1. DL manuals
  2. Yamaha
  3. Motorcycle
  4. R1 2003
  5. Service Manual

Yamaha R1 2003 Service Manual

Summary of R1 2003

  • Page 3: Yzf-R1P

    Yzf-r1p yzf-r1pc service manual lit-11616-15-47 5pw-28197-10

  • Page 5

    Eas00000 yzf-r1p/yzf-r1pc service manual ©2001 by yamaha motor corporation, u.S.A. First edition, december 2001 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-15-47.

  • Page 6: Notice

    Eas00003 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 7: How to Use This Manual

    Eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 the manual is di...

  • Page 8: Gen

    Eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 chassis 5 engine 6 cooling system 7 fuel injection system 8 electrical system 9 troubleshooting sy...

  • Page 10: Table of Contents

    Eas00012 table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 chassis chas 4 engine eng 5 cooling system cool 6 fuel injection system fi 7 electrical system elec 8 troubleshooting trbl shtg 9 – +.

  • Page 11: Chapter  1

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

  • Page 12: Chapter  3

    Tightening torques .............................................................................2-17 general tightening torque specifications ........................2-17 engine tightening torques ........................................................2-18 chassis tightening torques ..................

  • Page 13

    Engine ...........................................................................................................3-9 adjusting the valve clearance ..................................................3-9 synchronizing the throttle bodies .......................................3-14 adjusting the engine...

  • Page 14: Chapter  4

    Chapter 4 chassis front wheel and brake discs ...........................................................4-1 front wheel ........................................................................................4-2 removing the front wheel ...........................................................4-3...

  • Page 15: Chapter  5

    Handlebars .............................................................................................4-56 removing the handlebars ...........................................................4-58 checking the handlebars ...........................................................4-58 installing the ...

  • Page 16

    Cylinder head ........................................................................................5-19 removing the cylinder head ......................................................5-20 checking the cylinder head ......................................................5-20 installing the cylind...

  • Page 17

    Oil pan and oil pump ............................................................................5-51 oil pump ...............................................................................................5-53 removing the oil pan .......................................................................

  • Page 18: Chapter  6

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

  • Page 19: Chapter  8

    Air induction system ...........................................................................7-37 air induction .....................................................................................7-37 air cut-off valve ............................................................................7...

  • Page 20: Chapter  9

    Cooling system ......................................................................................8-41 circuit diagram ...............................................................................8-41 troubleshooting ............................................................................8-...

  • Page 21

    Faulty front fork legs .......................................................................9-5 leaking oil ...........................................................................................9-5 malfunction ......................................................................................

  • Page 22: Gen

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

  • Page 23: Gen

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

  • Page 24: Gen

    1 - 3 gen info features fi system the fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 284 kpa (2.84 kg/cm 2 , 40.4 psi) higher than the intake manifold pressure. Accordingly, when the energizing s...

  • Page 25: Gen

    1 - 4 gen info features fuel control block the fuel control block consists of the following main components: an engine trouble warning light is provided on meter panel. Component function control block ecu total fi system control throttle body air volume control pressure regulator fuel pressure dete...

  • Page 26: Gen

    1 - 5 gen info features components ecu (electronic control unit) the ecu is mounted underneath the seat. The main functions of the ecu are ignition control, fuel control, self-diagnosis, and load control. • ecu’s internal construction and functions the main components and functions of the ecu can be...

  • Page 27: Gen

    1 - 6 gen info features • ignition control the ignition control function of the ecu controls the ignition timing and the duration of ignition energizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position ...

  • Page 28: Gen

    1 - 7 gen info features fuel pump the fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump. The pump consi...

  • Page 29: Gen

    1 - 8 gen info features pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamb...

  • Page 30: Gen

    1 - 9 gen info features fuel injector upon receiving injection signals from the ecu, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The plunger that is integrated with the bottom of the core keeps the fuel passage closed....

  • Page 31: Gen

    1 - 10 gen info features crankshaft position sensor the crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the pick...

  • Page 32: Gen

    1 - 11 gen info features cylinder identification sensor the cylinder identification sensor is mounted on the middle of exhaust side head cover. When the exhaust camshaft rotates, the sensor generates a signal and sends it to the ecu. Based on this sig- nal and the signal from the crankshaft position...

  • Page 33: Gen

    1 - 12 gen info features throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison wit...

  • Page 34: Gen

    1 - 13 gen info features intake air pressure sensor and atmospheric pressure sensor • intake air pressure sensor the intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake...

  • Page 35: Gen

    1 - 14 gen info features coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to ...

  • Page 36: Gen

    1 - 15 gen info features lean angle cut-off switch the lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 v (low level). When the motorcycl...

  • Page 37: Gen

    1 - 16 gen info features fuel injection system operation and control the fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ecu. To determine the basic injection timing, the ecu calculates the intake air volume through the signals fro...

  • Page 38: Gen

    1 - 17 gen info features determining the final injection duration the intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weathe...

  • Page 39: Gen

    1 - 18 gen info features reactive injection duration: a lag is created between the time the ecu outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ecu calculates this lag in advance before sending the actuation signal to the injector. The battery...

  • Page 40: Gen

    1 - 19 gen info features three-way catalytic converter system system outline this is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint effort by the fi system and the three-way catalytic converter system. By effecting comprehensive control of the air-fuel r...

  • Page 41: Gen

    1 - 20 gen info features instrument function multi-function display the multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total dis- tance traveled) • two tripmeters (which show the distance traveled since they were l...

  • Page 42: Gen

    1 - 21 gen info features display brightness and engine speed indi- cator light control mode this mode cycles through five control func- tions, allowing you to make the following set- tings in the order listed below. 1. Display brightness: this function allows you to adjust the brightness of the mult...

  • Page 43: Gen

    1 - 22 gen info features to set the engine speed indicator light activation function note: _ the indicator light activation function can be set between 7,000 and 12,000 r/min in increments of 500 r/min. 1. Push the “reset” button to select the desired engine speed for activating the indicator light....

  • Page 44: Gen

    1 - 23 gen info important information eas00020 important information 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 the “special tools”. 3. When disassembling, a...

  • Page 45: Gen

    1 - 24 gen info important information eas00023 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals install ...

  • Page 46: Gen

    1 - 25 gen info checking the connections eas00026 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 discon...

  • Page 47: Gen

    1 - 26 gen info 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 inappropri- ate tools or improvised techniques. Special tools, p...

  • Page 48: Gen

    1 - 27 gen info special tools yu-38411 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. Ym-01434 rod holder this tool is used to support the damper adjusting rod. Rod puller ym-01437 rod puller these tools are used to pull up the front fork damper rod. Ym-01441 fo...

  • Page 49: Gen

    1 - 28 gen info special tools middle driven shaft bearing driver ym-4058-1 mechanical seal installer ym-33221 middle driven shaft bearing driver mechanical seal installer these tools are used to install the water pump seal. Ym-91042 universal clutch holder this tool is used to hold the clutch boss w...

  • Page 50: Gen

    1 - 29 gen info special tools ym-03112 pocket tester this instrument is needed for checking the engine oil temperature. Yb-35956 mity vac this tool used to measure the vacuum pressure. Ym-8037 piston ring compressor this tool is used to compress the piston rings when installing the piston into the c...

  • Page 51: Spec

    2 - 1 spec specifications general specifications item standard limit model code 5pw4 usa 5pw5 california 5pw6 canada ---- ---- ---- dimensions overall length 2,040 mm (80.3 in) ---- overall width 705 mm (27.8 in) ---- overall height 1,105 mm (43.5 in) ---- seat height 820 mm (32.3 in) ---- wheelbase...

  • Page 52: Spec

    2 - 2 spec engine specifications engine specifications item standard limit engine engine type liquid-cooled, 4-stroke, dohc ---- displacement 998 cm 3 (60.9 cu.In) ---- cylinder arrangement forward-inclined parallel 4-cylinder ---- bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- compression ratio 11....

  • Page 53: Spec

    2 - 3 spec engine specifications oil filter oil filter type cartridge (paper) ---- bypass valve opening pressure 80 ~ 120 kpa (0.8 ~ 1.2 kg/cm 2 , 11.6 ~ 17.4 psi) ---- oil pump oil pump type trochoid ---- inner-rotor-to-outer-rotor-tip clearance 0.01 ~ 0.10 mm (0.0004 ~ 0.0039 in) 0.18 mm (0.0071 i...

  • Page 54: Spec

    2 - 4 spec engine specifications camshafts drive system chain drive (right) ---- camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- camshaft-journal-to-camshaft- cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.0...

  • Page 55: Spec

    2 - 5 spec engine specifications timing chain model/number of links rh2015/130 ---- tensioning system automatic ---- valves, valve seats, valve guides valve clearance (cold) intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) ---- exhaust 0.21 ~ 0.27 mm (0.0083 ~ 0.0106 in) ---- valve dimensions valve head d...

  • Page 56: Spec

    2 - 6 spec engine specifications valve stem runout ---- 0.01 mm (0.0004 in) valve seat width intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- valve springs free length intake 38.9 mm (1.53 in) 37.0 mm (1.46 in) exhaust 40.67 mm (1.60 in) 38.6 mm (1.52 in) ...

  • Page 57: Spec

    2 - 7 spec engine specifications cylinders cylinder arrangement forward-inclined, parallel 4-cylinder ---- bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- compression ratio 11.8 : 1 ---- bore 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) ---- max. Taper ---- 0.05 mm (0.0020 in) max. Out-of-round ---- 0.05 mm...

  • Page 58: Spec

    2 - 8 spec engine specifications 2nd ring ring type taper ---- dimensions (b × t) 0.8 × 2.8 mm (0.03 × 0.11 in) ---- end gap (installed) 0.43 ~ 0.58 mm (0.017 ~ 0.023 in) 0.93 mm (0.037 in) ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.115 mm (0.0045 in) oil ring dimensions (b × t) 1.5...

  • Page 59: Spec

    2 - 9 spec engine specifications clutch clutch type wet, multiple disc ---- clutch release method outer pull, rack and pinion pull ---- clutch release method operation cable operation ---- operation left-hand operation ---- clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.4 ~ 0....

  • Page 60: Spec

    2 - 10 spec engine specifications air filter type wet element ---- fuel pump pump type electrical ---- model (manufacturer) 5pw (denso) ---- output pressure 94 kpa (2.94 kg/cm 2 , 42.6 psi) ---- throttle position sensor resistance 4.85 ~ 5.15 k Ω at 20 °c (68 °f) ---- output voltage (at idle) adjust...

  • Page 61: Spec

    2 - 11 spec chassis specifications chassis specifications item standard limit frame frame type diamond ---- caster angle 24° ---- trail 103 mm (4.06 in) ---- front wheel wheel type cast wheel ---- rim size 17 m/c × mt3.50 ---- material aluminum ---- wheel travel 120 mm (4.72 in) ---- wheel runout ma...

  • Page 62: Spec

    2 - 12 spec chassis specifications front brakes brake type dual disc brake ---- operation right hand operation ---- recommended fluid dot 4 ---- brake lever free play 2.3 ~ 11.5 mm (0.09 ~ 0.45 in) ---- brake discs diameter × thickness 298 × 5 mm (11.73 × 0.20 in) ---- min. Thickness ---- 4.5 mm (0....

  • Page 63: Spec

    2 - 13 spec chassis specifications front suspension suspension type telescopic fork ---- front fork type coil spring/oil damper ---- front fork travel 120 mm (4.72 in) ---- spring free length 251 mm (9.88 in) 246 mm (9.69 in) spacer length 74 mm (2.91 in) ---- installed length 244 mm (9.61 in) ---- ...

  • Page 64: Spec

    2 - 14 spec chassis specifications rear suspension suspension type swingarm (link suspension) ---- rear shock absorber assembly type coil spring/gas-oil damper ---- rear shock absorber assembly travel 65 mm (2.56 in) ---- spring free length 176.5 mm (6.95 in) ---- installed length 162.5 mm (6.4 in) ...

  • Page 65: Spec

    2 - 15 spec electrical specifications electrical specifications item standard limit system voltage 12 v ---- ignition system ignition system type transistorized coil ignition (digital) ---- ignition timing 5° btdc at 1,050 r/min ---- crankshaft position sensor resistance/color 248 ~ 372 Ω at 20 °c (...

