump couplers 8. Fuel injector lead.

  • Page 83: Cable Routing

    2-58 cable routing.

  • Page 84: Cable Routing

    2-59 cable routing 1. Turn signal/hazard relay 2. Headlight relay 3. Radiator fan motor relay 4. Fuel injection diagnostic tool coupler 5. Anti-theft alarm coupler 6. Fuse box 7. Plastic band 8. Ecu 9. Lean angle cut-off switch 10. Extension wire harness.

  • Page 85: Cable Routing

    2-60 cable routing.

  • Page 86: Cable Routing

    2-61 cable routing 1. Tail/brake light socket 2. Rear turn signal light coupler (left) 3. License plate light coupler 4. Rear turn signal light coupler (right) 5. Tail/brake light coupler 6. Plastic band 7. Extension wire harness a. Bottom view.

  • Page 88

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

  • Page 89

    Electrical system ..................................................................................3-29 checking and charging the battery ........................................3-29 checking the fuses..........................................................................3-29 replacing the headl...

  • Page 90: Periodic Maintenance

    3-1 periodic maintenance periodic maintenance eas00036 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the ne...

  • Page 91: Periodic Maintenance

    3-2 periodic maintenance odometer reading (x 1,000 km) annual no. Item check or maintenance job 1 10 20 30 40 check 17 * sidestand • check operation. ✓ ✓ ✓ ✓ ✓ ✓ switch 18 * front fork (see page 3-25) • check operation and for oil leakage. ✓ ✓ ✓ ✓ shock absorber 19 * assembly • check operation and s...

  • Page 92: Engine

    3-3 engine engine eas00049 adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead center (tdc...

  • Page 93: Engine

    3-4 engine note: to position the piston at top dead center (tdc) on the compression stroke, align the “i” mark “c” on the camshaft sprocket with the stationary pointer “d” on the cylinder head, as shown in the illustration. C. Measure the valve clearance with a thick- ness gauge “1”. Out of specific...

  • Page 94: Engine

    3-5 engine intake tappet cover bolt 10 nm (1.0 m·kg, 7.2 ft·lb) exhaust tappet cover bolt 10 nm (1.0 m·kg, 7.2 ft·lb) • intake tappet cover new 1 • exhaust tappet cover 12.Install: • air-filter-to-air-cut-off-valve hose refer to “air induction system” on page 7-11. • radiator refer to “radiator” on ...

  • Page 95: Engine

    3-6 engine throttle body end a. Loosen the locknut “2” on the accelerator cable. B. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle cable free play is obtained. C. Tighten the locknut. Note: if the specified throttle cable free play cannot be obtained on the throttle ...

  • Page 96: Engine

    3-7 engine 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap “a” (with a thickness gauge) out of specification → regap. Spark plug gap 0.7-0.8 mm (0.028-0.031 in) 7. Install: • spark plug spark plug 13 nm (1.3 m·kg, 9.4 ft·lb) note: before installing the s...

  • Page 97: Engine

    3-8 engine eas00067 measuring the compression pressure note: insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” on page 3-3. 2. Start the engine, warm it up for several min- u...

  • Page 98: Engine

    3-9 engine eas00069 checking the engine oil level 1. Place the vehicle on a level surface and hold it in an upright position. Note: make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it ...

  • Page 99: Engine

    3-10 engine 5. Install the engine oil tank dipstick. 6. Start the engine, warm it up for several min- utes, and then turn it off. 7. Check the engine oil level again. Note: before checking the engine oil level, wait a few minutes until the oil has settled. Eas00076 changing the engine oil 1. Start t...

  • Page 100: Engine

    3-11 engine caution: the engine oil tank must be filled with engine oil in two steps. First, fill the engine oil tank with 2.0 l (2.11 imp qt, 1.75 us qt) of the recommended engine oil. Then, start the engine, race it five or six times, turn it off, and then add the remainder of the engine oil. Quan...

  • Page 101: Engine

    3-12 engine note: if the specified clutch cable free play cannot be obtained on the handlebar end of the cable, ad- just the free play at the engine end of the cable using the adjusting nut. Engine end a. Loosen the locknut “1”. B. Turn the adjusting nut “2” in direction “a” or “b” until the specifi...

  • Page 102: Engine

    3-13 engine note: insert the air filter element into the air filter case as shown. 5. Install: • air filter case cover eas00094 checking the throttle body joint 1. Check: • throttle body joint “1” cracks/damage → replace. Refer to “fuel injection system” on page 7-4. Eas00096 checking the fuel hose ...

  • Page 103: Engine

    3-14 engine caution: make sure the breather hoses are routed correctly. Eas00099 checking the exhaust system the following procedure applies to all of the ex- haust pipes and gaskets. 1. Check: • exhaust pipes “1” • muffler “2” cracks/damage → replace. • gaskets “3” exhaust gas leaks → replace. 2. C...

  • Page 104: Engine

    3-15 engine caution: • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, if dis- tilled water is not available, soft wate...

  • Page 105: Engine

    3-16 engine eas00105 changing the coolant 1. Remove: • panel (right) refer to “fuel tank” on page 7-1. 2. Remove: • radiator cap warning a hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could caus...

  • Page 106: Engine

    3-17 engine recommended antifreeze high-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines mixing ratio 1:1 (antifreeze:water) quantity total amount 1.00 l (0.88 imp qt, 1.06 us qt) coolant reservoir capacity 0.25 l (0.22 imp qt, 0.26 us qt) from minimum to maxim...

  • Page 107: Chassis

    3-18 chassis chassis eaa00810 adjusting the front brake 1. Adjust: • brake lever position (distance ”a” from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. Note: be sure to align the settin...

  • Page 108: Chassis

    3-19 chassis locknut 18 nm (1.8 m·kg, 13 ft·lb) warning a soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operat- ed, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking p...

  • Page 109: Chassis

    3-20 chassis eas00118 checking the front and rear brake pads and brake pad pins the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pads wear indicator grooves “1” have almost dis- appeared → replace the brake pads as a set. Refer to “replacing the...

  • Page 110: Chassis

    3-21 chassis eas00134 bleeding the hydraulic brake system warning bleed the hydraulic brake system when- ever: • the system is disassembled • a brake hose is loosened, disconnected or replaced • the brake fluid level is very low • brake operation is faulty. Note: • be careful not to spill any brake ...

  • Page 111: Chassis

    3-22 chassis 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: • drive chain slack “a” out of specification → adjust. Drive chain slack 40.0-50.0 mm (1.57-1.97 in) 4. Loosen: • wheel axle nut “1” 5. Adjust: • drive chain slack a a. Loosen both...

  • Page 112: Chassis

    3-23 chassis 3 2 1 b a note: • to maintain the proper wheel alignment, ad- just both sides evenly. • push the rear wheel forward to make sure that there is no clearance between the swingarm end plates and the ends of the swingarm. C. Tighten the wheel axle nut to specification. D. Tighten the locknu...

  • Page 113: Chassis

    3-24 chassis d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, re- move the lower bracket and check the up- per and lower bearings. Refer to “steering head” on page 4-55. E. Install the rubber washer “2”. F. Install ...

  • Page 114: Chassis

    3-25 chassis • handlebar holder caps refer to “handlebar” on page 4-41. Eas00149 checking the front fork 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. 2. Check: • inner tubes “1” damage/scratches → replace. • oil se...

  • Page 115: Chassis

    3-26 chassis warning it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. Minimum tire tread depth 1.6 mm (0.063 in) basic weight: with oil and 192 kg (423 lb) full fuel tank ...

  • Page 116: Chassis

    3-27 chassis warning • 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 de- flation. • when using tube tires, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. • to avoid pinching...

  • Page 117: Chassis

    3-28 chassis recommended lubricant engine oil or a suitable cable lubricant note: hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. Eas00171 lubricating the levers and brake pedal lubricate the pivoting point and metal-to-metal m...

  • Page 118: Electrical System

    3-29 electrical system electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-49. Eas21770 checking the fuses refer to “electrical components” on page 8-48. Replacing the headlight bulb note: this model is equipped with a quartz bulb headlight. 1. Rep...

  • Page 119: Electrical System

    3-30 electrical system c. Install: • auxiliary light bulb into the socket (by push- ing it in) • auxiliary light socket (together with the bulb) by pushing it in. New 1 2 replacing the tail/brake light bulb 1. Replace: • tail/brake light bulb a. Remove: • tail/brake light bulb cover bolts “1” • tail...

  • Page 120: Electrical System

    3-31 electrical system caution: do not overtighten the screw, otherwise the lens may break. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ replacing the license plate light bulb 1. Replace: • license plate light bulb ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove: • reinforcement plate bolts and nuts • reinforcement ...

  • Page 122: Chassis

    Chassis general chassis ...................................................................................... 4-1 removing the seats ......................................................................... 4-1 removing the cowling .................................................................. ...

  • Page 123

    Assembling the rear brake caliper .........................................4-37 installing the rear brake caliper............................................4-37 removing the rear brake master cylinder ..........................4-38 checking the rear brake master cylinder...........................4...

  • Page 124: General Chassis

    4-1 general chassis removing the seats eas21830 general chassis order job/parts to remove q’ty remarks 1 key 1 turn counterclockwise. 2 passenger seat 1 3 driver seat 1 for installation, reverse the removal procedure..

  • Page 125: General Chassis

    4-2 general chassis removing the cowling order job/parts to remove q’ty remarks 1 headlight/auxiliary light/front turn signal light 1/1/1/1 disconnect. (left and right) couplers 2 headlight assembly 1 3 front fender 1 for installation, reverse the removal procedure..