  • Page 66: Spec

    2 - 16 spec electrical specifications electric starting system system type constant mesh ---- starter motor model (manufacturer) 5jj (yamaha) ---- power output 0.9 kw ---- brushes overall length 10.8 mm (0.43 in) 3.65 mm (0.14 in) spring force 5.28 ~ 7.92 n (528 ~ 792 g, 19.01 ~ 28.51 oz) ---- armat...

  • Page 67: Spec

    2 - 17 spec conversion table/tightening torques eas00028 conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table tightening torques eas00029 general tightening torque specifications t...

  • Page 68: Spec

    2 - 18 spec tightening torques engine tightening torques item fastener thread size q’ty tightening torque remarks nm m·kg ft·lb spark plugs — m10 4 13 1.3 9.4 cylinder head nut m10 2 20 + 121° (50) 2.0 + 121° (5.0) 14 + 121° (36) e cylinder head nut m10 6 20 + 105° (50) 2.0 + 105° (5.0) 14 + 105° (3...

  • Page 69: Spec

    2 - 19 spec tightening torques exhaust pipe and exhaust valve bolt m6 4 10 1.0 7.2 exhaust valve and housing bolt m6 3 10 1.0 7.2 exup pulley and arm shaft bolt m5 2 5 0.5 3.6 exhaust joint bolt m4 4 3 0.3 2.2 exhaust valve pipe bolt m8 1 20 2.0 14 air induction system pipe clamp — 4 3.5 0.35 2.5 cr...

  • Page 70: Spec

    2 - 20 spec tightening torques note: 1. First, tighten the bolt to approximately 20 nm (2.0 m • kg, 14 ft • lb) with a torque wrench. 2. Retighten the bolt to 20 nm (2.0 m • kg, 14 ft • lb), and tighten another 41 ~ 46° with a angle gauge or 32 nm (3.2 m • kg, 23 ft • lb) with a torque wrench. Exup ...

  • Page 71: Spec

    2 - 21 spec tightening torques chassis tightening torques item thread size tightening remarks nm m·kg ft·lb upper bracket and front fork m8 26 2.6 19 steering stem nut m28 115 11.5 83 handlebar and front fork m6 13 1.3 9.4 handlebar and upper bracket m6 13 1.3 9.4 lower ring nut m30 9 0.9 6.5 see no...

  • Page 72: Spec

    2 - 22 spec tightening torques note: 1.First, tighten the ring nut to approximately 50 nm (5.0 m • kg, 36 ft • lb) with a torque wrench, then loosen the ring nut completely. 2.Retighten the lower ring nut to specification. Coolant reservoir and radiator m6 5 0.5 3.6 tail cowling and frame m5 4 0.4 2...

  • Page 73: Spec

    2 - 23 spec lubrication points and lubricant types eas00031 lubrication points and lubricant types engine lubrication point lubricant oil seal lips ls o-rings ls bearings e crankshaft pins e piston surfaces e piston pins e connecting rod bolts and nuts m crankshaft journals e camshaft lobes m camsha...

  • Page 74: Spec

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

  • Page 75: Spec

    2 - 25 spec cooling system diagrams eas00033 cooling system diagrams 1 radiator fan 2 radiator 3 water pump.

  • Page 76: Spec

    2 - 26 spec cooling system diagrams 1 thermostat 2 radiator cap 3 coolant reservoir 4 radiator 5 oil cooler 6 water jacket joint.

  • Page 77: Spec

    2 - 27 spec cooling system diagrams 1 water pump 2 radiator cap 3 thermostat 4 thermostat housing.

  • Page 78: Spec

    2 - 28 spec cooling system diagrams 1 radiator.

  • Page 79: Spec

    2 - 29 spec engine oil lubrication chart engine oil lubrication chart exhaust camshaft intake camshaft piston cooler main gallery oil filter oil cooler relief valve oil pump strainer main axle mission cooler drive axle.

  • Page 80: Spec

    2 - 30 spec lubrication diagrams eas00034 lubrication diagrams 1 intake camshaft 2 exhaust camshaft 3 oil filter cartridge 4 oil level switch.

  • Page 81: Spec

    2 - 31 spec lubrication diagrams 1 intake camshaft 2 exhaust camshaft 3 crankshaft 4 oil cooler 5 oil pipe 6 oil strainer 7 oil pump.

  • Page 82: Spec

    2 - 32 spec lubrication diagrams 1 oil cooler 2 oil filter cartridge 3 oil level switch 4 oil strainer 5 oil pump 6 oil pipe.

  • Page 83: Spec

    2 - 33 spec lubrication diagrams 1 main axle 2 oil delivery pipe 3 drive axle.

  • Page 84: Spec

    2 - 34 spec lubrication diagrams 1 cylinder head 2 crankshaft.

  • Page 85: Spec

    2 - 35 spec cable routing eas00035 cable routing 1 headlight drain plug È make sure to securely insert the coupler and boot. É the headlight lead can be routed by either of the head- light or the boss. Do not catch the headlight lead when assembling the front cowling. Ê do not make the lead stretch ...

  • Page 86: Spec

    2 - 36 spec cable routing 1 handlebar switch (left) 2 main switch 3 throttle position sensor lead 4 guide-air 5 handlebar switch (right) 6 wiring section ! 7 ac magneto lead 8 speed sensor lead 9 (–) lead 0 rear brake switch lead a exup servo motor lead b ac magneto lead c ai system lead d oil level...

  • Page 87: Spec

    2 - 37 spec cable routing È route the horn lead under the rib of bracket horn positioning the stepped part of protector outside the rib. É make the horn lead face the outside. Ê route the handlebar switch lead along the groove of the guide-air. Ë handlebar switch (right) lead coupler. Ì fasten the w...

  • Page 88: Spec

    2 - 38 spec cable routing Ú route under the wire harness to the assembling point !. Û insert the holding clamp of the wire harness to the frame. Ü fasten the wire harness with the clamp inserted to the frame. Ý route the radiator fan motor lead above the wire harness. Þ assembling point # beneath th...

  • Page 89: Spec

    2 - 39 spec cable routing pass the filter of throttle body through the hole of rubber baffle and release it under the ignition coil plate. Route the sub lead coupler behind the ignition coil. Pass the camshaft position sensor lead through the hole of cover 1 and connect it. After branching the harne...

  • Page 90: Spec

    2 - 40 spec cable routing 1 turn signal light lead 2 radiator hose 3 reservoir tank breather hose (l = 440) 4 clutch cable 5 crankshaft position sensor lead 6 rear brake switch lead 7 wiring section # 8 coolant breather hose 9 clutch cable 0 handlebar switch lead a main switch lead b assembling poin...

  • Page 91: Spec

    2 - 41 spec cable routing Ô to turn signal light Õ in this area, pass the handlebar switch (right) lead behind of the throttle cable. Ö route the coolant temperature sensor lead between the engine and the radiator hose. × route the clutch cable through the inside of radiator hose and fasten it with ...

  • Page 92: Spec

    2 - 42 spec cable routing 1 ignition coil plate 2 rubber baffle 3 assembling point ± 4 assembling point ! 5 to wiring section ± 6 to wiring sections ±, # 7 oil level switch lead 8 sidestand switch lead 9 clamp 0 exup servo motor lead a air cleaner drain hose b ai system lead c fuel tank breather hos...

  • Page 93: Spec

    2 - 43 spec cable routing Ê clamp the air cleaner drain hose, fuel tank breather hose, drain hose, ai system hose, ai system lead and ac magneto. Route the air cleaner drain hose, fuel tank breather hose and drain hose outside the ai system hose, ai system lead and ac magneto lead. Route the fuel ta...

  • Page 94: Spec

    2 - 44 spec cable routing Õ point the tip of the band to the inner side. Ö routing position of each hose except the ai system hose is not regulated in the clamp. × pass all the hoses under the injector sub lead and wire har- ness. Ø neutral switch lead: fasten the exup servo motor lead and rear brak...

  • Page 95: Spec

    2 - 45 spec for california 1 canister 2 roll over valve assembly 3 hose (fuel tank breather – canister) 4 hose (canister – roll over valve) 5 hose (roll over valve – throttle body) È to throttle body É to atomosphere cable routing.

  • Page 96: Chk

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

  • Page 97: Chk

    3 - 2 chk adj * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months. Note: ● air filter • this model’s air filter is...

  • Page 98: Chk

    3 - 3 chk adj seats eas00039 seats t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the seats remove the parts in the order listed. 1 passenger seat 1 2 rider seat 1 for installation, reverse the removal procedure..

  • Page 99: Chk

    3 - 4 chk adj fuel tank eas00040 fuel tank t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the fuel tank remove the parts in the order listed. Rider seat refer to “seats”. 1 bolt 1 2 bolt 1 3 f...

  • Page 100: Chk

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

  • Page 101: Chk

    3 - 6 chk adj 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. • install the fuel pump as shown in the illustra- tion. • tighten the fuel pump bolts in stage...

  • Page 102: Chk

    3 - 7 chk adj cowlings eas00042 cowlings order job/part q’ty remarks removing the cowlings remove the parts in the order listed. Rider and passenger seats refer to “seats”. 1 tail cowling 1 2 bottom cowling 1 3 front cowling inner panel (left) 1 4 front cowling inner panel (right) 1 5 left side cowl...

  • Page 103: Chk

    3 - 8 chk adj air filter case eas00043 air filter case t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 3 nm (0.3 m • kg, 2.2 ft • ib) t r . . Order job/part q’ty remarks removing the air filter case remove the parts in the order listed. Rider seat and fuel tank refer to “seats” and “fuel tank”. 1 crankcase ...

  • Page 104: Chk

    3 - 9 chk adj adjusting the valve clearance eas00045 engine 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 pis...

  • Page 105: Chk

    3 - 10 chk adj adjusting the valve clearance 4. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark a on the pickup rotor with the cra...

  • Page 106: Chk

    3 - 11 chk adj adjusting the valve clearance 5. Remove: • camshaft note: _ • refer to “disassembling the engine—camshaft and cylinder head” in chapter 5. • when removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: • ...

  • Page 107: Chk

    3 - 12 chk adj adjusting the valve clearance c. Round off the original valve pad number according to the following table. Last digit rounded value 0 or 2 0 5 5 8 10 example: original valve pad number = 148 (thickness =1.48 mm) rounded value = 150 d. Locate the rounded number of the original valve pa...

  • Page 108: Chk

    3 - 13 chk adj adjusting the valve clearance valve pad selection table intake exhaust measured clearance installed pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 19...

  • Page 109: Chk

    3 - 14 chk adj adjusting the valve clearance/ synchronizing the throttle bodies note: @ • refer to “assembling and adjusting the engine—cylinder head and camshaft” in chapter 5. • lubricate the camshaft bearings, camshaft lobes and camshaft journals. • first, install the exhaust camshaft. • align th...

  • Page 110: Chk

    3 - 15 chk adj synchronizing the throttle bodies 4. Install: • carburetor syncronizer 1 (onto the synchronizing hose) • digital tachometer (near the spark plug) 5. Install: • fuel tank refer to “fuel tank”. 6. Start the engine and let it warm up for sev- eral minutes. 7. Measure: • engine idling spe...

  • Page 111: Chk

    3 - 16 chk adj synchronizing the throttle bodies/ adjusting the engine idling speed note: @ the difference in vacuum pressure between two throttle bodies should not exceed 1.33 kpa (10 mmhg, 0.39 inhg). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Measure: • engine idling speed out of specif...

  • Page 112: Chk

    3 - 17 chk adj adjusting the engine idling speed/ adjusting the throttle cable free play 2. Install: • digital tachometer (onto the spark plug lead of cylinder #1) 3. Check: • engine idling speed out of specification → adjust. 4. Adjust: • engine idling speed ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 113: Chk

    3 - 18 chk adj adjusting the throttle cable free play 2. Remove: • rider seat refer to “seats”. • fuel tank refer to “fuel tank”. • air filter case refer to “air filter case”. 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ note: _ when the throttle is opened,...

  • Page 114: Chk

    3 - 19 chk adj adjusting the throttle cable free play/ checking the spark plugs d. Tighten the locknut. Warning _ after adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ...

  • Page 115: Chk

    3 - 20 chk adj checking the spark plugs/ measuring the compression pressure 4. Check: • electrode 1 damage/wear → replace the spark plug. • insulator 2 abnormal color → replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Me...

  • Page 116: Chk

    3 - 21 chk adj measuring the compression pressure 1. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance”. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • rider seat refer to “seats”. • fuel tank refer to “fuel...

  • Page 117: Chk

    3 - 22 chk adj measuring the compression pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning _ to prevent sparking, ground all spark plug leads befor...

  • Page 118: Chk

    3 - 23 chk adj measuring the compression pressure/ checking the engine oil level 7. Install: • spark plug • ignition coil 8. Install: • rubber baffle • ignition coil plates • air filter case refer to “air filter case”. • fuel tank refer to “fuel tank”. • rider seat refer to “seats”. T r . . 13 nm (1...

  • Page 119: Chk

    3 - 24 chk adj checking the engine oil level/ changing the engine oil 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Note: _ before checking the engine oil level, wait a few minutes until the oil has settled. Eas00073 changing the en...

  • Page 120: Chk

    3 - 25 chk adj changing the engine oil c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Oil filter cartridge 17 nm (1.7 m · kg, 12 ft · lb) 6. Check: • engine oil drain bolt gasket damage → replace. 7. Ins...

  • Page 121: Chk

    3 - 26 chk adj changing the engine oil/ adjusting the clutch cable free play 13.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1. B. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. ...

  • Page 122: Chk

    3 - 27 chk adj adjusting the clutch cable free play 2. Adjust: • clutch cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ handlebar side a. Turn the adjusting dial 1 in direction a or b until the specified clutch cable free play is obtained. Note: _ if the specified clutch cable free...

  • Page 123: Chk

    3 - 28 chk adj replacing the air filter element eas00086 replacing the air filter element 1. Remove: • rider seat refer to “seats”. • fuel tank refer to “fuel tank”. 2. Remove: • air filter case cover 1 3. Check: • air filter element 1 damage → replace. Note: replace the air filter element at period...

  • Page 124: Chk

    3 - 29 chk adj checking the fuel and breather hoses/ checking the crankcase breather hose eas00096 checking the fuel and breather hoses the following procedure applies to all of the fuel and breather hoses. 1. Remove: • rider seat refer to “seats”. • fuel tank refer to “fuel tank”. 2. Check: • breat...

  • Page 125: Chk

    3 - 30 chk adj checking the crankcase breather hose/ checking the exhaust system 3. Install: • fuel tank refer to “fuel tank”. • rider seat refer to “seats”. Eas00099 checking the exhaust system the following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • radiator refer to “...

  • Page 126: Chk

    3 - 31 chk adj adjusting the exup cables eas00101 adjusting the exup cables 1. Remove: • bottom cowling refer to “cowlings”. 2. Remove: • exup valve pulley cover 1 3. Check: • exup system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the main switch on. B. Check that the exup v...

  • Page 127: Chk

    3 - 32 chk adj adjusting the exup cables/ checking the coolant level 7. Install: • bottom cowling refer to “cowlings”. Eas00102 checking the coolant level 1. Stand the motorcycle on a level surface. Note: _ • place the motorcycle on a suitable stand. • make sure the motorcycle is upright. 2. Check: ...

  • Page 128: Chk

    3 - 33 chk adj checking the cooling system eas00104 checking the cooling system 1. Remove: • bottom cowling • side cowlings refer to “cowlings”. 2. Check: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil cooler 4 • oil cooler inlet hose 5 • oil cooler outlet hose 6 • water jacket ...

  • Page 129: Chk

    3 - 34 chk adj changing the coolant eas00105 changing the coolant 1. Remove: • side cowling • bottom cowling refer to “cowlings”. 2. Disconnect: • coolant reservoir hose 1 3. Drain: • coolant (from the coolant reservoir) 4. Remove: • radiator cap 1 warning _ a hot radiator is under pressure. Therefo...

  • Page 130: Chk

    3 - 35 chk adj changing the coolant 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning _ • if coolant splashes in your eyes, thor- oughly wash them with water an...

  • Page 131: Chk

    3 - 36 chk adj changing the coolant 11.Install: • radiator cap 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then stop it. 15.Check: • coolant level refer to “ch...

  • Page 132: Chk

    3 - 37 chk adj adjusting the front brake eas00107 chassis adjusting the front brake 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) note: _ • while pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. • ...

  • Page 133: Chk

    3 - 38 chk adj adjusting the rear brake eas00110 adjusting the rear brake 1. Check: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket) out of specification → adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 134: Chk

    3 - 39 chk adj adjusting the rear brake/ checking the brake fluid level 3. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch”. Eas00115 checking the brake fluid level 1. Stand the motorcycle on a level surface. Note: _ • place the motorcycle on a suitable stand. • mak...

  • Page 135: Chk

    3 - 40 chk adj checking the front and rear brake pads/ adjusting the rear brake light switch eas00122 checking the front and rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad • rear brake pad wear indicator groove 1 almost dis...

  • Page 136: Chk

    3 - 41 chk adj checking the front and rear brake hoses/ bleeding the hydraulic brake system eas00131 checking the front and rear brake hoses the following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose cracks/damage/wear → replace. 2. Check: • brake hose cl...

  • Page 137: Chk

    3 - 42 chk adj bleeding the hydraulic brake system 1. Bleed: • hydraulic brake system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. B. Install the brake fluid reservoir diaphragm. C. Connect a clear plastic h...

  • Page 138: Chk

    3 - 43 chk adj adjusting the shift pedal/ adjusting the drive chain slack eas00136 adjusting the shift pedal 1. Check: • shift pedal position (distance a from the bottom of the rider footrest bracket to the top of the shift pedal) out of specification → adjust. 2. Adjust: • shift pedal position ▼▼▼ ...

  • Page 139: Chk

    3 - 44 chk adj adjusting the drive chain slack 3. Check: • drive chain slack a out of specification → adjust. T r . . Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) 4. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle nut 1. B. Loosen both locknuts...

  • Page 140: Chk

    3 - 45 chk adj lubricating the drive chain/ checking and adjusting the steering head eas00142 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, espe...

  • Page 141: Chk

    3 - 46 chk adj checking and adjusting the steering head 3. Remove: • upper bracket refer to “handlebars” and “stterling head” in chapter 4. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. B. Loos...

  • Page 142: Chk

    3 - 47 chk adj checking and adjusting the steering head e. Install the rubber washer 3. F. Install the upper ring nut 2. G. Finger tighten the upper ring nut 2, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligne...

  • Page 143: Chk

    3 - 48 chk adj checking and adjusting the steering head/ checking the front fork g. Reinstall the upper bracket and measure the steering head tension again as described above. H. Repeat the above procedure until the steer- ing head tension is within specification. I. Grasp the bottom of the front fo...

  • Page 144: Chk

    3 - 49 chk adj adjusting the front fork legs eas00155 adjusting the front fork legs the following procedure applies to both of the front fork legs. Warning _ • always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • securely support the motor...

  • Page 145: Chk

    3 - 50 chk adj adjusting the front fork legs rebound damping caution: _ never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 146: Chk

    3 - 51 chk adj adjusting the front fork legs/adjusting the rear shock absorber assembly ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ direction a compression damping is increased (suspen- sion is harder). Direction b compression damping is decreased (suspen- sion is softer). Adjusting positions ...

  • Page 147: Chk

    3 - 52 chk adj adjusting the rear shock absorber assembly ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ rebound damping caution: _ never go beyond the maximum or mini- mum adjustment positions. Direction a spring preload is increased (suspension is harder). Direction b spring preload is decrease...

  • Page 148: Chk

    3 - 53 chk adj adjusting the rear shock absorber assembly/checking the tires 1. Adjust: • compression damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00162 checking the tires the followi...

  • Page 149: Chk

    3 - 54 chk adj checking the tires * total weight of rider, passenger, cargo and acces- sories warning _ it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. Basic weight (with oil and a full fuel tank) for usa, canada 193 kg (426 lb)...

  • Page 150: Chk

    3 - 55 chk adj checking the tires warning _ • do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • when using a tube tire, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. •...

  • Page 151: Chk

    3 - 56 chk adj checking the tires/ checking the wheels front tire rear tire warning _ new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Note: _ for tire...

  • Page 152: Chk

    3 - 57 chk adj checking and lubricating the cables/ lubricating the levers and pedals/lubricating the sidestand/lubricating the rear suspension eas00170 checking and lubricating the cables the following procedure applies to all of the inner and outer cables. Warning _ damaged outer cable may cause t...

  • Page 153: Chk

    3 - 58 chk adj checking and charging the battery eas00178 electrical system checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...

  • Page 154: Chk

    3 - 59 chk adj checking and charging the battery note: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery...

  • Page 155: Chk

    3 - 60 chk adj checking and charging the battery 5. Charge: • battery (refer to the appropriate charging method illustration) warning _ do not quick charge a battery. Caution: _ • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage curre...

  • Page 156: Chk

    3 - 61 chk adj checking and charging the battery charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current w...

  • Page 157: Chk

    3 - 62 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. No yes make sure that the current is higher than the standard charging current writ...

  • Page 158: Chk

    3 - 63 chk adj checking and charging the battery/ checking the fuses 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) caution: _ first, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals dirt → clean with a wire brush....

  • Page 159: Chk

    3 - 64 chk adj checking the fuses 3. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “off”. B. Install a new fuse of the correct amperage rating. C. Set on the switches to verify if the electrical circuit is operational. D. If the fuse immediately bl...

  • Page 160: Chk

    3 - 65 chk adj replacing the headlight bulbs eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 2. Remove: • headlight bulb cover 2 3. Remove: • headlight bulb holder 1 4. Remove: • headlight bulb 2 warning _ si...

  • Page 161: Chk

    3 - 66 chk adj adjusting the headlight beam eas00184 adjusting the headlight beam 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • headlight bea...

  • Page 162: Chas

    4 - 1 chas eas00514 chassis front wheel and brake discs order job/part q’ty remarks removing the front wheel and brake discs remove the parts in the order listed. Note: _ place the motorcycle on a suitable stand so that the front wheel is elevated. 1 brake hose holder (left and right) 2 2 brake cali...

  • Page 163: Chas

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

  • Page 164: Chas

    4 - 3 chas front wheel and brake discs eas00521 removing the front wheel 1. Stand the motorcycle on a level surface. Warning _ securely support the motorcycle so that there is no danger of it falling over. Note: _ place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remov...

  • Page 165: Chas

    4 - 4 chas front wheel and brake discs 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 over the specified limits → replace. Radial wheel runout limit 1.0 mm (0.04 in) lateral wheel runout limit 0.5 mm (0.02 in) 4. Check: • wheel bearings front wheel turns roughly or is loose → replace t...

  • Page 166: Chas

    4 - 5 chas front wheel and brake discs eas00533 checking the brake discs the following procedure applies to all of the brake discs. 1. Check: • brake disc damage/galling → replace. 2. Measure: • brake disc deflection out of specification → correct the brake disc deflection or replace the brake disc....

  • Page 167: Chas

    4 - 6 chas front wheel and brake discs d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ...

  • Page 168: Chas

    4 - 7 chas front wheel and brake discs 8. Tighten wheel axle pinch bolt 1, and then pinch bolt 2 to the specified torque. 9. Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle. 10.Tighten wheel axle pinch bolt 3, and then pinch bolt 4 to the spec...

  • Page 169: Chas

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

  • Page 170: Chas

    4 - 9 chas rear wheel and brake disc eas00551 rear wheel and brake disc t r . . 27 nm (2.7 m • kg, 20 ft • ib) t r . . 150 nm (15.0 m • kg, 108 ft • lb) order job/part q’ty remarks removing the rear wheel remove the parts in the order listed. Note: @ place the motorcycle on a suitable stand so that ...

  • Page 171: Chas

    4 - 10 chas rear wheel and brake disc eas00560 rear wheel order job/part q’ty remarks disassembling the rear wheel remove the parts in the order listed. 1 spacer 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for installation, reverse the disassembly procedure..