  • Page 126: General Chassis

    4-3 general chassis removing the rear fender cover, license bracket and tail/brake light assembly order job/parts to remove q’ty remarks 1 plate 1 2 brackets/muffler stay 2/1 3 tail/brake light/license light/rear turn 1/1/1/1 disconnect. Signal lights (left and right) couplers 4 license bracket and ...

  • Page 127: General Chassis

    4-4 general chassis removing the air filter case and crankcase breather chamber order job/parts to remove q’ty remarks seats refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air filter case joint clamp screw 1 loosen. 2 intake air temperature sensor coupler 1 dis...

  • Page 128: General Chassis

    4-5 general chassis installing the air filter case joint clamp 1. Install: • air filter case joint clamp “1” note: to install the air filter case joint clamp, align slot “a” with the projection “b” on the air filter case. 1 a b.

  • Page 129: Front Wheel

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

  • Page 130: Front Wheel

    4-7 front wheel 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..

  • Page 131: Front Wheel

    4-8 front wheel eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Ewa13120 warning 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 132: Front Wheel

    4-9 front wheel 4. Check: • wheel bearings front wheel turns roughly or is loose → re- place the wheel bearings. • oil seals damage/wear → replace. Eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals new new ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the new wheel bearings ...

  • Page 133: Front Wheel

    4-10 front wheel f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. G. The spot where all the marks come to rest is the front wheel’s heavy spot “x”. X 1 x 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3. Adjust: • front wheel static balance 4. Check: • front wheel...

  • Page 134: Front Wheel

    4-11 front wheel 2. Check: • front brake discs refer to “checking the front brake discs” on page 4-23. 3. Lubricate: • oil seal lips • collars recommended lubricant lithium-soap-based grease 4. Install: • front wheel note: install the tire and wheel with the mark “1” pointing in the direction of whe...

  • Page 135: Rear Wheel

    4-12 rear wheel removing the rear wheel eas22020 rear wheel order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 rear wheel axle nut 1 2 drive chain adjusting locknut (left and right) 2 loosen. 3 drive chain adjusting bolt (left an...

  • Page 136: Rear Wheel

    4-13 rear wheel 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 spacer 1 6 oil seal 1 7 bearing 1 8 rear wheel drive hub 1 9 rear wheel drive hub da...

  • Page 137: Rear Wheel

    4-14 rear wheel disassembling the rear wheel order job/parts to remove q’ty remarks 1 bearing 1 2 spacer 1 3 oil seal 1 4 bearing 1 for installation, reverse the removal procedure..

  • Page 138: Rear Wheel

    4-15 rear wheel eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Ewa13120 warning 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. Loosen: • wheel axle nut “1” • loc...

  • Page 139: Rear Wheel

    4-16 rear wheel ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. B. Clean the rear wheel drive hub with a clean- cloth, especially the surfaces that contact the sprocket. C. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 70 nm (...

  • Page 140: Rear Wheel

    4-17 rear wheel rear brake disc bolt 30 nm (3.0 m·kg, 22 ft·lb) loctite ® note: tighten the brake disc bolts in stages and in a crisscross pattern. 2. Check: • rear brake disc refer to “checking the rear brake disc” on page 4-35. 3. Lubricate: • oil seal lips • collars recommended lubricant lithium-...

  • Page 141: Front Brake

    4-18 front brake removing the front brake pads eas22210 front brake 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 front brake pad 2 4 brake pad spring 2 for installation, reverse the removal...

  • Page 142: Front Brake

    4-19 front brake removing the front brake master cylinder order job/parts to remove q’ty remarks drain. Brake fluid refer to “bleeding the hydraulic brake system” on page 3-21. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 brake lever ...

  • Page 143: Front Brake

    4-20 front brake disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 master cylinder kit 1 4 spring 1 5 master cylinder 1 6 push rod 1 for assembly, reverse the disassembly procedure..

  • Page 144: Front Brake

    4-21 front brake removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Drain. Brake fluid refer to “bleeding the hydraulic brake system” on page 3-21. 1 front brake hose union bolt 1 2 copper washer 2 3 front bra...

  • Page 145: Front Brake

    4-22 front brake 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 front brake pad 2 2 brake pad clip 2 3 brake pad spring 1 4 brake caliper piston 2 5 brake caliper piston seal 4 6 bleed screw 1 for a...

  • Page 146: Front Brake

    4-23 front brake eas22220 introduction ewa14100 warning disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the e...

  • Page 147: Front Brake

    4-24 front brake 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 6. ...

  • Page 148: Front Brake

    4-25 front brake 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 page 3-19. 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hyd...

  • Page 149: Front Brake

    4-26 front brake eas22390 checking the front brake calipers recommended brake component replacement schedule brake pads if necessary piston seals every two years brake hoses every four years every two years and brake fluid whenever the brake is disassembled 1. Check: • brake caliper pistons “1” rust...

  • Page 150: Front Brake

    4-27 front brake ewa13530 warning proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca- ble routing” on page 2-40. Ewa13530 caution: when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake cali...

  • Page 151: Front Brake

    4-28 front brake 3. Remove: • brake lever • master cylinder bracket • master cylinder assembly 4. Remove: • circlip (from the master cylinder assembly) • master cylinder kit eas22510 checking the front brake master cylinder 1. Check: • brake master cylinder “1” damage/scratches/wear → replace. • bra...

  • Page 152: Front Brake

    4-29 front brake 2. Install: • copper washers “1” • front brake hose “2” • front brake hose union bolt “3” new a 1 2 front brake hose union bolt 30 nm (3.0 m·kg, 22 ft·lb) ewa13530 warning proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca- ble routing” on page 2...

  • Page 153: Rear Brake

    4-30 rear brake removing the rear brake pads eas22550 rear brake order job/parts to remove q’ty remarks rear wheel refer to “removing the rear wheel” on page 4-15. 1 brake pad clip 1 2 brake pad pin 1 3 rear brake pad 2 4 brake pad spring 2 5 blade screw 1 for installation, reverse the removal proce...

  • Page 154: Rear Brake

    4-31 rear brake removing the rear brake master cylinder order job/parts to remove q’ty remarks drain. Brake fluid refer to “bleeding the hydraulic brake system” on page 3-21. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 brake fluid re...

  • Page 155: Rear Brake

    4-32 rear brake disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake hose joint 1 2 brake master cylinder kit 1 3 brake master cylinder body 1 for assembly, reverse the disassembly procedure..

  • Page 156: Rear Brake

    4-33 rear brake removing the rear brake caliper order job/parts to remove q’ty remarks drain. Brake fluid refer to “bleeding the hydraulic brake system” on page 3-21. Rear wheel refer to “removing the rear wheel” on page 4-15. 1 rear brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 re...

  • Page 157: Rear Brake

    4-34 rear brake disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 brake caliper bracket 1 2 brake pad clip 1 3 brake pad pin 1 4 brake pad 2 5 brake pad spring 2 6 bleed screw 1 for installation, reverse the removal procedure..

  • Page 158: Rear Brake

    4-35 rear brake eas22560 introduction ewa14100 warning disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the en...

  • Page 159: Rear Brake

    4-36 rear brake note: always install new brake pads and brake pad springs as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake caliper piston i...

  • Page 160: Rear Brake

    4-37 rear brake ewa13550 warning • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • never try to pry out the brake caliper pis- ton. B. Remove the brake caliper piston seals. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ eas22640 che...

  • Page 161: Rear Brake

    4-38 rear brake • rear wheel refer to “rear wheel” on page 4-12. • copper washers • rear brake hose “1” • rear brake hose union bolt “2” new rear brake hose union bolt 30 nm (3.0 m·kg, 22 ft·lb) ewa13530 warning proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca-...

  • Page 162: Rear Brake

    4-39 rear brake note: to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cyl...

  • Page 163: Rear Brake

    4-40 rear brake right side plate bolt 23 nm (2.3 m·kg, 17 ft·lb) rear brake switch 24 nm (2.4 m·kg, 17.5 ft·lb) 2. Install: • right side plate • copper washers “2” • rear brake hose “3” • rear brake switch “1” new eas22740 warning proper brake hose routing is essential to insure safe vehicle operati...

  • Page 164: Handlebar

    4-41 handlebar removing the handlebar eas22840 handlebar order job/parts to remove q’ty remarks 1 rearview mirror (left and right) 2 2 plastic band 4 3 front brake light switch coupler 1 disconnect. 4 brake master cylinder holder 1 5 brake master cylinder 1 6 grip end 2 7 throttle cable holder 1 8 r...

  • Page 165: Handlebar

    4-42 handlebar removing the handlebar order job/parts to remove q’ty remarks 16 handlebar 1 for installation, reverse the removal procedure..

  • Page 166: Handlebar

    4-43 handlebar eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Ewa13120 warning 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

    4-44 handlebar 4. Install: • front brake master cylinder “1” • front brake master cylinder holder “2” note: • make sure that the "up" mark “a” with the bracket is pointed upward. • align the punch mark “b” on the handlebar with the gap of the master cylinder bracket. Front brake master cylinder hold...

  • Page 168: Handlebar

    4-45 handlebar 9. Install: • cable ties “1” (secure the left handlebar switch lead) • cable ties “2” (secure the right handlebar switch lead) • grip ends “3” • bolt caps “4” grip end bolt 23 nm (2.3 m·kg, 17 ft·lb) note: refer to “cable routing” on page 2-40. 10. Install: • band “1” (secure the clut...

  • Page 169: Front Fork

    4-46 front fork removing the front fork legs eas22950 front fork 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. Front fender refer to “general chassis” on page 4-1. 1 cap bolt 1 loosen. 2 upper br...