  • Page 172: Chas

    4 - 11 chas rear wheel and brake disc t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 100 nm (10 m • kg, 72 ft • lb) order job/part q’ty remarks remove the brake disc and rear wheel sprocket remove the parts in the order listed. 1 brake disc 1 2 rear wheel sprocket 1 3 collar (left and right) 2 4 oil...

  • Page 173: Chas

    4 - 12 chas rear wheel and brake disc eas00561 removing the rear wheel 1. Stand the motorcycle on a level surface. Warning _ securely support the motorcycle so that there is no danger of it falling over. Note: _ place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: ...

  • Page 174: Chas

    4 - 13 chas rear wheel and brake disc 5. Remove: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collar eas00565 checking the rear wheel 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals refer to “checking the front wheel”. 2. Check: • tire • rear wheel ...

  • Page 175: Chas

    4 - 14 chas rear wheel and brake disc eas00568 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth a wear → replace the rear wheel sprocket. Bent teeth → replace the rear wheel sprocket. B correct 1 drive chain roller 2 rear wheel sprocket 2. Replace: •...

  • Page 176: Chas

    4 - 15 chas rear wheel and brake disc 2. Adjust: • drive chain slack refer to “adjusting the drive chain slack” in chapter 3. 3. Tighten: • wheel axle nut • brake caliper bolts warning _ make sure the brake hose is routed prop- erly. Caution: _ do not loosen the wheel axle nut after tight- ening it ...

  • Page 177: Chas

    4 - 16 chas front and rear brakes eas00577 front and rear brakes front brake pads t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. The f...

  • Page 178: Chas

    4 - 17 chas front and rear brakes rear brake pads t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 27 nm (2.7 m • kg, 20 ft • ib) order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. 1 brake caliper 1 2 brake pad 2 3 brake pad shim 2/2 4 brake pad spring 2 5 b...

  • Page 179: Chas

    4 - 18 chas front and rear brakes eas00579 caution: _ disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: warning • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, t...

  • Page 180: Chas

    4 - 19 chas front and rear brakes 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit out of specification → replace the brake pads as a set. 5. Install: • brake pad shims (onto the brake...

  • Page 181: Chas

    4 - 20 chas front and rear brakes ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your fing...

  • Page 182: Chas

    4 - 21 chas front and rear brakes eas00583 replacing the rear brake pads note: _ when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: • brake caliper 1 2. Remove: • brake pads 1 (along with the brake pad shims) 3. Measure: •...

  • Page 183: Chas

    4 - 22 chas front and rear brakes ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your fing...

  • Page 184: Chas

    4 - 23 chas front and rear brakes eas00584 front brake master cylinder t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) order job/part q’ty remarks removing the front brake master cylinder remove the parts in the order listed. Brake fluid drain. 1 brake fluid reservoir c...

  • Page 185: Chas

    4 - 24 chas front and rear brakes t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) order job/part q’ty remarks 13 brake hose 1 14 brake master cylinder bracket 1 15 brake master cylinder 1 16 front brake switch 1 for installation, reverse the removal procedure..

  • Page 186: Chas

    4 - 25 chas front and rear brakes eas00585 order job/part q’ty remarks disassembling the front brake master cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder 1 for assembly, reverse the disassembly procedure..

  • Page 187: Chas

    4 - 26 chas front and rear brakes eas00586 rear brake master cylinder t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) order job/part q’ty remarks removing the rear brake master cylinder remove the parts in the order listed. Brake f...

  • Page 188: Chas

    4 - 27 chas front and rear brakes eas00587 t r . . 16 nm (1.6 m • kg, 12 ft • ib) order job/part q’ty remarks disassembling the rear brake master cylinder remove the parts in the order listed. 1 brake master cylinder kit 1 2 brake master cylinder 1 for assembly, reverse the disassembly procedure..

  • Page 189: Chas

    4 - 28 chas front and rear brakes eas00588 disassembling the front brake master cylinder note: _ before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • brake switch coupler 1 (from the brake switch) 2. Remove: • union bolt 2 • coppe...

  • Page 190: Chas

    4 - 29 chas front and rear brakes eas00593 checking the front and rear brake master cylinders the following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruc...

  • Page 191: Chas

    4 - 30 chas front and rear brakes eas00607 assembling and installing the front brake master cylinder warning _ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components. Recommended brake f...

  • Page 192: Chas

    4 - 31 chas front and rear brakes 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning _ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the...

  • Page 193: Chas

    4 - 32 chas front and rear brakes eas00610 assembling the rear brake master cylinder 1. Install: • copper washers • brake hose • union bolt caution: _ when installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder. W...

  • Page 194: Chas

    4 - 33 chas front and rear brakes 3. Bleed: • brake system refer to “bleeding the hydraulic brake system” in chapter 3. 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” in chapter 3. 5. Adjus...

  • Page 195: Chas

    4 - 34 chas front and rear brakes eas00613 front brake calipers t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) order job/part q’ty remarks removing the front brake calipers remove the parts in the order listed. The following proce...

  • Page 196: Chas

    4 - 35 chas front and rear brakes eas00615 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) order job/part q’ty remarks disassembling the front brake calipers remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake...

  • Page 197: Chas

    4 - 36 chas front and rear brakes eas00616 rear brake caliper t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 27 nm (2.7 m • kg, 20 ft • ib) order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Brake fluid drain. 1 union bolt 1 2 copper washer 2 3 brake ho...

  • Page 198: Chas

    4 - 37 chas front and rear brakes eas00617 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) order job/part q’ty remarks disassembling the rear brake caliper remove the parts in the order listed. 1 brake caliper piston 2 2 brake caliper piston seal 4 3 bleed screw 1 for assembly, reverse the disassembly proced...

  • Page 199: Chas

    4 - 38 chas front and rear brakes eas00625 disassembling the front brake calipers the following procedure applies to both of the brake calipers. Note: _ before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake ho...

  • Page 200: Chas

    4 - 39 chas front and rear brakes eas00627 disassembling the rear brake caliper note: _ before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose note: _ put the end of the brake hose into a container and pum...

  • Page 201: Chas

    4 - 40 chas front and rear brakes eas00633 checking the front and rear brake calipers recommended brake component replacement schedule brake pads if necessary piston seals every two years brake hoses every four years brake fluid every two years and whenever the brake is disassem- bled 1. Check: • br...

  • Page 202: Chas

    4 - 41 chas front and rear brakes eas00640 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. Warning _ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use so...

  • Page 203: Chas

    4 - 42 chas front and rear brakes 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning _ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the...

  • Page 204: Chas

    4 - 43 chas front and rear brakes assembling and installing the rear brake caliper warning @ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components as they will cause the piston seals to...

  • Page 205: Chas

    4 - 44 chas front and rear brakes 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning _ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the...

  • Page 206: Chas

    4 - 45 chas front fork eas00647 front fork t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) order job/part q’ty remarks removing the front fork legs remo...

  • Page 207: Chas

    4 - 46 chas front fork eas00648 t r . . 40 nm (4.0 m • kg, 29 ft • ib) order job/part q’ty remarks disassembling the front fork legs remove the parts in the order listed. 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 nut 1 5 spring seat 1 6 fork spring 1 7 damper adjusting rod 1 8 outer tube 1 9 dust seal 1 ...

  • Page 208: Chas

    4 - 47 chas front fork t r . . 40 nm (4.0 m • kg, 29 ft • ib) order job/part q’ty remarks c damper rod assembly bolt 1 d copper washer 1 e damper rod assembly 1 f inner tube 1 for assembly, reverse the disassembly procedure..

  • Page 209: Chas

    4 - 48 chas 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. Note: _ place the motorcycle on a suitable...

  • Page 210: Chas

    4 - 49 chas front fork note: @ use the side of the rod holder that is marked “b”. C. Loosen the nut. D. Remove the cap bolt. E. Remove the rod holder and fork spring com- pressor. Warning _ the fork spring is compressed. F. Remove the spacer and nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 211: Chas

    4 - 50 chas front fork eas00656 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 bends/damage/scratches → replace. Warning @ do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measur...

  • Page 212: Chas

    4 - 51 chas 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 ...

  • Page 213: Chas

    4 - 52 chas front fork 4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 caution: @ make sure the numbered side of the oil seal faces out side. Note: _ • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the inner tu...

  • Page 214: Chas

    4 - 53 chas front fork 8. Install: • rod puller 1 (onto the damper rod 2) rod puller ym-01437 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) note: _ • while filling the front fork leg, keep it upright. • after filling, slowly pump the front fork leg up and down t...

  • Page 215: Chas

    4 - 54 chas front fork d. Press down on the spacer with the fork spring compressor 1. E. Pull up the rod puller and install the rod holder 2 between the nut 3 and the spacer 4. Note: _ use the side of the rod holder that is marked “b”. F. Remove the rod puller and adapter. G. Install the nut 1 and p...

  • Page 216: Chas

    4 - 55 chas front fork eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg temporarily tighten the upper and lower bracket pinch bolts. Note: _ make sure the inner fork tube is flush with the top of the handlebar holder...

  • Page 217: Chas

    4 - 56 chas handlebars eas00665 handlebars t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 115 nm (11.5 m • kg, 83 ft • lb) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty...

  • Page 218: Chas

    4 - 57 chas handlebars t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 115 nm (11.5 m • kg, 83 ft • lb) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty remarks 11 front br...

  • Page 219: Chas

    4 - 58 chas handlebars eas00667 removing the handlebars 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: • handlebar grip note: _ blow compressed air between the left handle- bar and the handlebar grip, an...

  • Page 220: Chas

    4 - 59 chas handlebars 2. Install: • right handlebar switch 1 note: _ align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: • brake master cylinder holder 1 caution: _ • install the brake master cylinder holder with the “up” mark facing up. • first,...

  • Page 221: Chas

    4 - 60 chas handlebars 6. Install: • left handlebar switch 1 note: _ align the projection a on the left handlebar switch with the hole b in the left handlebar. 7. Install: • handlebar grip ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the l...

  • Page 222: Chas

    4 - 61 chas steering head eas00676 steering head t r . . 1st 50 nm (5.0 m • kg, 36 ft • lb) 2nd 9 nm (0.9 m • kg, 6.5 ft • lb) t r . . 115 nm (11.5 m • kg, 83 ft • lb) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) order job/part q’ty remarks removing the lower bracke...

  • Page 223: Chas

    4 - 62 chas steering head t r . . 1st 50 nm (5.0 m • kg, 36 ft • lb) 2nd 9 nm (0.9 m • kg, 6.5 ft • lb) t r . . 115 nm (11.5 m • kg, 83 ft • lb) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) order job/part q’ty remarks 12 lower ring nut 1 13 lower bracket 1 14 bearin...

  • Page 224: Chas

    4 - 63 chas steering head eas00677 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: • ring nut 1 (with the steering nut wrench 2) warning _ securely support the lower bracket so ...

  • Page 225: Chas

    4 - 64 chas steering head b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. C. Install a new rubber seal and new bearing races. Caution: _ if the bearing race is not installed properly, the steering head pipe could be damaged. Note: _ • always replace the bearings...

  • Page 226: Chas

    4 - 65 chas rear shock absorber assembly eas00685 rear shock absorber assembly t r . . 45 nm (4.5 m • kg, 33 ft • ib) t r . . 45 nm (4.5 m • kg, 33 ft • ib) t r . . 45 nm (4.5 m • kg, 33 ft • ib) 1 order job/part q’ty remarks removing the rear shock absorber assembly remove the parts in the order li...

  • Page 227: Chas

    4 - 66 chas rear shock absorber assembly eas00687 handling the rear shock absorber and gas cylinder warning _ this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following inf...

  • Page 228: Chas

    4 - 67 chas rear shock absorber assembly eas00690 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Warning _ becurely support the motorcycle so that there is no danger of it falling over. Note: _ place the motorcycle on a suitable stand so that the rear wheel is ...

  • Page 229: Chas

    4 - 68 chas rear shock absorber assembly eas00695 checking the rear shock absorber assembly 1. Check: • rear shock absorber rod bends/damage → replace the rear shock absorber assembly. • rear shock absorber gas leaks/oil leaks → replace the rear shock absorber assembly. • spring damage/wear → replac...

  • Page 230: Chas

    4 - 69 chas swingarm and drive chain eas00700 swingarm and drive chain t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 105 nm (10.5 m • kg, 76 ft • lb) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty remarks remo...

  • Page 231: Chas

    4 - 70 chas swingarm and drive chain t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 105 nm (10.5 m • kg, 76 ft • lb) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job/part q’ty remarks 8 drive chain 1 9 dust cover 2 10 driv...

  • Page 232: Chas

    4 - 71 chas swingarm and drive chain eas00703 removing the swingarm 1. Stand the motorcycle on a level surface. Warning _ securely support the motorcycle so that there is no danger of it falling over. Note: _ place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: • r...

  • Page 233: Chas

    4 - 72 chas swingarm and drive chain eas00704 removing the drive chain 1. Stand the motorcycle on a level surface. Warning _ securely support the motorcycle so that there is no danger of it falling over. Note: _ place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: ...

  • Page 234: Chas

    4 - 73 chas swingarm and drive chain 3. Wash: • pivot shaft • dust covers • spacer • washers • bearings recommended cleaning solvent kerosene 4. Check: • dust covers 1 • spacer 2 damage/wear → replace. • bearings 3 damage/pitting → replace. 5. Check: • connecting arms 1 • relay arm 2 damage/wear → r...

  • Page 235: Chas

    4 - 74 chas swingarm and drive chain 2. Check: • drive chain stiffness → clean and lubricate or replace. 3. Clean: • drive chain ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe the drive chain with a clean cloth. B. Put the drive chain in kerosene and remove any remaining dirt. C. Remove t...

  • Page 236: Chas

    4 - 75 chas swingarm and drive chain 6. Check: • drive sprocket • rear wheel sprocket more than 1/4 tooth a wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprockets as a set. B correct 1 drive chain roller 2 drive chain sprocket eas00711 installing the swinga...

  • Page 237: Eng

    5 - 1 eng eas00188 overhauling the engine engine drive sprocket t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 85 nm (8.5 m • kg, 61 ft • ib) order job/part q’ty remarks removing the drive sprocket remove the parts in the order listed. 1 locknut 2 2 shift rod 1 3 drive sprocket cover 1 4 lock washe...

  • Page 238: Eng

    5 - 2 eng engine eas00189 exhaust pipe t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 38 nm (3.8 m • kg, 27 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) order job/part q’ty remarks removing the exhaust pipe remove the ...

  • Page 239: Eng

    5 - 3 eng engine t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 38 nm (3.8 m • kg, 27 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) order job/part q’ty remarks 7 exhaust valve pipe 1 8 muffler 1 for installation, revers...

  • Page 240: Eng

    5 - 4 eng engine leads and hoses t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks disconnecting the leads and hoses disconnect the parts in the order listed. Air filter case refer to “air filter case” in chapter 3. Throttle body assembly refe...

  • Page 241: Eng

    5 - 5 eng engine t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 3 clutch cable 1 4 crankcase breather hose 1 5 starter motor lead 1 disconnect. 6 ground lead 1 disconnect. 7 starter motor 1 8 stator coil assembly coupler 1 disconnect. 9 pic...

  • Page 242: Eng

    5 - 6 eng engine eas00191 engine t r . . 50 nm (5.0 m • kg, 36 ft • ib) 45 nm (4.5 m • kg, 33 ft • ib) t r . . T r . . 45 nm (4.5 m • kg, 33 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) 6 t r . . 45 nm (4.5 m • kg, 33 ft • ib) 8 t r . . 7 nm (0.7 m • kg, 5.1...

  • Page 243: Eng

    5 - 7 eng engine eas00192 installing the engine 1. Install: • engine mounting adjust bolts 1 • rear mounting bolts 2 • self-locking nuts 3 • left front mounting bolt 4 • right front mounting bolt 5 • pinch bolt 6 note: _ • lubricate the rear mounting bolt threads with lithium soap base grease. • do ...

  • Page 244: Eng

    5 - 8 eng camshaft eas00194 camshaft cylinder head covers t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the cylinder head covers remove the parts in the order listed. Throttle body assembly...

  • Page 245: Eng

    5 - 9 eng camshaft eas00196 camshafts t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) order job/part q’ty remarks removing the camshafts remove the pa...

  • Page 246: Eng

    5 - 10 eng camshaft t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) order job/part q’ty remarks 13 pin 1 14 timing chain guide (intake side) 1 for ins...

  • Page 247: Eng

    5 - 11 eng camshaft eas00198 removing the camshafts 1. Align: • tdc mark on the pickup coil rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark a on t...

  • Page 248: Eng

    5 - 12 eng camshaft 6. Remove: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pins caution: _ to prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 7. Remove: • intake cam...

  • Page 249: Eng

    5 - 13 eng camshaft 3. Measure: • camshaft runout out of specification → replace. 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance out of specification → measure the cam- shaft journal diameter. Camshaft runout limit 0.03 mm (0.0012 in) camshaft-journal-to-camshaft- cap clearance 0.028 ~ 0...

  • Page 250: Eng

    5 - 14 eng camshaft 5. Measure: • camshaft journal diameter a out of specification → replace the cam- shaft. Within specification → replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) eas00208 checking the timing chain, camshaft...

  • Page 251: Eng

    5 - 15 eng camshaft eas00210 checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage → replace. 2. Check: • one-way cam operation rough movement → replace the timing chain tensioner housing. 3. Check: • cap bolt • copper washer • spring • one-way cam • gasket • timing ch...

  • Page 252: Eng

    5 - 16 eng camshaft caution: _ the camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. 4. Install: • intake camshaft sprocket • exhaust camshaft sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwi...

  • Page 253: Eng

    5 - 17 eng camshaft 6. Install: • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. B. With the timing chain tensioner rod turned all the way i...

  • Page 254: Eng

    5 - 18 eng camshaft 9. Tighten: • camshaft sprocket bolts caution: _ be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 10.Install: • timing chain guide (top side) 11.Measure: • valve clearance out of spe...

  • Page 255: Eng

    5 - 19 eng cylinder head eas00221 cylinder head 2nd 140˚ or 65 nm (6.5 m • kg, 47 ft • lb) t r . . 1st 20 nm (2.0 m • kg, 14 ft • lb) 2nd 105˚ or 50 nm (5.0 m • kg, 36 ft • lb) t r . . 1st 20 nm (2.0 m • kg, 14 ft • lb) 2nd 121˚ or 50 nm (5.0 m • kg, 36 ft • lb) t r . . 1st 20 nm (2.0 m • kg, 14 ft ...

  • Page 256: Eng

    5 - 20 eng cylinder head eas00222 removing the cylinder head 1. Remove: • cylinder head nuts • cylinder head bolts note: _ • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas00227 checking the cylind...

  • Page 257: Eng

    5 - 21 eng cylinder head eas00233 installing the cylinder head 1. Install: • gasket 1 • dowel pins 2 2. Install: • cylinder head note: _ pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head nuts 1 ~ 6 1st 2nd • cylinder head nuts 7, 0 1st 2nd • cylinder head nuts 8, 9 1...

  • Page 258: Eng

    5 - 22 eng valves and valve springs eas00236 valves and valve springs order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 intake valve lifter 12 2 intake valve pad 12 3 intake valve cotter 24 4 intake valve...

  • Page 259: Eng

    5 - 23 eng valves and valve springs order job/part q’ty remarks 10 exhaust valve lifter 8 11 exhaust valve pad 8 12 exhaust valve cotter 16 13 exhaust valve upper spring seat 8 14 exhaust valve spring 8 15 exhaust valve oil seal 8 16 exhaust valve lower spring seat 8 17 exhaust valve 8 18 exhaust va...

  • Page 260: Eng

    5 - 24 eng 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. Remove: •...

  • Page 261: Eng

    5 - 25 eng valves and valve springs 4. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 note: _ identify the position of each part very carefully so that it can be reinstalled in its original place. Eas00239 checking the valves and valve guides the f...

  • Page 262: Eng

    5 - 26 eng 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 → ...

  • Page 263: Eng

    5 - 27 eng valves and valve springs eas00240 checking the valve seats the following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat pitting/wear → replace the cylinder head. 3. Measure: • valve seat w...

  • Page 264: Eng

    5 - 28 eng valves and valve springs ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound a to the valve face. Caution: _ do not let the lapping compound enter the gap between the valve stem and the valve guide. B. Apply molybdenum disulfide oil onto the valve stem. C....

  • Page 265: Eng

    5 - 29 eng 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) intake valve spring 82 ~ 96 n (8.2 ~ 9.6 kg, 18.43 ~ 21.58 lb) at 34.5 mm (1.36 in) exhaust valve spring 110...

  • Page 266: Eng

    5 - 30 eng valves and valve springs 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) recommended lubricant molybdenum disulfide oil 3. Install: • valve 1 • lower spring seat 2 • valve stem seal 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) note: _...

  • Page 267: Eng

    5 - 31 eng valves and valve springs 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Caution: _ hitting the valve tip with excessive force could damage the valve. 6. Install: • valve pad 1 • valve lifter 2 note: _ • lubricate the valve lifter and...

  • Page 268: Eng

    5 - 32 eng generator t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 65 nm (6.5 m • kg, 47 ft • ib) + 60˚ order job/part q’ty remarks removing the stator coil assembly remove the parts in the order listed. Rider seat and fuel tank refer to “seats” and “fuel tan...

  • Page 269: Eng

    5 - 33 eng generator removing the generator 1. Remove: • generator rotor cover 1 note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor bolt 1 • washer note: @ while holding the gen...

  • Page 270: Eng

    5 - 34 eng generator caution: • clean the tapered portion of the crank- shaft and the generator rotor hub with lacquer thinner. • lubricate the generator rotor bolt threads with engine oil. 3. Tighten: • generator rotor bolt 1 note: @ while holding the generator rotor 2 with the rotor holding tool 3...

  • Page 271: Eng

    5 - 35 eng generator warning when the bolt are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and per- form the procedure again. Caution: • do not use a torque wrench to tighten the bolt to the specified angle. • tighten the bol...

  • Page 272: Eng

    5 - 36 eng pickup coil pickup coil t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 60 nm (6.0 m • kg, 43 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the pickup coil and pickup coil rotor remove the parts in the order li...

  • Page 273: Eng

    5 - 37 eng pickup coil t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 60 nm (6.0 m • kg, 43 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 7 crankshaft position sensor coupler 1 disconnect. 8 crankshaft position sensor 1 9 pickup ...

  • Page 274: Eng

    5 - 38 eng pickup coil removing the pickup coil rotor 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 note: @ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove:...

  • Page 275: Eng

    5 - 39 eng pickup coil 2. Tighten: • pickup coil rotor bolt 1 note: @ while holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Rotor holding tool yu-01235 t r . . 60 nm (6.0 m · kg, 43 ft · lb) 3. Apply: • sealant (onto the crankshaft position sensor lea...

  • Page 276: Eng

    5 - 40 eng clutch clutch clutch cover t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) order job/part q’ty remarks removing the clutch cover remove the parts in the order listed. Bottom cowling and right side cowling refer to “cowlings” in chapter 3. Engine oil drain. ...

  • Page 277: Eng

    5 - 41 eng clutch pull lever shaft order job/part q’ty remarks removing the pull lever shaft remove the parts in the order listed. 1 circlip 2 2 pull lever 1 3 pull lever spring 1 4 pull lever shaft 1 5 oil seal 1 6 bearing 2 for installation, reverse the removal procedure..

  • Page 278: Eng

    5 - 42 eng clutch eas00274 clutch t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 105 nm (10.5 m • kg, 76 ft • lb) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks removing the clutch remove the parts in the order listed. 1 clutch spring plate retainer 1 2 clutch spring plate 1 3 c...

  • Page 279: Eng

    5 - 43 eng clutch t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 105 nm (10.5 m • kg, 76 ft • lb) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks 15 thrust washer 1 16 clutch housing 1 17 bearing 1 18 starter clutch gear 1 19 bearing 1 20 starter clutch assembly 1 21 circlip 1 22...