  • Page 170: Front Fork

    4-47 front fork 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 spacer 1 4 washer 1 5 front fork spring 1 6 piston ring 1 7 dust seal 1 8 oil seal clip 1 9 damper rod assembly bolt 1 10...

  • Page 171: Front Fork

    4-48 front fork disassembling the front fork legs order job/parts to remove q’ty remarks 16 inner tube bushing 1 17 oil flow stopper 1 18 outer tube 1 for assembly, reverse the disassembly procedure..

  • Page 172: Front Fork

    4-49 front fork eas00649 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that th...

  • Page 173: Front Fork

    4-50 front fork caution: • excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. • avoid bottoming the inner tube into the out- er tube during the above procedure, as the oil flow stopper will be damaged. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ eas00657 che...

  • Page 174: Front Fork

    4-51 front fork eas00659 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling and a loss of stability. Note: • when assembling the front f...

  • Page 175: Front Fork

    4-52 front fork 5. Install: • oil seal “1” (with the fork seal driver weight and fork seal driver attachment) caution: make sure the numbered side of the oil seal faces up. Note: • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the...

  • Page 176: Front Fork

    4-53 front fork front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 95.0 mm (3.74 in) 9. Measure: • front fork leg oil level “a” out of specification → correct. Note: • while filling the front fork leg, keep it upright. • after ...

  • Page 177: Front Fork

    4-54 front fork warning make sure the brake hoses are routed prop- erly..

  • Page 178: Steering Head

    4-55 steering head removing the lower bracket eas23090 steering head order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Front wheel refer to “front wheel” on page 4-6. Front fender refer to “general chassis” on page 4-1. Front fork legs refer to “front fork” on page 4...

  • Page 179: Steering Head

    4-56 steering head removing the lower bracket order job/parts to remove q’ty remarks 9 lower ring nut 1 10 lower bracket 1 11 bearing cover 1 12 bearing 1 13 plate washer 1 14 lower bearing 1 15 dust seal 1 for installation, reverse the removal procedure..

  • Page 180: Steering Head

    4-57 steering head eas00679 removing the lower bracket 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • steering stem nut • washer • upper bracket • lock washer • upper ring nut “1” • rubber washer • lower...

  • Page 181: Steering Head

    4-58 steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ note: • always replace the bearings and bearing races as a set. • whenever the steering head is disassem- bled, replace the dust seal. 4. Check: • upper bracket • lower bracket (along with the steering stem) • bends/cracks/damage → replace. Eas0068...

  • Page 182: Steering Head

    4-59 steering head steering stem nut 110 nm (11.0 m·kg, 79 ft·lb) 7. Tighten: • upper bracket pinch bolts upper bracket pinch bolt 28 nm (2.8 m·kg, 20 ft·lb) 8. Install: • handlebar • upper handlebar holders upper handlebar holder bolt 23 nm (2.3 m·kg, 17 ft·lb) • handlebar holder caps refer to “han...

  • Page 183: Rear Shock Absorber Assembly

    4-60 rear shock absorber assembly removing the rear shock absorber assembly eas23160 rear shock absorber assembly order job/parts to remove q’ty remarks 1 bolt 1 2 special washer 1 3 flange bolt 1 4 bar cross 1 5 flange nut 1 6 bolt 1 7 rear shock absorber assembly 1 for installation, reverse the re...

  • Page 184: Rear Shock Absorber Assembly

    4-61 rear shock absorber assembly eas23180 handling the rear shock absorber ewa13740 warning this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held re- s...

  • Page 185: Rear Shock Absorber Assembly

    4-62 rear shock absorber assembly 3. Install: • rear shock absorber assembly “1” (into the frame support bracket) • flange bolt “4” • bar cross “5” note: tighten the flange bolt into the bar cross until just touching. Do not fully tighten the bolt. 4. Install: • special washer “6” (into the bolt “7”...

  • Page 186: Swingarm

    4-63 swingarm removing the swingarm eas23330 swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-12. Rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-60. 1 rear fender cover 1 2 self-locking nut/plate washer 1/1 3 pivot shaft/plate...

  • Page 187: Swingarm

    4-64 swingarm removing the swingarm order job/parts to remove q’ty remarks 13 ball joint 1 14 chain puller 2 15 bolt 2 16 flange nut 2 for installation, reverse the removal procedure..

  • Page 188: Swingarm

    4-65 swingarm eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Ewa13120 warning 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 wheel refer to “rear wh...

  • Page 189: Swingarm

    4-66 swingarm 4. Check: • thrust covers • dust seal • oil seals damage/wear → replace. • ball joint • bearings damage/pitting → replace. • collars • spacers/bush damage/scratches → replace. Eas23380 installing the swingarm 1. Lubricate: • bearings • ball joint • spacers/bush • pivot shaft recommende...

  • Page 190: Chain Drive

    4-67 chain drive removing the drive sprocket and drive chain eas23400 chain drive order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-12. Rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-60. Swingarm refer to “swingarm” on page 4-63. Shift ...

  • Page 191: Chain Drive

    4-68 chain drive eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Ewa13120 warning 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: • swingarm • drive chain...

  • Page 192: Chain Drive

    4-69 chain drive ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check: • o-rings “1” damage •replace the drive chain. • drive chain rollers “2” damage/wear → replace the drive chain. • drive chain side plates “3” damage/wear → replace the drive chain. Cracks → replace the drive chain and make sure the battery ...

  • Page 193: Chain Drive

    4-70 chain drive 2. Install: • drive sprocket “1” • lock washer “2” • drive sprocket nut “3” new drive sprocket nut 120 nm (12.0 m·kg, 85 ft·lb) note: • install the drive sprocket “1” and drive sprock- et nut “3” in the direction shown. • while applying the rear brake, tighten the drive sprocket nut...

  • Page 194: Engine

    Engine engine removal ........................................................................................ 5-1 installing the engine ...................................................................... 5-7 cylinder head .............................................................................

  • Page 195

    Oil pump .......................................................................................................5-41 checking the oil pump ....................................................................5-44 checking the oil delivery pipes and hoses ...........................5-44 assembling the...

  • Page 196: Engine Removal

    5-1 engine removal removing the exhaust pipes and muffler eas23710 engine removal order job/parts to remove q’ty remarks seats refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Rear mud guard and rear fender refer to “general chassis” on page 4-1. 1 cover 1 2 muffle...

  • Page 197: Engine Removal

    5-2 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 3-10. 1 oil tank outlet pipe 1 2 oil tank inlet pipe 1 3 oil tank breather hose 1 disconnect. 4 side cover stay 1 5 oil tank 1 for installation, reverse the re...

  • Page 198: Engine Removal

    5-3 engine removal removing the leads, cables, hoses, and ignition coil order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-16. Radiator refer to “radiator” on page 6-1. Rear wheel refer to “rear wheel” on page 4-12. Rear shock absorber assembly refer to “...

  • Page 199: Engine Removal

    5-4 engine removal removing the leads, cables, hoses, and ignition coil order job/parts to remove q’ty remarks 4 neutral switch connector 1 disconnect. 5 speed sensor coupler 1 disconnect. 6 ignition coil lead 2 disconnect. 7 ignition coil 1 8 intake air pressure sensor coupler 1 disconnect. 9 vacuu...

  • Page 200: Engine Removal

    5-5 engine removal removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the frame and engine. 1 tension pipe (l.H.) 1 2 special nut 1 loosen. 3 engine upper bracket bolt/nut 2/2 4 engine upper mounting bolt/nut 1/1 5 engine upper bracket (left) 1 6 engine upp...

  • Page 201: Engine Removal

    5-6 engine removal removing the engine order job/parts to remove q’ty remarks 7 engine front mounting bracket bolt/nut 2/2 8 engine front bracket bolt/nut 2/2 9 engine front bracket 1 10 engine rear mounting bolt/nut 1/1 11 engine 1 for installation, reverse the removal procedure..

  • Page 202: Engine Removal

    5-7 engine removal eas00192 installing the engine 1. Install: • engine (on the frame) • special tool “1” note: insert the special tool “1” in its position until it is engaged to the special nut grooves “2”. Engine alignment tool “1” 90890-11097 2. Install: • engine rear mounting bolt/nut “3” (tighte...

  • Page 203: Engine Removal

    5-8 engine removal tension pipe bolts 30 nm (3.0 m·kg, 22 ft·lb) engine rear mounting bolt/nut “3” 65 nm (6.5 m·kg, 47 ft·lb) engine front bracket bolts/nuts “5” 65 nm (6.5 m·kg, 47 ft·lb) engine front mounting bracket bolts/nuts “6” 65 nm (6.5 m·kg, 47 ft·lb) engine upper bracket bolts/nuts “9” 65 ...

  • Page 204: Cylinder Head

    5-9 cylinder head removing the cylinder head eas00221 cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Timing mark accessing screw/crank-shaft refer to “adjusting the valve end accessing screw clearance” on page 3-3. 1 spark plug 1 2 camshaft sprocke...

  • Page 205: Cylinder Head

    5-10 cylinder head eas00225 removing the cylinder head 1. Align: • “i” mark “a” on the a.C. Magneto rotor (with the stationary pointer “b” on the a.C. Mag- neto cover) b a 2. Loosen: • camshaft sprocket bolts “1” note: while holding the a.C. Magneto rotor nut with a wrench, remove the bolt. 1 d c ▼▼...