  • Page 280: Eng

    5 - 44 eng clutch eas00277 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1 note: _ while holding the clutch boss 2 with the uni- versal clutch holder 3, loosen the clutch boss nut. 3. Remove: • clutch boss nut 1 • lock washer 2 • clutch boss assembly 3 • thrust ...

  • Page 281: Eng

    5 - 45 eng clutch eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1) out of specification → replace the ...

  • Page 282: Eng

    5 - 46 eng clutch 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 shaft pinion gear teeth 1 • pull rod teeth 2 damage/wear → replace the pull rod a...

  • Page 283: Eng

    5 - 47 eng clutch 2. Check: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the starter clutch drive gear onto the starter clutch and hold the starter clutch. B. When turning the starter clutch drive gear clockwise È, the starter clutch and the starter clutch ...

  • Page 284: Eng

    5 - 48 eng clutch 5. Install: • friction plates • clutch plates note: _ first, install a friction plate and then alternate between a clutch plate and a friction plate. 6. Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 • clutch spring plate retainer 4 note: tighten t...

  • Page 285: Eng

    5 - 49 eng shift shaft eas00327 shift shaft shift shaft and stopper lever t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) order job/part q’ty remarks removing the shift shaft and stop- per lever remove the parts in the order listed. Drive sprocket cover refer to “engin...

  • Page 286: Eng

    5 - 50 eng shift shaft checking the shift shaft 1. Check: • shift shaft 1 bends/damage/wear → replace. • shift shaft spring 2 damage/wear → replace. Checking the stopper lever 1. Check: • stopper lever 1 bends/damage → replace. Roller turns roughly → replace the stopper lever. Installing the shift s...

  • Page 287: Eng

    5 - 51 eng oil pan and oil pump eas00356 oil pan and oil pump t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 43 nm (4.3 m • kg, 31 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib)...

  • Page 288: Eng

    5 - 52 eng oil pan and oil pump t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 43 nm (4.3 m • kg, 31 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7....

  • Page 289: Eng

    5 - 53 eng oil pan and oil pump eas00360 oil pump t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 oil/water pump assembly driven sprocket 1 2 washer 1 3 oil pump housing 1 4 ...

  • Page 290: Eng

    5 - 54 eng oil pan and oil pump eas00362 removing the oil pan 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins note: _ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas00364 checking the oil p...

  • Page 291: Eng

    5 - 55 eng oil pan and oil pump 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas00365 checking the relief valve 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • o-ring 4 damage/wear → replace the defective part(s). Eas00367 c...

  • Page 292: Eng

    5 - 56 eng oil pan and oil pump eas00374 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • pin 1 • inner rotor 2 • outer rotor 3 • oil pump housing 4 • oil pump housing screw note: _ when installing the inner rotor, alig...

  • Page 293: Eng

    5 - 57 eng oil pan and oil pump eas00378 installing the oil strainer 1. Install: • oil strainer housing 1 note: _ the arrow mark a on the oil strainer housing must point towards the front of the engine. T r . . 10 nm (1.0 m · kg, 7.2 ft · lb) eas00380 installing the oil pan 1. Install: • dowel pins ...

  • Page 294: Eng

    5 - 58 eng crankcase eas00381 crankcase t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the crankcase remove the parts in the order listed. Engine refer to “engine”. Cylinder head refer to “cylinder head”. Pickup coil and pickup co...

  • Page 295: Eng

    5 - 59 eng crankcase t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 6 washer 1 7 oil/water pump assembly drive sprocket 1 8 washer 1 9 plate 1 10 lower crankcase 1 11 dowel pin 3 for installation, reverse the removal procedure..

  • Page 296: Eng

    5 - 60 eng crankcase eas00384 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts note: _ • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing ...

  • Page 297: Eng

    5 - 61 eng crankcase eas00399 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air...

  • Page 298: Eng

    5 - 62 eng crankcase eas00414 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) recommended lubricant engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) note: _ do not allow any sealant to come into contact with the oil gallery or ...

  • Page 299: Eng

    5 - 63 eng crankcase 6. Install: • lower crankcase 1 (onto the upper crankcase 2) caution: _ before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts note: _ • lubricate the bolt threads wi...

  • Page 300: Eng

    5 - 64 eng connecting rods and pistons eas00382 connecting rods and pistons t r . . 20 nm (2.0 m • kg, 14 ft • ib) + 120˚ order job/part q’ty remarks removing the connecting rods and pistons remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 connecting rod cap 4 2 big ...

  • Page 301: Eng

    5 - 65 eng connecting rods and pistons eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod 1 • big end bearings note: _ identify the position of each big end bearing so that it can be reinstalled in ...

  • Page 302: Eng

    5 - 66 eng connecting rods and pistons 3. Remove: • top ring • 2nd ring • oil ring note: _ when removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Eas00387 removing the crankshaft assembly 1. Remove: • crankshaft assembly 1 • cranksh...

  • Page 303: Eng

    5 - 67 eng connecting rods and pistons b. If out of specification, replace the cylinder, and the pistons and piston rings as a set. Cylinder bore “c” 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) wear limit 74.06 mm (2.9157 in) taper limit “t” 0.05 mm (0.002 in) out of round “r” 0.05 mm (0.002 in) “c” = max...

  • Page 304: Eng

    5 - 68 eng connecting rods and pistons eas00263 checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and piston rings as a set. Note: _ before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring groove...

  • Page 305: Eng

    5 - 69 eng connecting rods and pistons checking the piston pins the following procedure applies to all of the piston pins. 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a out of specificatio...

  • Page 306: Eng

    5 - 70 eng connecting rods and pistons ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following procedure applies to all of the connecting rods. Caution: @ do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prev...

  • Page 307: Eng

    5 - 71 eng connecting rods and pistons e. Tighten the connecting rod nuts. F. Replace the connecting rod bolts and nuts with new ones. Caution: tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. G. Clean the connecting rod bolts and ...

  • Page 308: Eng

    5 - 72 eng connecting rods and pistons 2. Select: • big end bearings (p1 ~ p4) note: @ • the numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. • “p1” ~ “p4” refer to the bearings shown in the crankshaft ill...

  • Page 309: Eng

    5 - 73 eng connecting rods and pistons 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip 4 note: @ • apply engine oil onto the piston pin. • make sure that the “y” mark a on the con- necting rod faces left when the arrow mark b on the piston is pointing u...

  • Page 310: Eng

    5 - 74 eng connecting rods and pistons 6. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaft pin). • connecting rod cap (onto the connecting rod) note: @ • align the projections on the big end bearings with the notches in the connecting rods and connecti...

  • Page 311: Eng

    5 - 75 eng connecting rods and pistons e. Tighten the nut further to reach the speci- fied angle (120°). Warning when the nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt with a new one and per- form the procedure again. Caution: • do not ...

  • Page 312: Eng

    5 - 76 eng crankshaft crankshaft order job/part q’ty remarks removing the crankshaft assembly remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. Connecting rod caps refer to “connecting rods and pistons”. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft j...

  • Page 313: Eng

    5 - 77 eng crankshaft eas00395 checking the crankshaft 1. Measure: • crankshaft runout out of specification → replace the crank- shaft. 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces scratches/wear → replace the crankshaft. Crankshaft runout less than 0.03 mm (0...

  • Page 314: Eng

    5 - 78 eng crankshaft c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. Note: _ align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. D. Put a piece of plastigauge ® 2 on each crankshaft journal. ...

  • Page 315: Eng

    5 - 79 eng crankshaft g. Remove the lower crankcase and the crank- shaft journal lower bearings. H. Measure the compressed plastigauge ® width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft jour...

  • Page 316: Eng

    5 - 80 eng crankshaft eas00407 installing the crankshaft 1. Install: • crankshaft journal upper bearings 1 (into the upper crankcase) note: _ • align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. • be sure to install each crankshaft journal upp...

  • Page 317: Eng

    5 - 81 eng transmission eas00419 transmission t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the transmission, shift drum assembly, and shift forks remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. St...

  • Page 318: Eng

    5 - 82 eng transmission t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 10 shift drum assembly 1 11 shift fork “c” 1 12 main axle assembly 1 for installation, reverse the removal procedure..

  • Page 319: Eng

    5 - 83 eng transmission order job/part q’ty remarks disassembling the main axle assembly disassembly the parts in the order listed. 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 toothed spacer 1 6 toothed washer 2 7 circlip 2 8 3rd/4th pinion gear...

  • Page 320: Eng

    5 - 84 eng transmission order job/part q’ty remarks a main axle/1st pinion gear 1 b bearing 1 c main axle bearing housing 1 for assembly, reverse the disassembly procedure..

  • Page 321: Eng

    5 - 85 eng transmission order job/part q’ty remarks disassembling the drive axle assembly disassembly the parts in the order listed. 1 washer 1 2 1st wheel gear 1 3 spacer 1 4 5th wheel gear 1 5 circlip 3 6 washer 3 7 3rd wheel gear 1 8 toothed spacer 2 9 toothed lock washer 1 0 toothed lock washer ...

  • Page 322: Eng

    5 - 86 eng transmission order job/part q’ty remarks a 4th wheel gear 1 b 6th wheel gear 1 c 2nd wheel gear 1 d spacer 1 e drive axle 1 f bearing 1 g spacer 1 for assembly, reverse the disassembly procedure..

  • Page 323: Eng

    5 - 87 eng transmission eas00420 removing the transmission 1. Remove: • main axle assembly 1 (with the torx ® wrench t30) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten ...

  • Page 324: Eng

    5 - 88 eng transmission eas00422 checking the shift drum assembly 1. Check: • shift drum grooves damage/scratches/wear → replace the shift drum assembly. • shift drum segment 1 damage/wear → replace the shift drum assembly. • shift drum bearing 2 damage/pitting → replace the shift drum assembly. Eas...

  • Page 325: Eng

    5 - 89 eng transmission 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmission axle assemblies. 5. Check: • transmission gear movement rough movement → replace the defective part(s). 6. Check: • circlips bends/damage/looseness...

  • Page 326: Cool

    6 - 1 cool eas00454 cooling system radiator order job/part q’ty remarks removing the radiator remove the parts in the order listed. Rider seat and fuel tank refer to “seats” and “fuel tank” in chapter 3. Air filter case and rubber cover refer to “air filter case” in chapter 3. Bottom cowling and sid...

  • Page 327: Cool

    6 - 2 cool radiator order job/part q’ty remarks 3 radiator inlet hose 1 4 radiator outlet hose 1 5 water pump breather hose 1 6 radiator 1 7 radiator fan 1 8 water pump inlet pipe 1 for installation, reverse the removal procedure..

  • Page 328: Cool

    6 - 3 cool 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 • radiator pipes cra...

  • Page 329: Cool

    6 - 4 cool radiator eas00456 installing the radiator 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: • cooling system leaks → repair or replace any faulty part. 3. Measure: • radiator cap opening pressure belo...

  • Page 330: Cool

    6 - 5 cool oil cooler eas00457 oil cooler t r . . 35 nm (3.5 m • kg, 25 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the oil cooler remove the parts in the order listed. Radiator a...

  • Page 331: Cool

    6 - 6 cool oil cooler eas00458 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear → replace. Eas00459 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a c...

  • Page 332: Cool

    6 - 7 cool thermostat eas00460 thermostat t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the thermostat assembly remove the parts in the order listed. Rider seat and fuel tank refer to “seats” and “fuel tank” in chapter 3. Air fil...

  • Page 333: Cool

    6 - 8 cool thermostat t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 5 thermostat assembly 1 6 thermostat assembly inlet pipe (left) 1 for installation, reverse the removal procedure..

  • Page 334: Cool

    6 - 9 cool thermostat eas00461 ‘ t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks disassembling the thermostat housing remove the parts in the order listed. 1 thermostat housing cover 1 2 thermostat 1 3 thermostat housing 1 for assembly, reve...

  • Page 335: Cool

    6 - 10 cool thermostat eas00462 checking the thermostat 1. Check: • thermostat does not open at 71 ~ 85 °c (160 ~ 185 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the w...