  • Page 206: Cylinder Head

    5-11 cylinder head 2. Check: • cylinder head damage/scratches → replace. • cylinder head water jacket mineral deposits/rust → eliminate. 3. Measure: • cylinder head warpage out of specification → resurface the cylin- der head. Maximum cylinder head warpage 0.03 mm (0.0012 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 207: Cylinder Head

    5-12 cylinder head checking the camshaft sprocket 1. Check: • camshaft sprocket wear/damage → replace the camshaft sprocket and timing chain as a set. A. 1/4 of a tooth b. Correct 1. Roller 2. Sprocket eas00231 installing the cylinder head 1. Install: • dowel pins • cylinder head gasket 2. Install: ...

  • Page 208: Cylinder Head

    5-13 cylinder head c. Install the timing chain “1” onto the camshaft sprocket “2”, then the camshaft sprocket on- to the camshaft, and then finger tighten the camshaft sprocket bolts. Note: to install the camshaft sprocket, install the pro- jection “3” on the camshaft sprocket into the slot “a” in t...

  • Page 209: Cylinder Head

    5-14 cylinder head note: check that the “i” mark “a” on the a.C. Magne- to rotor is aligned with the stationary pointer “b” on the a.C. Magneto cover. • “i” mark “c” note: check that the “i” mark “c” on the camshaft sprocket is aligned with the stationary pointer “d” on the cylinder head. Out of ali...

  • Page 210: Rocker Arms and Camshaft

    5-15 rocker arms and camshaft removing the rocker arms and camshaft rocker arms and camshaft order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-9. 1 bearing retainer 1 2 rocker arm shaft 2 3 rocker arm 2 4 locknut/valve adjuster 4/4 5 camshaft 1 6 decompressor le...

  • Page 211: Rocker Arms and Camshaft

    5-16 rocker arms and camshaft eas00202 removing the rocker arms and camshaft 1. Loosen: • locknuts • adjusting screws 2. Remove: • camshaft retainer “1” 3. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm note: remove the rocker arm shafts with th...

  • Page 212: Rocker Arms and Camshaft

    5-17 rocker arms and camshaft 3. Measure: • camshaft runout out of specification → replace. Camshaft runout limit 0.040 mm (0.0016 in) checking the decompression system 1. Check: • decompression system a. Check the decompression system with the camshaft sprocket installed on and the de- compressor p...

  • Page 213: Rocker Arms and Camshaft

    5-18 rocker arms and camshaft above 0.081 mm (0.0032 in) → replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009-0.037 mm (0.0004-0.0015 in) : 0.081 mm (0.0032 in) eas00220 installing the camshaft and rocker arms 1. Install: • bearing “1” (onto the camshaft) note: • apply eng...

  • Page 214: Rocker Arms and Camshaft

    5-19 rocker arms and camshaft 7. Install: • camshaft retainer • camshaft retainer bolts 1 2 3 camshaft retainer bolts 10 nm (1.0 m·kg, 7.2 ft·lb) loctite ®.

  • Page 215: Valves and Valve Springs

    5-20 valves and valve springs removing the valves and valve springs eas00236 valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-9. Rocker arms/rocker arm shafts/camshaft refer to “rocker arms and camshaft” on page 5-15. 1 valve cotter 8 2...

  • Page 216: Valves and Valve Springs

    5-21 valves and valve springs eas00237 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve se...

  • Page 217: Valves and Valve Springs

    5-22 valves and valve springs valve-stem-to-valve-guide clearance intake 0.010-0.037 mm (0.0004-0.0015 in) : 0.08 mm (0.0031 in) exhaust 0.025-0.052 mm (0.0010-0.0020 in) : 0.10 mm (0.0039 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Install the new valve guide with the valve guide installer “2” and valv...

  • Page 218: Valves and Valve Springs

    5-23 valves and valve springs 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear •grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness “...

  • Page 219: Valves and Valve Springs

    5-24 valves and valve springs 4. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Caution: do not l...

  • Page 220: Valves and Valve Springs

    5-25 valves and valve springs 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. B. Installed length compressed valve spring force (installed) 171-197 n at 35.00 mm (17.44-20.09 kg at 35.00 mm, 38.44-44.29 lb at 1.38 in) 3. Measure: • valve spring tilt “...

  • Page 221: Valves and Valve Springs

    5-26 valves and valve springs note: • install the valve spring with the larger pitch “a” facing up. • install the valve spring with its painted end facing up. B. Smaller pitch 4. Install: • valve cotters note: install the valve cotters by compressing the valve spring with the valve spring compressor...

  • Page 222: Cylinder and Piston

    5-27 cylinder and piston removing the cylinder and piston eas00251 cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-9. 1 timing chain guide (exhaust) 1 2 water jacket joint 1 3 o-ring 1 4 cylinder 1 5 cylinder gasket 1 6 dowel pin 2 7 piston...

  • Page 223: Cylinder and Piston

    5-28 cylinder and piston eas00253 removing the cylinder and piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” caution: do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the pist...

  • Page 224: Cylinder and Piston

    5-29 cylinder and piston b. If out of specification, replace the cylinder and the piston and piston rings as a set. C. Measure piston skirt diameter “p” with the micrometer. A. 10 mm (0.39 in) from the bottom edge of the piston d. If out of specification, replace the piston and piston rings as a set...

  • Page 225: Cylinder and Piston

    5-30 cylinder and piston 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. Piston ring end gap top ring 0.20-0.35 mm (0.0079-0.0...

  • Page 226: Cylinder and Piston

    5-31 cylinder and piston 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” note: • apply engine oil to the piston pin. • make sure the punch mark a on the piston points towards the exhaust side of the cylin- der. • before installing the piston pin clips, cover the crankcase opening wi...

  • Page 227: Cylinder and Piston

    5-32 cylinder and piston 8. Tighten: • cylinder bolts cylinder bolts “1” l = 116 mm (4.57 in) 1 st 15 nm (1.5 m·kg, 11 ft·lb) 2 nd 50 nm (5.0 m·kg, 36 ft·lb) cylinder bolts “2” l = 109 mm (4.29 in) 1 st 15 nm (1.5 m·kg, 11 ft·lb) 2 nd 50 nm (5.0 m·kg, 36 ft·lb) cylinder bolts (timing chain side) “3”...

  • Page 228: Clutch

    5-33 clutch removing the clutch cover eas00273 clutch order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-10. 1 clutch cable 1 2 clutch cable holder 1 3 clutch cover 1 4 gasket 1 5 dowel pin 2 for installation, reverse the removal procedure. (7).

  • Page 229: Clutch

    5-34 clutch removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 1 2 circlip 1 3 washer 2 4 pull lever 1 5 pull lever spring 1 6 pull lever shaft 1 7 oil seal 1 8 bearing 2 for installation, reverse the removal procedure. New new new e 2 3 4 5 7 8 8 6 3 1 e.

  • Page 230: Clutch

    5-35 clutch removing the clutch order job/parts to remove q’ty remarks 1 clutch spring 5 2 pressure plate 1 3 pull rod 1 4 friction plate 1 4 inside diameter (plate with notched tabs) = 119 mm (4.69 in) 5 clutch plate 6 6 friction plate 2 2 inside diameter (plate with no notched tabs) = 119 mm (4.69...

  • Page 231: Clutch

    5-36 clutch universal clutch holder 90890-04086 friction plate 1 thickness 2.90-3.10 mm (0.114-0.122 in) : 2.80 mm (0.110 in) friction plate 2 thickness 2.92-3.08 mm (0.115-0.121 in) : 2.80 mm (0.110 in) friction plate 3 thickness 2.90-3.10 mm (0.114-0.122 in) : 2.80 mm (0.110 in) eas00275 removing ...

  • Page 232: Clutch

    5-37 clutch 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clutch plates as a set. Clutch plate warpage limit 0.20 mm (0.0079 in) eas00282 checking the clutch springs the following procedure applies to all of the clutch springs. 1...

  • Page 233: Clutch

    5-38 clutch clutch boss nut 90 nm (9.0 m·kg, 65 ft·lb) universal clutch holder 90890-04086 eas00286 checking the pressure plate 1. Check: • pressure plate “1” cracks/damage → replace. • bearing “2” damage/wear → replace. Eas00287 checking the pull lever shaft and pull rod 1. Check: • pull lever shaf...

  • Page 234: Clutch

    5-39 clutch 4. Lubricate: • friction plates • clutch plates (with the recommended lubricant) recommended lubricant engine oil 5. Install: • clutch damper spring seat “1” • clutch damper spring “2” • friction plate 3 “3” • clutch plates “4” • friction plates 1 “5”, “7” • friction plates 2 “6” note: •...

  • Page 235: Clutch

    5-40 clutch note: • install the pull lever with the “up” mark facing up. • align the punch mark “a” on the pull lever with the punch mark “b” on the clutch cover. • install the pull lever spring “1” as shown. 9. Install: • clutch cable “1” 10.Check: • clutch cable length “a” out of specification → a...

  • Page 236: Oil Pump

    5-41 oil pump removing the oil pump oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-10. Coolant drain. Refer to “changing the coolant” on page 3-16. Water pump assembly refer to “water pump” on page 6-7. Clutch cable holder/clutch housin...

  • Page 237: Oil Pump

    5-42 oil pump removing the oil pump order job/parts to remove q’ty remarks 8 oil baffle plate 1 1 9 circlip 1 10 oil pump driven gear 1 11 oil baffle plate 2 1 12 oil pump 1 13 oil pump gasket 1 14 o-ring 2 for installation, reverse the removal procedure..

  • Page 238: Oil Pump

    5-43 oil pump disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing 1/oil seal 1/1 2 oil pump outer rotor 1 1 3 dowel pin 1 4 oil pump inner rotor 1 1 5 oil pump housing cover/oil seal 1/1 6 dowel pin 2 7 oil pump shaft 1 8 dowel pin 1 9 oil pump inner rotor 2 1 10 oil...