  • Page 336: Cool

    6 - 11 cool thermostat eas00464 assembling the thermostat assembly 1. Install: • thermostat housing 1 • thermostat 2 • o-ring 3 • thermostat housing cover 4 note: _ install the thermostat with its breather hole a facing up. New 2. Install: • coolant temperature sensor 1 caution: _ use extreme care w...

  • Page 337: Cool

    6 - 12 cool water pump eas00468 water pump t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the impeller shaft remove the parts in the order listed. Note: • the water pump and oil pump are com- bined into one unit (oil/water pump assembly). • it is not necessary to remove...

  • Page 338: Cool

    6 - 13 cool water pump t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 5 water pump seal 1 6 oil seal 1 7 bearing 1 for installation, reverse the removal procedure..

  • Page 339: Cool

    6 - 14 cool water pump eas00471 disassembling the water pump 1. Remove: • water pump seal 1 note: _ tap out the water pump seal from the inside of the water pump housing. 2 water pump housing 2. Remove: • oil seal 1 • bearing 2 note: _ tap out the bearing and oil seal from the out- side of the water...

  • Page 340: Cool

    6 - 15 cool water pump eas00475 assembling the water pump 1. Install: • oil seal 1 (into the water pump housing 2) note: _ • before installing the oil seal, apply tap water or coolant onto its out surface. • install the oil seal with a socket that matches its outside diameter. 2. Install: • water pu...

  • Page 341: Cool

    6 - 16 cool water pump 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: _ make sure the rubber damper and rubber damper holder are flush with the impeller. 1 straightedge 2 impeller impeller shaft tilt limit 0.15 mm (0.0059 in).

  • Page 342: Fuel Injection System

    7 - 1 fi fuel injection system fuel injection system 1 ignition coil 2 air filter case 3 intake temperature sensor 4 fuel delivery hose 5 fuel tank 6 fuel pump 7 fuel return hose 8 intake air pressure sensor 9 throttle position sensor 0 fuel injector a catalytic converter b crankshaft position senso...

  • Page 343

    7 - 2 fi fuel injection system wiring diagram off r un l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/ b r /b o /g o gy /g gy /r l gy /r l...

  • Page 344

    7 - 3 fi fuel injection system ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute cha...

  • Page 345

    7 - 4 fi fuel injection system substitute characteristics operation control (fail-safe action) if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven, the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operati...

  • Page 346

    7 - 5 fi fuel injection system troubleshooring chart “engine runs irregularly.” or “engine trouble warning light is illuminated.” * engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is illumi- nated checking the self-diagno...

  • Page 347

    7 - 6 fi fuel injection system diagnostic mode • in this mode, diagnostic codes are input into the ecu in accordance with the number of times the start switch has been operated. • in accordance with the diagnostic codes, the ecu displays the values received from the sensors and actuates the actuator...

  • Page 348

    7 - 7 fi fuel injection system diagnostic fault code table fault code no. Symptom probable cause of malfunction code of diagnostic mode 11 no normal signals are received from the cylinder identification sensor. Note: this code number appears if the con- dition continued for 10 seconds in which the s...

  • Page 349

    7 - 8 fi fuel injection system 33 open circuit is detected in the primary lead of the ignition coil (#1). • open or short circuit in wiring harness. • malfunction in ignition coil. • malfunction in ecu. • malfunction in a component of ignition cut-off circuit system. 30 34 open circuit is detected i...

  • Page 350

    7 - 9 fi fuel injection system diagnostic mode table set the meter display from the regular mode to the diagnosis mode. For the setting method, refer to “diagnostic mode”. Note: • check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is ...

  • Page 351

    7 - 10 fi fuel injection system 32 ignition coil #3 after 1 second has elapsed from the time the engine stop switch has been turned from off to on, it actuates ignition coil #3 for five times every second and illuminates the engine trouble warning light. * connect an ignition checker. * if the engin...

  • Page 352

    7 - 11 fi fuel injection system 52 headlight relay 1 after 1 second has elapsed from the time the engine stop switch has been turned from off to on, it actuates the head- light relay five times every 5 seconds and illuminates the engine trouble warning light. (on 2 seconds, off 3 seconds) * if the e...

  • Page 353

    7 - 12 fi fuel injection system troubleshooting details this section describes the measures per fault code number displayed on the meter.Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunc...

  • Page 354

    7 - 13 fi fuel injection system fault code no. 12 symptom no normal signals are received from the crankshaft position sensor. Used diagnostic code no.-- inspection operation item and probable cause operation item and countermeasure reinstatement method installed condition of sensor check the install...

  • Page 355

    7 - 14 fi fuel injection system fault code no. 13 symptom intake air pressure sensor - open or short circuit detected. Used diagnostic code no. 03 (intake air pressure sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method defective intake air pre...

  • Page 356

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

  • Page 357

    7 - 16 fi fuel injection system fault code no. 17 symptom exup servo motor potention circuit - open or short circuit detected. Used diagnostic code 53 inspection operation item and probable cause operation item and countermeasure reinstatement method defective exup servo motor potention circuit. Rep...

  • Page 358

    7 - 17 fi fuel injection system fault code no. 18 symptom exup servo motor is stuck. Used diagnostic code 53 inspection operation item and probable cause operation item and countermeasure reinstatement method defective exup servo motor. Replace if defective. 1. Disconnect the exup cables from the ex...

  • Page 359

    7 - 18 fi fuel injection system fault code no. 19 symptom open circuit is detected in the input line from the sidestand switch to the ecu. Used diagnostic code no. 20 (sidestand switch) inspection operation item and probable cause operation item and countermeasure reinstatement method defective side...

  • Page 360

    7 - 19 fi fuel injection system fault code no. 22 symptom open or short circuit detected from the intake temperature sensor. Used diagnostic code no. 05 (intake temperature sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method installed condition...

  • Page 361

    7 - 20 fi fuel injection system fault code no. 23 symptom open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code no. 02 (atmospheric pressure sensor) inspection operation item and probable cause operation item and countermeasure reinstatement method defective atmos...

  • Page 362

    7 - 21 fi fuel injection system fault code no. 30 symptom the motorcycle has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) inspection operation item and probable cause operation item and countermeasure reinstatement method defective lean angle cut-off switch replace if defectiv...

  • Page 363

    7 - 22 fi fuel injection system fault code no. 33 symptom malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code no. 30 (ignition coil #1) inspection operation item and probable cause operation item and countermeasure reinstatement method defective ignition coil (te...

  • Page 364

    7 - 23 fi fuel injection system fault code no. 36 symptom malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code no. 33 (ignition coil #4) inspection operation item and probable cause operation item and countermeasure reinstatement method defective ignition coil (te...

  • Page 365

    7 - 24 fi fuel injection system fault code no. 42 symptom 1 no normal signals are received from the speed sensor. 2 open or short circuit is detected in the neutral switch. Used diagnostic code no. 07 (speed sensor) no. 21 (neutral switch) inspection operation item and probable cause operation item ...

  • Page 366

    7 - 25 fi fuel injection system fault code no. 43 symptom the ecu is unable to monitor the battery voltage. Used diagnostic code no. 09 (fuel system voltage) inspection operation item and probable cause operation item and countermeasure reinstatement method malfunction in ecu fuel injection system r...

  • Page 367

    7 - 26 fi fuel injection system fault code no. 44 symptom error is detected while reading or writing on eep-rom. Used diagnostic no. 60 (eep-rom improper cylinder indication) inspection operation item and probable cause operation item and countermeasure reinstatement method malfunction in ecu execut...

  • Page 368

    7 - 27 fi fuel injection system fault code no. Er-1 symptom no signal are received from the ecu. Used diagnostic code no. -- inspection operation item and probable cause operation item and countermeasure reinstatement method open or short circuit in wiring harness and/or sub lead. Repair or replace ...

  • Page 369

    7 - 28 fi fuel injection system fault code no. Er-4 symptom non-registered data has been received from the meter. Used diagnostic code no. -- inspection operation item and probable cause operation item and countermeasure reinstatement method open or short circuit in wiring harness and/or sub lead. R...

  • Page 370

    7 - 29 fi throttle bodies throttle bodies order job/part q’ty remarks removing the throttle bodies remove the parts in the order listed. Seats/fuel tank/rubber sheet refer to “seats” and “fuel tank” in chapter 3. Air filter case refer to “air filter case” in chapter 3. Coolant drain. Refer to “chang...

  • Page 371

    7 - 30 fi throttle bodies order job/part q’ty remarks 5 throttle cable 2 disconnect. 6 plunger control unit hose 2 disconnect. 7 throttle body joint 4 for installation, reverse the removal procedure..

  • Page 372

    7 - 31 fi throttle bodies order job/part q’ty remarks removing the injector remove the parts in the order listed. 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor 1 disconnect. 3 cylinder #1-injector coupler 1 disconnect. 4 cylinder #2-injector coupler 1 disconnect. 5 cy...

  • Page 373

    7 - 32 fi throttle bodies order job/part q’ty remarks 11 intake air pressure sensor 1 12 fuel distributor 1 13 injector 4 14 throttle position sensor 1 for installation, reverse the removal procedure..

  • Page 374

    7 - 33 fi throttle bodies caution: the throttle bodies should not be disas- sembled unnecessarily. Checking the injector 1. Check: • injector damage → replace. Checking the throttle body 1. Check: • throttle body cracks/damage → replace the throttle bodies. 2. Check: • fuel passages obstruction → cl...

  • Page 375

    7 - 34 fi throttle bodies checking the pressure regulator 1. Check: • pressure regulator damage → replace. Checking the fuel pump and pressure regulator operation 1. Check: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank. Refer to “seats” and ...

  • Page 376

    7 - 35 fi throttle bodies faulty → replace the pressure regulator. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ increase the vacuum pressure → fuel pressure is decreased decrease the vacuum pressure → fuel pressure is increased eas00500 checking and adjusting the throttle position sensor note: ...

  • Page 377

    7 - 36 fi throttle bodies f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → replace the throttle position sensor. The slot is worn or broken → replace the throttle position s...

  • Page 378

    7 - 37 fi air induction system eas00507 air induction system air induction the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve ...

  • Page 379

    7 - 38 fi air induction system eas00509 air induction system diagrams 1 air cut-off valve 2 reed valve 3 air cleaner È to cylinder #1 É to cylinder #2 Ê to cylinder #3 Ë to cylinder #4.

  • Page 380

    7 - 39 fi air induction system eas00510 checking the air induction system 1. Check: • hoses loose connection → connect properly. Cracks/damage → replace. • pipes cracks/damage → replace. 2. Check: • reed valve 1 • reed valve stopper • reed valve seat cracks/damage → replace the reed valve. 3. Measur...

  • Page 381

    7 - 40 fi air induction system 5. Check • al system solenoid ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the ai system solenoid coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the ai system solenoid terminal as shown. C. Measure the ai system solenoid resistan...

  • Page 382: Elec

    8 - 1 – + elec eas00729 electrical electrical components 1 fuse box 2 front brake switch 3 clutch switch 4 battery 5 starter relay 6 fuel injection system fuse 7 main fuse 8 neutral switch 9 rear brake switch 0 sidestand switch a oil level switch b radiator fan motor c horn d ignition coil electrica...

  • Page 383: Elec

    8 - 2 – + elec electrical components 1 coolant temperature sensor 2 intake air temperature sensor 3 intake air pressure sensor 4 lean angle cut-off switch 5 atmospheric pressure sensor 6 ecu 7 starting circuit cut-off relay 8 turn signal relay 9 speed sensor 0 crankshaft position sensor a cylinder i...

  • Page 384: Elec

    8 - 3 – + elec checking switch continuity eas00730 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: _ never insert the tester probes into the cou...

  • Page 385: Elec

    8 - 4 – + elec checking the switches eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 386: Elec

    8 - 5 – + elec checking the bulbs and bulb sockets eas00732 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 387: Elec

    8 - 6 – + elec checking the bulbs and bulb sockets checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: • bulb warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Cau...

  • Page 388: Elec

    8 - 7 – + elec checking the bulbs and bulb sockets 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 sa...

  • Page 389: Elec

    8 - 8 – + elec ignition system eas00735 ignition system circuit diagram y /b l /r b /r ch dg b /y y /l sb /w l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l...