  • Page 239: Oil Pump

    5-44 oil pump eas00364 checking the oil pump 1. Check: • oil pump driven gear “1” • oil pump housing 1 “2” • oil pump housing cover “3” • oil pump housing 2 “4” cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-...

  • Page 240: Oil Pump

    5-45 oil pump eas00375 assembling the oil pump 1. Lubricate: • oil pump inner rotor 1 • oil pump inner rotor 2 • oil pump outer rotor 1 • oil pump outer rotor 2 • oil pump shaft (with the recommended lubricant) recommended lubricant engine oil 2. Install: • oil pump outer rotor 2 “1” • oil pump inne...

  • Page 241: Balancer Driven Gear

    5-46 balancer driven gear removing the balancer driven gear balancer driven gear order job/parts to remove q’ty remarks water pump assembly refer to “water pump” on page 6-7. Clutch housing refer to “clutch” on page 5-33. Crankcase cover (right) refer to “oil pump” on page 5-41. 1 balancer driven ge...

  • Page 242: Balancer Driven Gear

    5-47 balancer driven gear removing the balancer driven gear and balancer drive gear 1. Straighten the lock washer tab. 2. Loosen: • balancer driven gear nut “1” • primary drive gear nut “2” note: place an aluminum plate “a” between the teeth of the balancer driven gear “3” and balancer drive gear “4...

  • Page 243: Balancer Driven Gear

    5-48 balancer driven gear note: place an aluminum plate “a” between the teeth of the balancer drive gear and balancer driven gear. 3. Bend the lock washer tab. 4 3 a 1 2 a.

  • Page 244: Shift Shaft

    5-49 shift shaft removing the shift shaft and stopper lever eas00327 shift shaft and stopper lever order job/parts to remove q’ty remarks water pump assembly refer to “water pump” on page 6-7. Clutch housing refer to “clutch” on page 5-33. Crankcase cover (right) refer to “oil pump” on page 5-41. 1 ...

  • Page 245: Shift Shaft

    5-50 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks 13 washer 2 14 shift shaft spring stopper 1 for installation, reverse the removal procedure..

  • Page 246: Shift Shaft

    5-51 shift shaft eas00329 checking the shift shaft 1. Check: • shift shaft “1” • shift shaft pawl “2” bends/damage/wear → replace. • shift shaft spring “3” damage/wear → replace. Eas00330 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace ...

  • Page 247

    5-52 starter clutch and a.C. Magneto removing the starter clutch and a.C. Magneto eas00341 starter clutch and a.C. Magneto order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-10. Starter motor refer to “electric starter” on page 5-57. Drive sprocket ...

  • Page 248

    5-53 starter clutch and a.C. Magneto removing the starter clutch and a.C. Magneto order job/parts to remove q’ty remarks 11 starter clutch idle gear 1 12 a.C. Magneto rotor 1 13 starter clutch 1 14 woodruff key 1 15 starter clutch gear 1 16 bearing 1 17 washer 1 for installation, reverse the removal...

  • Page 249

    5-54 starter clutch and a.C. Magneto eas00346 removing the a.C. Magneto rotor 1. Remove: • torque limiter cover caution: do not remove the bearing “1”. 2. Remove: • a.C. Magneto cover note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fu...

  • Page 250

    5-55 starter clutch and a.C. Magneto eas00351 checking the starter clutch 1. Check: • starter clutch rollers “1” damage/wear → replace. 2. Check: • starter clutch idle gear “1” • starter clutch gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s con...

  • Page 251

    5-56 starter clutch and a.C. Magneto 2. Apply: • yamaha bond no. 1215 “1” (into the slits) yamaha bond no. 1215 90890-85505 3. Install: • starter clutch “1” (to a.C. Magneto rotor) • starter clutch bolts 1 starter clutch bolts 30 nm (3.0 m·kg, 22 ft·lb) loctite ® 4. Install: • woodruff key • a.C. Ma...

  • Page 252: Electric Starter

    5-57 electric starter removing the starter motor eas24780 electric starter order job/parts to remove q’ty remarks 1 crankcase-to-crankcase-breather-chamber hose 1 disconnect. 2 air-filter-to-crankcase-breather-chamber hose 1 disconnect. 3 crankcase breather chamber 1 4 starter motor lead 1 disconnec...

  • Page 253: Electric Starter

    5-58 electric starter disassembling the starter motor order job/parts to remove q’ty remarks 1 circlip 1 disconnect. 2 starter motor gear 1 disconnect. 3 o-ring 1 4 front bracket 1 disconnect. 5 shims 1 disconnect. 6 lock washer 1 7 rear bracket 1 8 shims 1 9 brush holder assembly 1 10 brush 1 11 ar...

  • Page 254: Electric Starter

    5-59 electric starter 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. Limit 27.0 mm (1.06 in) 3. Measure: • mica undercut “a” out of specification → scrape the mic...

  • Page 255: Electric Starter

    5-60 electric starter 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas00772 assembling the starter motor 1. Install: • brush seat “1” note: align the tab “a” on the brush seat with the slot “b” in the starter motor...

  • Page 256: Crankcase

    5-61 crankcase separating the crankcase crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-9. Cylinder/piston refer to “cylinder and piston” on page 5-27. A.C. Magneto refer to “starter clutch and a.C. Magne...

  • Page 257: Crankcase

    5-62 crankcase separating the crankcase order job/parts to remove q’ty remarks 7 crankcase (left) 1 8 dowel pin/o-ring 1/1 9 dowel pin 2 10 oil strainer 1 11 oil delivery pipe 3 1 12 o-ring 2 for installation, reverse the removal procedure. New t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (...

  • Page 258: Crankcase

    5-63 crankcase removing the crankcase bearings order job/parts to remove q’ty remarks crankshaft/balancer refer to “crankshaft” on page 5-61. Transmission refer to “transmission” on page 5-70. 1 oil seal holder 1 2 oil seal 3 3 bearing retainer 1 4 bearing 7 for installation, reverse the removal pro...

  • Page 259: Crankcase

    5-64 crankcase separating the crankcase 1. Separate: • right crankcase “1” • left crankcase “2” 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. Note: • loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • loosen the bolts in stages, using ...

  • Page 260: Crankcase

    5-65 crankcase eas00401 checking the bearings and oil seals 1. Check: • bearings clean and lubricate the bearings, and then rotate the inner race with your finger. Rough movement → replace. 2. Check: • oil seals damage/wear → replace. Eas00399 checking the crankcase 1. Thoroughly wash the crankcase ...

  • Page 261: Crankcase

    5-66 crankcase caution: before installing and torquing the crank- case bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. 7. Install: • lead holder “1” • crankcase bolts å left crankcase ∫ right crankcase 8. Tighten: • cra...

  • Page 262: Crankshaft

    5-67 crankshaft removing the crankshaft and balancer eas00381 crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61. 1 balancer 1 2 crankshaft 1 for installation, reverse the removal procedure. 1 2.

  • Page 263: Crankshaft

    5-68 crankshaft eas00388 removing the crankshaft assembly 1. Remove: • crankshaft “1” note: • remove the crankshaft with the crankcase separating tool “2”. • make sure the crankcase separating tool is centered over the crankshaft. Crankcase separating tool 90890-01135 eas00394 checking the crankshaf...

  • Page 264: Crankshaft

    5-69 crankshaft eas00408 installing the crankshaft 1. Install: • crankshaft “1” note: install the crankshaft with the crankshaft in- staller pot, crankshaft installer bolt, adapter and spacer (crankshaft installer). Crankshaft installer pot “2” 90890-01274 crankshaft installer bolt “3” 90890-01275 a...

  • Page 265: Transmission

    5-70 transmission removing the transmission, shift drum, and shift forks eas00419 transmission order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61. 1 shift fork “c” 1 2 shift fork “r” 1 3 shift fork “l” 1 4 shift drum 1 5 main axle assembly 1 6 spacer 1 7 dri...

  • Page 266: Transmission

    5-71 transmission disassembling the main axle order job/parts to remove q’ty remarks 1 circlip 1 2 2 nd pinion gear 1 3 toothed lock washer 1 4 toothed washer retainer 1 5 5 th pinion gear 1 6 toothed spacer 1 7 toothed washer 2 8 circlip 2 9 3 rd pinion gear 1 10 4 th pinion gear 1 11 main axle/1 s...

  • Page 267: Transmission

    5-72 transmission disassembling the drive axle order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 1 st wheel gear 1 4 4 th wheel gear 1 5 circlip 2 6 toothed washer 2 7 3 rd wheel gear 1 8 5 th wheel gear 1 9 2 nd wheel gear 1 10 drive axle 1 11 o-ring 1 for assembly, reverse the disass...

  • Page 268: Transmission

    5-73 transmission eas00421 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 movement rough movement → replace the shift forks. E...

  • Page 269: Transmission

    5-74 transmission 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • 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 →...

  • Page 270: Transmission

    5-75 transmission 2. Check: • shift operation unsmooth operation → repair. Note: • apply engine oil to each gear and bearing thoroughly. • before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely..

  • Page 272: Cooling System

    Cooling system radiator ..................................................................................................... 6-1 checking the radiator ................................................................... 6-2 installing the radiator .......................................................

  • Page 274: Radiator

    6-1 radiator removing the radiator eas00454 radiator order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3-16. 1 radiator cap 1 2 radiator cover 2 3 coolant reservoir hose/cap 1/1 4 coolant throttle body hose 1 dis...

  • Page 275: Radiator

    6-2 radiator eas00455 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Note: straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses cracks/damage → replace. 3. M...

  • Page 276: Radiator

    6-3 radiator 3. Check: • cooling system leaks → repair or replace any faulty part. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Attach the radiator cap tester “1” and radia- tor tester adapter “2” to the radiator. B. Apply 100 kpa (1.0 kg/cm 2 , 14.2233 psi) of pressure and make sure there is no drop in pres...

  • Page 277: Thermostat

    6-4 thermostat removing the thermostat eas00460 thermostat order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-16. 1 coolant temperature sensor coupler 1 2 hose clamp 1 3 radiator inlet hose 1 disconnect. 4 thermostat cover 1 5 o-ring 1 6 thermostat 1 7 co...

  • Page 278: Thermostat

    6-5 thermostat eas00462 checking the thermostat 1. Check: • thermostat “1” does not open at 71-85 °c (159.8-185 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring...

  • Page 279: Thermostat

    6-6 thermostat 3. Install: • copper washer • coolant temperature sensor new coolant temperature sensor 18 nm (1.8 m·kg, 13 ft·lb) caution: use extreme care when handling the cool- ant temperature sensor. Replace the sen- sor if it is dropped or subjected to a strong impact. 4. Fill: • cooling system...

  • Page 280: Water Pump

    6-7 water pump removing the water pump eas00468 water pump order job/parts to remove q’ty remarks note: it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant drain. Refer to “changing the coolant” on page 3-16. 1 hose clamp...

  • Page 281: Water Pump

    6-8 water pump disassembling the water pump order job/parts to remove q’ty remarks 1 circlip 1 2 impeller shaft gear 1 3 pin 1 4 washer 1 5 impeller shaft assembly 1 6 water pump seal 1 7 oil seal 1 8 bearing 1 9 o-ring 1 10 water pump housing 1 for assembly, reverse the disassembly procedure. New n...

  • Page 282: Water Pump

    6-9 water pump eas00470 disassembling the water pump 1. Remove: • water pump seal “1” note: tap out the water pump seal from water pump housing in the direction of the arrow shown. 2. Water pump housing 2. Remove: • bearing “1” • oil seal “2” note: tap out the bearing and oil seal from water pump ho...

  • Page 283: Water Pump

    6-10 water pump eas00475 assembling the water pump 1. Install: • oil seal “1” (into the water pump housing “2”) • bearing “3” note: • before installing the oil seal, apply tap water or coolant onto its outer surface. • install the oil seal with a socket that matches its outside diameter. 2. Install:...

  • Page 284: Water Pump

    6-11 water pump 5. Install: • impeller shaft assembly “1” • washer • pin • impeller shaft gear • circlip note: after installation, check that the impeller shaft rotates smoothly. Eas00478 installing the water pump 1. Install: • water pump outlet hose “1” • o-rings • water pump outlet pipe (to the wa...

  • Page 285: Water Pump

    6-12 water pump 6. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-2..

  • Page 286: Fuel Injection System

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

  • Page 288: Fuel Tank

    Removing the fuel tank and fuel pump 7-1 fuel tank fuel tank order job/parts to remove q’ty remarks seats refer to “general chassis” on page 4-1. 1 fuel tank panels (right and left) 2 2 fuel pump coupler 1 disconnect. 3 fuel sender coupler 1 disconnect. 4 fuel tank overflow hose 1 disconnect. 5 fuel...

  • Page 289: Fuel Tank

    7-2 fuel tank removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • seats refer to “general chassis” on page 4-1. • bolts “1” • panels “2” (right and left) 3. Remove: • fuel tank rear bolt “3” 4. Remove: • fuel tank front bolts “4” 5. Remove:...

  • Page 290: Fuel Tank

    7-3 fuel tank installing the fuel pump 1. Install: • fuel pump note: • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • align the projection “a” on the fuel pump with the slot in the fuel pump bracket. • tighten the bolts ...

  • Page 291: Throttle Body Assembly

    7-4 throttle body assembly removing the throttle body assembly throttle body assembly order job/parts to remove q’ty remarks seats refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “air filter case” on page 4-4. Coolant drain. Refer to “chan...

  • Page 292: Throttle Body Assembly

    7-5 throttle body assembly removing the throttle body assembly order job/parts to remove q’ty remarks 9 throttle body assembly 1 refer to “installing the throttle body assembly” on page 7-7. 10 throttle body joint clamp 2 11 throttle body joint 1 for installation, reverse the removal procedure..

  • Page 293: Throttle Body Assembly

    7-6 throttle body assembly disassembling the throttle body assembly order job/parts to remove q’ty remarks 1 throttle position sensor 1 2 fuel injection pipe 1 3 fuel injector 1 refer to “air filter case” on page 4-4. 4 throttle body 1 for assembly, reverse the disassembly procedure. Caution: do not...

  • Page 294: Throttle Body Assembly

    7-7 throttle body assembly eas00912 checking the fuel injector 1. Check: • fuel injector damage → replace. 2. Check: • fuel injector resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the injection wire harness cou- pler from the fuel injector. B. Connect the pocket tester ( Ω x 1) to the fue...

  • Page 295: Throttle Body Assembly

    7-8 throttle body assembly 3. Install: • throttle body assembly note: align the projection “a” on the throttle body as- sembly with the slot “b” throttle body joint. 4. Install: • throttle cable 5. Adjust: • throttle lever free play refer to “adjusting the throttle cable free play” on page 3-5. 6. A...

  • Page 296: Throttle Body Assembly

    7-9 throttle body assembly d. Connect the fuel pump coupler “4” and fuel sender coupler “5” to the fuel pump. Refer to “fuel tank” on page 7-1. E. Set the main switch to “on” and the engine stop switch to “ i ”. F. Start the engine. G. Measure the fuel pressure. Out of specification → replace the fu...

  • Page 297: Throttle Body Assembly

    7-10 throttle body assembly throttle position sensor resistance 0-5 ± 1.0 k Ω at 20 °c (68 °f) (yellow-black/blue) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ note: check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ sl...

  • Page 298: Air Induction System

    7-11 air induction system air induction system eas00507 air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens...

  • Page 299: Air Induction System

    7-12 air induction system eas00509 air induction system diagrams 1. Air filter case 2. Reed valve 3. Air cut-off valve 4. Exhaust port 4 3 2 4 1.

  • Page 300: Air Induction System

    7-13 air induction system removing the air cut-off valve assembly air cut-off valve assembly order job/parts to remove q’ty remarks seats refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air induction system solenoid coupler 1 disconnect. 2 air cut-off valve outl...

  • Page 301: Air Induction System

    7-14 air induction system disassembling the air cut-off valve assembly order job/parts to remove q’ty remarks 1 air cut-off valve cover 1 2 reed valve assembly 1 3 air cut-off valve 1 for assembly, reverse the disassembly procedure. Lt lt 3 2 1.

  • Page 302: Air Induction System

    7-15 air induction system eas00918 checking the air induction system 1. Check: • hoses loose connections → connect properly. Cracks/damage → replace. • pipe cracks/damage → replace. Refer to “cylinder head” on page 5-9. 2. Check: • reed valve • reed valve stopper • reed valve seat • cracks/damage → ...

  • Page 303: Fuel Injection System

    7-16 fuel injection system eas00895 fuel injection system 1. Fuel injection system relay 2. Engine trouble warning light 3. Battery 4. Air induction system solenoid 5. Ignition coil/spark plug 6. Fuel tank 7. Idling adjustment screw 8. Fuel pump 9. Intake air pressure sensor 10. Ecu 11. Lean angle c...

  • Page 304: Fuel Injection System

    7-17 fuel injection system wiring diagram yw 12v10w t acho g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b lr yg b lr yg b rl b gw yg yg l l l br l gy rw or or rb rb r lw brw brw rw by gy gy pw pw l l w a...

  • Page 305: Fuel Injection System

    7-18 fuel injection system 1. Crankshaft position sensor 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 14. Fuel injection system relay 16. Ignition coil 17. Spark plug 18. Fuel injector 19. Air induction system solenoid 20. Intake air temperature sensor 21. Coolant temperature sensor 22. ...

  • Page 306: Fuel Injection System

    7-19 fuel injection system ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine con- trol system is operating normally. If this function detects a malfunction in the system, it immedi- ately operates the engine under substitute charact...

  • Page 307: Fuel Injection System

    7-20 fuel injection system eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for th...

  • Page 308: Fuel Injection System

    7-21 fuel injection system fault item symptom fail-safe action startability driveability code no. Vehicle system power supply to the fuel 46 power supply injection system relay is not — yes yes (monitor voltage) normal. Ecu internal faulty ecu memory. When 50 malfunction this malfunction is detected...

  • Page 309: Fuel Injection System

    7-22 fuel injection system eas00904 troubleshooting chart engine operation is not normal or the engine trouble warning light is on. * engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displa...

  • Page 310: Fuel Injection System

    7-23 fuel injection system eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators with the fi diagnostic tool connected to the vehicle and set to the normal mode or the diagnostic monitor- ing mode. Fi diagnostic tool 90890-03182 setting the no...

  • Page 311: Fuel Injection System

    7-24 fuel injection system note: • “diag” appears on the lcd of the fi diag- nostic tool. • “power” led (green) comes on. 4. Press the “up” button to select the co ad- justment mode “co” or the diagnostic mode “diag”. 5. After selecting “diag”, press the “mode” button. 6. Select the diagnostic code ...

  • Page 312: Fuel Injection System

    7-25 fuel injection system eas00906 diagnostic monitoring code table fault code no. Symptom probable cause of malfunction diagnostic code 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wire harness • defective crankshaft position sensor • disconnect...

  • Page 313: Fuel Injection System

    7-26 fuel injection system 44 an error is detected while reading or writing on eeprom. • malfunction in ecu (the co adjustment value is not properly written on or read from the internal memory.) d60 46 power supply to the fuel injection sys- tem relay is not normal. • open circuit in wire harness • ...

  • Page 314: Fuel Injection System

    7-27 fuel injection system d08 lean angle cut-off switch displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 v overturned: 3.7 ~ 4.4 v d09 fuel system voltage (bat- tery voltage) displays the fuel system voltage (battery voltage). Set the engine stop switch to “ ”. Approximately 12.0 v...

  • Page 315: Fuel Injection System

    7-28 fuel injection system troubleshooting details this section describes the countermeasures per fault code number displayed on the fi diagnostic tool. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service o...

  • Page 316: Fuel Injection System

    7-29 fuel injection system fault code no. 13 symptom open or short circuit is detected from the intake air pressure sensor. Used diagnostic code no. 03 (intake air pressure sensor) order item/components check or maintenance job restore method 1 coupler connections intake air pressure sensor coupler ...

  • Page 317: Fuel Injection System

    7-30 fuel injection system fault code no. 14 symptom intake air pressure sensor hose is disconnected or clogged. Used diagnostic code no. 03 (intake air pressure sensor) order item/components check or maintenance job restore method 1 disconnected, clogged, kinked, or pinched intake air pressure sens...

  • Page 318: Fuel Injection System

    7-31 fuel injection system fault code no. 16 symptom the throttle position sensor is detected stuck. Used diagnostic code no. 01 (throttle position sensor) order item/components check or maintenance job restore method 1 defective throttle position sensor replace the sensor if it is defective. Refer ...

  • Page 319: Fuel Injection System

    7-32 fuel injection system fault code no. 22 symptom open or short circuit is detected from the intake air temperature sensor. Used diagnostic code no. 05 (intake air temperature sensor) order item/components check or maintenance job restore method 1 intake air temperature sensor installation check ...

  • Page 320: Fuel Injection System

    7-33 fuel injection system fault code no. 30 symptom the motorcycle has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) order item/components check or maintenance job restore method 1 the motorcycle has overturned. Raise the motorcycle upright. Reinstated by set- ting the main sw...

  • Page 321: Fuel Injection System

    7-34 fuel injection system fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code no. 07 (speed sensor) a1 ~ a4 / no. 21 (neutral switch) b1 ~ b4 order item/components check or maintenance jo...

  • Page 322: Fuel Injection System

    7-35 fuel injection system b-1 coupler connections neutral switch connector wiring harness ecu coupler check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. If necessary, repair the coupler or securely con- nect it. Reinstated by starting the engine, ...

  • Page 323: Fuel Injection System

    7-36 fuel injection system fault code no. 43 symptom the ecu is unable to monitor the battery voltage. Used diagnostic code no. 09, 50 (fuel system voltage) order item/components check or maintenance job restore method 1 coupler connections fuel injection system relay cou- pler wiring harness ecu co...

  • Page 324: Fuel Injection System

    7-37 fuel injection system fault code no. 44 symptom error is detected while reading or writing on eeprom (co adjustment value). Used diagnostic code no. 60 (eeprom improper cylinder indication) order item/components check or maintenance job restore method 1 malfunction in ecu execute the diagnostic...

  • Page 326: Electrical System

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

  • Page 327

    Checking the coolant temperature sensor........................8-57 checking the fuel sender ............................................................8-58 checking the speed sensor.........................................................8-58 checking the throttle position sensor.....................

  • Page 328: Ignition System

    8-1 ignition system eas27090 ignition system eas27110 circuit diagram 17 28 29 30 31 32 33 34 35 36 a 50 49 48 47 46 a 2 9 14 12 42 4141 yw 12v10w ta c h o g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b ...

  • Page 329: Ignition System

    8-2 ignition system 1. Crankshaft position sensor 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 13. Starting circuit cut-off relay 16. Ignition coil 17. Spark plug 22. Ecu 26. Lean angle cut-off switch 38. Sidestand switch 41. Engine stop switch 45. Clutch switch 67. Ignition fuse.

  • Page 330: Ignition System

    8-3 ignition system eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Seats 2. Side panels (left and right) 3. Fuel tank 4. Battery cover 1. Check the fuses. (main and ignition) refer to “c...

  • Page 331: Ignition System

    8-4 ignition system 8. Check the main switch. Refer to “checking the switches” on page 8-43. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-43. Replace the main switch/immobilizer unit. Replace the right handlebar switch. Ok ok 10.Check the neutral switch. Refer to “chec...

  • Page 332: Electric Starting System

    8-5 electric starting system eas27160 electric starting system eas27170 circuit diagram 28 29 34 35 36 50 49 48 47 46 a 2 9 14 12 42 41 g ch b1 brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r p br brw - fuel gw gw b rl b gw br l gy rw rb gy ch gnd gr speed +v backup hi beam el yl r b b yl...

  • Page 333: Electric Starting System

    8-6 electric starting system 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 9. Starter relay 10. Starter motor 12. Relay unit 13. Starting circuit cut-off relay 38. Sidestand switch 41. Engine stop switch 42. Start switch 45. Clutch switch 67. Ignition fuse.

  • Page 334: Electric Starting System

    8-7 electric starting system eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ i” 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 ...

  • Page 335: Electric Starting System

    8-8 electric starting system å when the transmission is in neutral ∫ 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 s...

  • Page 336: Electric Starting System

    8-9 electric starting system eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Seats 2. Side panels (left and right) 3. Fuel tank 4. Battery cover 1. Check the fuses. (main and ignition) refer to “checking the fuses” on page 8-...

  • Page 337: Electric Starting System

    8-10 electric starting system 8. Check the engine stop switch. Refer to “checking the switches” on page 8-43. 9. Check the neutral switch. Refer to “checking the switches” on page 8-43. Replace the right handlebar switch. Replace the neutral switch. Ok ok 10. Check the sidestand switch. Refer to “ch...

  • Page 338: Charging System

    8-11 charging system eas27200 charging system eas27210 circuit diagram 2 9 brl brr r 7.5a r r r gy gw 10a rg r 10a w w lw rw br r sb gl r b w w w sb sb rw rg back up ind. Ign. Alarm ctic gnd b b2 rg yl lg rw b bb rg yl gl rw bb yl b r br b b b w w b b w w on off p main brr r brl brr r brl gy gw w w ...

  • Page 339: Charging System

    8-12 charging system 2. A.C. Magneto 5. Rectifier/regulator 7. Battery 8. Main fuse.

  • Page 340: Charging System

    8-13 charging system eas27220 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Seats 2. Side panels (left and right) 3. Fuel tank 4. Battery cover 1. Check the fuses. (main) refer to “checking the fuses” on page 8-48. 2. Check the bat...

  • Page 341: Charging System

    8-14 charging system.

  • Page 342: Lighting System

    8-15 lighting system eas27240 lighting system eas27250 circuit diagram 17 28 29 30 31 32 33 34 35 36 a 50 49 48 47 46 a 2 9 14 12 42 41 yw 12v10w ta c h o g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b l...

  • Page 343: Lighting System

    8-16 lighting system 4. Main switch 7. Battery 8. Main fuse 22. Ecu 32. High beam indicator light 44. Headlight relay 48. Dimmer switch 49. Pass switch 56. Headlight 58. Tail/brake light 59. Auxiliary light 64. Parking lighting fuse 65. Headlight fuse.

  • Page 344: Lighting System

    8-17 lighting system 1. Check the condition of each bulb and bulb socket. Refer to “checking the bulbs and bulb sockets” on page 8-46. 3. Check the battery. Refer to “checking and charging the battery” on page 8-49. Replace the bulb(s) and bulb socket(s). • clean the battery terminals. • recharge or...

  • Page 345: Lighting System

    8-18 lighting system 10. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-15. Properly connect or repair the lighting system wiring. Ng ok 8. Check the high beam indicator light led. Refer to “checking the leds” on page 8-47. Replace the meter assembly. Ng 9. Check the m...

  • Page 346: Signaling System

    8-19 signaling system eas27270 signaling system eas27280 circuit diagram 17 28 29 30 31 32 33 34 35 36 a 50 49 48 47 46 a 2 9 14 12 42 41 yw 12v10w t acho g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b l...

  • Page 347: Signaling System

    8-20 signaling system 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 12. Relay unit 21. Coolant temperature sensor 22. Ecu 23. Speed sensor 28. Neutral indicator light 29. Multi-function meter 30. Fuel level warning light 31. Turn signal indicator light 33. Coolant temperature warning ligh...

  • Page 348: Signaling System

    8-21 signaling system 1. Check the fuses. (main, ignition, signaling system, parking lighting, and backup fuse) refer to “checking the fuses” on page 8-48. 2. Check the battery. Refer to “checking and charging the battery” on page 8-49. Replace the bulb(s) and bulb socket(s). • clean the battery ter...

  • Page 349: Signaling System

    8-22 signaling system 3. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or repair the signaling system wiring. Ng ok the circuit is ok. Ok ok 1. Check the front brake light switch. Refer to “checking the switches” on page 8-43. Replace the front b...

  • Page 350: Signaling System

    8-23 signaling system ok 5. Check the turn signal/hazard relay. Refer to “checking the turn signal/hazard relay” on page 8-53. Replace the turn signal/hazard relay. Ng 6. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or repair the signaling syste...

  • Page 351: Signaling System

    8-24 signaling system 3. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or repair the signaling system wiring. Ng ok the circuit is ok. 1. Check the speed sensor. Refer to “checking the speed sensor” on page 8-58. Replace the speed sensor. Ng ok 2...

  • Page 352: Cooling System

    8-25 cooling system eas00807 cooling system circuit diagram 17 28 29 30 31 32 33 34 35 36 a 50 49 48 47 46 a 2 9 14 12 42 41 yw 12v10w ta c h o g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b lr yg b lr y...

  • Page 353: Cooling System

    8-26 cooling system 4. Main switch 7. Battery 8. Main fuse 22. Ecu 62. Radiator fan motor 63. Radiator fan motor relay 67. Ignition fuse 68. Radiator fan motor fuse.

  • Page 354: Cooling System

    8-27 cooling system 1. Check the fuses. (main, radiator fan motor and ignition). Refer to “checking the fuses”on page 8-48. 2. Check the battery. Refer to “checking and charging the battery” on page 8-49. Replace the fuse(s). • clean the battery terminals. • recharge or replace the battery. Ng ok ng...

  • Page 355: Cooling System

    8-28 cooling system.

  • Page 356: Immobilizer System

    8-29 immobilizer system et5yu1002 immobilizer system et5yu1003 circuit diagram 17 28 29 30 31 32 33 35 36 a 50 49 48 47 46 2 9 14 12 42 41 yw 12v10w t acho g ch b1 bw yw brl brl brr brr b l l r 7.5a (black) l b (black) r b r r r b p p b lr b lr 12v5w br brw - fuel lg wy bl bl y l (black) bl gw gw b ...

  • Page 357: Immobilizer System

    8-30 immobilizer system 4. Main switch 7. Battery 8. Main fuse 22. Ecu 27. Multi-function meter unit 34. Immobilizer system indicator light 67. Ignition fuse 69. Backup fuse (immobilizer unit, multi-function meter unit) 71. Anti-theft alarm (optional) 72. Immobilizer unit.

  • Page 358: Immobilizer System

    8-31 immobilizer system 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 359: Immobilizer System

    8-32 immobilizer system * accessory locks mean the seat lock and fuel tank cap. Parts to be replaced key registration requirement main switch/immo- bilizer unit standard key ecu accesso- ry lock* and key main switch immobiliz- er unit standard key is lost √ new standard key all keys have been lost (...

  • Page 360: Immobilizer System

    8-33 immobilizer system standby mode a. Main switch “on” b. Main switch “off” c. Led on d. Led off e. Standby mode on f. Standby mode off 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-r...

  • Page 361: Immobilizer System

    8-34 immobilizer system standard key registration a. Main switch “on” b. Main switch “off” c. Led on d. Led off e. Less than 5.0 s f. Code re-registering key g. First standard key h. Second standard key i. Registration mode a. Registration of the second standard key is complete. B. Immobilizer syste...

  • Page 362: Immobilizer System

    8-35 immobilizer system 1. Check the fuses. (main, ignition and backup). Refer to “checking the fuses” on page 8-48. 2. Check the battery. Refer to “checking and charging the battery” on page 8-49. Replace the fuse(s). • clean the battery terminals. • recharge or replace the battery. Ng ok ng eas277...

  • Page 363: Immobilizer System

    8-36 immobilizer system fault part symptom cause action code 51 immobilizer code cannot be 1. Radio wave 1. Keep magnets, unit transmitted between interference caused metal objects, the key and the by objects around the and other immobilizer unit. Keys and antenna. Immobilizer 2. Immobilizer unit sy...

  • Page 364: Immobilizer System

    8-37 immobilizer system fault part symptom cause action code 55 immobilizer key code same standard key register another unit registration was attempted to be standard key. Malfunction. Registered two consecutive times. 56 ecu unidentified code noise interference 1. Check the wire is received. Or dis...

  • Page 365: Immobilizer System

    8-38 immobilizer system.

  • Page 366: Electrical Components

    8-39 electrical components eas27970 electrical components.

  • Page 367: Electrical Components

    8-40 electrical components 1. Starter relay 2. Main fuse 3. Battery 4. Fuel pump 5. Throttle position sensor 6. Coolant temperature sensor 7. Fuel injector 8. Ecu (electronic control unit) 9. Lean angle cut-off switch 10. Turn signal/hazard relay 11. Headlight relay 12. Radiator fan motor relay 13. ...

  • Page 368: Electrical Components

    8-41 electrical components.

  • Page 369: Electrical Components

    8-42 electrical components 1. Front brake light switch 2. Right handlebar switch 3. Clutch switch 4. Left handlebar switch 5. Main switch 6. Immobilizer unit 7. Ignition coil 8. Plug cap 9. Spark plug 10. Intake air pressure sensor 11. Fuse box 12. Rear brake light switch 13. Intake air temperature ...

  • Page 370: Electrical Components

    8-43 electrical components eas27980 checking the switches.

  • Page 371: Electrical Components

    8-44 electrical components 1. Main switch 2. Clutch switch 3. Horn switch 4. Pass switch 5. Dimmer switch 6. Turn signal switch 7. Hazard switch 8. Sidestand switch 9. Front brake light switch 10. Engine stop switch 11. Start switch 12. Neutral switch 13. Rear brake light switch 14. Fuses.

  • Page 372: Electrical Components

    8-45 electrical components 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. Eca14370 caution: never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 373: Electrical Components

    8-46 electrical components 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 conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket o...

  • Page 374: Electrical Components

    8-47 electrical components 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 375: Electrical Components

    8-48 electrical components immobilizer system indicator led connect the pocket tester (kΩ x 1) to the meter coupler. Positive tester probe → black/white continuity negative tester probe → green/blue positive tester probe → green/blue no continuity negative tester probe → black/white warning • a wire...

  • Page 376: Electrical Components

    8-49 electrical components warning never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a f...

  • Page 377: Electrical Components

    8-50 electrical components 3. Remove: • battery band • battery 4. Check: • battery charge ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to the battery termi- nals. • positive tester probe → positive battery terminal • negative tester probe → negative battery terminal note: • the charge...

  • Page 378: Electrical Components

    8-51 electrical components • standard charging current is reached battery is good. • standard charging current is not reached replace the battery. D. Adjust the voltage so that the current is at the standard charging level. E. Set the time according to the charging time suitable for the open-circuit...

  • Page 379: Electrical Components

    8-52 electrical components pocket tester 90890-03112 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω x 1) and bat- tery (12 v) to the relay terminal as shown. Check the relay operation. Out of specification → replace. Starter relay 1. Positive battery terminal 2. Negat...

  • Page 380: Electrical Components

    8-53 electrical components radiator fan motor relay result continuity (between “3” and “4”) et5yu1021 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is f...

  • Page 381: Electrical Components

    8-54 electrical components a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester (Ω x 1) to the re- lay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼...

  • Page 382: Electrical Components

    8-55 electrical components 2. Check: • secondary coil resistance out of specification → replace. C. Measure the primary coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ secondary coil resistance 10.4-15.6 k Ω at 20 °c (68 °f) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from th...

  • Page 383: Electrical Components

    8-56 electrical components lean angle cut-off switch output voltage less than 65°: 0.4–1.4 v more than 65°: 3.7–4.4 v eas28130 checking the lean angle cut-off switch 1. Remove: • lean angle cut-off switch 2. Check: • lean angle cut-off switch output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼...

  • Page 384: Electrical Components

    8-57 electrical components coil resistance 1.15–1.25 Ω at 20 °c (68 °f) eas28180 checking the horn 1. Check: • horn resistance out of specification →replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn ter- minals. B. Connect the pocket tester (Ω x 1) to the horn term...

  • Page 385: Electrical Components

    8-58 electrical components 3. Install: • coolant temperature sensor coolant temperature sensor 18 nm (1.8 m·kg, 13 ft·lb) eas28230 checking the fuel sender this model is equipped with a self-diagnosis de- vice for the fuel sender circuit. If the fuel sender circuit is defective, the following cycle ...

  • Page 386: Electrical Components

    8-59 electrical components eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor maximum resistance out of specification → replace the throttle position sensor. Resistance 4.0–6.0 k Ω /blue-black/blue ▼▼▼▼▼▼...

  • Page 387: Electrical Components

    8-60 electrical components intake pressure sensor output voltage 3.4-3.8 v ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the intake air pressure sensor coupler as shown. Pocket tester 90890-03112 • positive tester probe → pink/white “1” • negative tester probe → black/bl...

  • Page 388: Electrical Components

    8-61 electrical components checking the starter motor 1. Check: • starter motor a. Connect the positive battery terminal “1” and starter motor lead “2” with a jumper lead “3”. Warning • a wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, oth...

  • Page 390: Troubleshooting

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

  • Page 392: Troubleshooting

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

  • Page 393: Troubleshooting

    9-2 troubleshooting electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug • 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 • broken or shorted p...

  • Page 394: Troubleshooting

    9-3 troubleshooting eas28590 overheating engine 1. Clogged coolant passages 2. Cylinder head and piston • heavy carbon buildup 3. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator ...

  • Page 395: Troubleshooting

    9-4 troubleshooting 4. Swingarm • worn bearing or bushing • bent or damaged swingarm 5. Rear shock absorber assembly • faulty rear shock absorber spring • leaking oil or gas 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect wheel...

  • Page 396

    Wiring diagram mt-03 2006 1. Crankshaft position sensor 2. A.C. Magneto 3. Neutral switch 4. Main switch 5. Rectifier/regulator 6. Wire plus lead 7. Battery 8. Main fuse 9. Starter relay 10. Starter motor 11. Wire minus lead 12. Relay unit 13. Starting circuit cut-off relay 14. Fuel injection system...

  • Page 397

    Color code.

  • Page 399

    Yamaha motor italia s.P.A..

  • Page 400

    Mt-03 2006 wiring diagram.