  • Page 390: Elec

    8 - 9 – + elec ignition system eas00737 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Ignition coil resistance 6. Crankshaft position sensor resistance 7. Main switch 8. Engine stop switch 9. Neutral switch 10.Sidestand switch 11.Starting circui...

  • Page 391: Elec

    8 - 10 – + elec ignition system eas00743 eas00747 4. Ignition spark gap the following procedure applies to all of the spark plugs. • disconnect the spark plug cap from the spark plug. • connect the ignition checker 1 as shown. 2 ignition coil • set the main switch to “on”. • measure the ignition spa...

  • Page 392: Elec

    8 - 11 – + elec ignition system eas00748 eas00749 eas00750 eas00751 eas00752 6. Crankshaft position sensor resistance • disconnect the crankshaft position sensor coupler from the wire harness. • connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler as shown. Positive tester ...

  • Page 393: Elec

    8 - 12 – + elec ignition system eas00753 eas00754 11.Starting circuit cut-off relay • disconnect the starting circuit cut-off relay coupler from the wire harness. • connect the pocket tester ( Ω × 1) to the starting circuit cut-off relay coupler as shown. • check the starting circuit cut-off relay f...

  • Page 394: Elec

    8 - 13 – + elec electric starting system eas00755 electric starting system circuit diagram l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/...

  • Page 395: Elec

    8 - 14 – + elec electric starting system eas00756 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission...

  • Page 396: Elec

    8 - 15 – + elec electric starting system eas00757 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Neutral switch 9. Sidestand switch 10.Clutch switch 11.Start switch 12.Wiring con...

  • Page 397: Elec

    8 - 16 – + elec eas00759 eas00761 eas00749 eas00750 eas00751 4. Starting circuit cut-off relay • disconnect the starting circuit cut-off relay coupler from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay coupler as shown. Positive bat...

  • Page 398: Elec

    8 - 17 – + elec electric starting system eas00752 eas00763 eas00764 eas00766 9. Sidestand switch • check the sidestand switch for continuity. Refer to “checking the switches”. • is the sidestand switch ok? Yes no replace the side- stand switch. 10.Clutch switch • check the clutch switch for continui...

  • Page 399: Elec

    8 - 18 – + elec electric starting system eas00767 starter motor t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Rider seat refer to “seats” in chapter 3. Fuel tank refer to “fue...

  • Page 400: Elec

    8 - 19 – + elec electric starting system eas00768 t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) order job/part q’ty remarks disassembling the starter motor disassembly the parts in the order listed. 1 starter motor rear cover 1 2 bearing 1 3 starter motor yoke 1 4 o-ring 2 5 armature assembly 1 6 brush 2 7...

  • Page 401: Elec

    8 - 20 – + elec electric starting system eas00769 checking the starter motor 1. Check: • commutator dirt → clean with 600-grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. 3. Measure: • mica undercut a out of specification → scrape the mica to the ...

  • Page 402: Elec

    8 - 21 – + elec electric starting system 5. Measure: • brush length a out of specification → replace the brushes as a set. Brush length wear limit 3.65 mm (0.14 in) 6. Measure: • brush spring force out of specification → replace the brush springs as a set. 7. Check: • gear teeth damage/wear → replac...

  • Page 403: Elec

    8 - 22 – + elec charging system eas00773 charging system circuit diagram (black) r br/l r br/l l/y l/b l/b l/y r b (gray) w w w on off r w r/w l/w r/w l/w r r r r b b b b b r w r b r b r w w w w w r w b r br/l br/l l/b r/w l/y (red) (red) r r/g 1 2 3 4 5 8 6 7 9 w 2 ac magneto 3 rectifier/regulator ...

  • Page 404: Elec

    8 - 23 – + elec charging system eas00774 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) note: _ • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Bottom cowling • trouble...

  • Page 405: Elec

    8 - 24 – + elec charging system eas00776 eas00779 4. Stator coil resistance • remove the generator cover. • connect the pocket tester ( Ω × 1) to the stator coils as shown. Positive tester probe → white 1 negative tester probe → white 2 positive tester probe → white 1 negative tester probe → white 3...

  • Page 406: Elec

    8 - 25 – + elec lighting system eas00780 lighting system circuit diagram l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/ b r /b o /g o gy ...

  • Page 407: Elec

    8 - 26 – + elec lighting system 1 main switch 5 battery 6 fuse (main) c ecu x hi beam indicator light [ meter light c dimmer switch l auxiliary light m headlight n license light o taillight u headlight relay (on/off) v headlight relay (dimmer) x fuse (signal) y fuse (headlight).

  • Page 408: Elec

    8 - 27 – + elec lighting system eas00781 troubleshooting check: 1. Main, signal and headlight fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Headlight relay (on/off) 6. Headlight relay (dimmer) 7. Wiring connections (of the entire lighting system) note: _ • before troubleshooting, remove the fo...

  • Page 409: Elec

    8 - 28 – + elec lighting system yes no yes no eas00787 5. Headlight relay (on/off) • disconnect the headlight relay (on/off) from the coupler. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the headlight relay (on/off) coupler as shown. Positive battery lead → red/yellow 1 negative bat...

  • Page 410: Elec

    8 - 29 – + elec lighting system eas00788 checking the lighting system 1. The headlight and the high beam indicator light fail to come on. Yes no yes no 1. Headlight bulb and socket • check the headlight bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” • are the headligh...

  • Page 411: Elec

    8 - 30 – + elec lighting system eas00789 2. The meter light fails to come on. Eas00790 3. The tail/brake light fails to come on. 1. Meter light bulb and socket • check the meter light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” • are the meter light bulb and socket...

  • Page 412: Elec

    8 - 31 – + elec lighting system eas00791 4. The auxiliary light fails to come on. Eas00792 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket • check the auxiliary light bulb and socket for continuity. Refer to “checking the bulbs and sockets” • are the auxiliary light b...

  • Page 413: Elec

    8 - 32 – + elec signaling system eas00793 signaling system circuit diagram l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/ b r /b o /g o g...

  • Page 414: Elec

    8 - 33 – + elec signaling system 1 main switch 4 fuse (back up) 5 battery 6 fuse (main) 0 starting circuit cut-off relay b fuel pump c ecu i speed sensor r neutral switch s fuel level warning light t oil level warning light u neutral indicator light w coolant temperature indicator light y turn signa...

  • Page 415: Elec

    8 - 34 – + elec signaling system eas00794 troubleshooting check: 1. Main, ignition, signaling and back up fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: _ • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Bottom cowling 4. S...

  • Page 416: Elec

    8 - 35 – + elec signaling system eas00797 2. The tail/brake light fails to come on. 2. Voltage • connect the pocket tester (dc 20 v) to the horn connector at the horn terminal as shown. Positive tester probe → pink 1 negative tester probe → ground • set the main switch to “on”. • push the horn switc...

  • Page 417: Elec

    8 - 36 – + elec signaling system eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. Yes no this circuit is ok. The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired. 1. Turn signal indicator light bulb and socket • c...

  • Page 418: Elec

    8 - 37 – + elec signaling system eas00801 4. The neutral indicator light fails to come on. Left turn signal light positive tester probe → chocolate 1 negative tester probe → ground right turn signal light positive tester probe → dark green 2 negative tester probe → ground È É Ê • set the main switch...

  • Page 419: Elec

    8 - 38 – + elec signaling system eas00802 5. The oil level warning light fails to come on. Eas00803 6. The fuel level indicator light fails to come on. 1. Oil level warning light bulb and socket • check the oil level warning light bulb and socket for continuity. Refer to “checking the bulbs and bulb...

  • Page 420: Elec

    8 - 39 – + elec signaling system eas00806 7. The speedometer fails to come on. 2. Fuel sender • drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. • disconnect the fuel sender coupler from the wire harness. • connect the pocket tester ( Ω × 1) to the fuel sender as shown....

  • Page 421: Elec

    8 - 40 – + elec signaling system 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → yellow/blue 1 negative tester probe → black/white 2 • set the main switch to “on”. • elevate the rear wheel and slowly rotate it. • me...

  • Page 422: Elec

    8 - 41 – + elec cooling system eas00807 cooling system circuit diagram l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/ b r /b o /g o gy /g...

  • Page 423: Elec

    8 - 42 – + elec cooling system eas00808 troubleshooting check: 1. Main, ignition and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Radiator fan motor relay 6. Coolant temperature sensor 7. Wiring connections (the entire cooling system) note: _ • before troubleshooting, ...

  • Page 424: Elec

    8 - 43 – + elec cooling system eas00809 yes no 4. Radiator fan motor • disconnect the radiator fan motor coupler from the wire harness. • connect the battery (dc 12 v) as shown. Positive battery lead → blue 1 negative battery lead → black 2 • does the radiator fan motor turn? Yes no the radiator fan...

  • Page 425: Elec

    8 - 44 – + elec cooling system eas00812 eas00813 6. Coolant temperature sensor • remove the coolant temperature sensor from the thermostat housing. • connect the pocket tester ( Ω × 1k) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a container filled with ...

  • Page 426: Elec

    8 - 45 – + elec fuel pump system fuel pump system circuit diagram l /r r /y br /w p /w y b /l (bla ck) (bla ck) y b /l br /w p /w (bla ck) g /w b r /l b cord head light main harness a wire sub lead 4 main harness g r /l l/ b r /b o /b g /b l (bla ck) g /b l r /b o /b r /l l/ b r /b o /g o gy /g gy /...

  • Page 427: Elec

    8 - 46 – + elec fuel pump system eas00815 fuel pump system the ecu includes the control unit for the fuel pump. 1 battery 2 main fuse 3 main switch 4 ignition fuse 5 engine stop switch 6 ecu 7 fuel injection system fuse 8 fuel injection system relay 9 fuel pump.

  • Page 428: Elec

    8 - 47 – + elec fuel pump system eas00816 troubleshooting check: 1. Main and fuel injection system fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay (the fuel injection system relay) 6. Fuel pump 7. Wiring connections (the entire fuel system) note: _ • before tr...

  • Page 429: Elec

    8 - 48 – + elec fuel pump system eas00759 eas00817 eas00818 5. Starting circuit cut-off relay • disconnect the starting circuit cut-off relay coupler from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay coupler as shown. Positive batt...

  • Page 430: Elec

    8 - 49 – + elec fuel pump system eas00819 checking the fuel pump warning _ gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • stop the engine before refueling. • do not smoke, and keep...

  • Page 431: Trbl

    9 - 1 trbl shtg eas00844 troubleshooting 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 man- ual for checks, adjustments, and replacement of...

  • Page 432: Trbl

    9 - 2 trbl shtg starting failures/ incorrect engine idling speed electrical systems battery • discharged battery • faulty battery fuse(s) • blown, damaged or incorrect fuse • improperly installed fuse spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • wo...

  • Page 433: Trbl

    9 - 3 trbl shtg poor medium-and-high-speed performance/ faulty gear shifting/faulty clutch eas00848 poor medium-and-high-speed performance refer to “starting failures”. Engine air filter • clogged air filter element fuel system fuel pump • faulty fuel pump eas00850 faulty gear shifting shifting is d...

  • Page 434: Trbl

    9 - 4 trbl shtg overheating/overcooling/ poor braking performance eas00855 overheating engine clogged coolant passages • cylinder head(s) and piston(s) • heavy carbon buildup engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system coolant • low coolant level ...

  • Page 435: Trbl

    9 - 5 trbl shtg faulty front fork legs/ unstable handling eas00861 faulty front fork legs leaking oil • bent, damaged or rusty inner tube • cracked or damaged outer tube • improperly installed oil seal • damaged oil seal lip • incorrect oil level (high) • loose damper rod assembly bolt • damaged dam...

  • Page 436: Trbl

    9 - 6 trbl shtg faulty lighting or signaling system eas00866 faulty lighting or signaling system headlight does not come on • wrong headlight bulb • too many electrical accessories • hard charging • incorrect connection • improperly grounded circuit • poor contacts (main switch) • burnt-out headligh...

  • Page 437

    Yzf-r1p/yzf-r1pc wiring diagram 1 main switch 2 ac magneto 3 rectifier/regulator 4 fuse (back up) 5 battery 6 fuse (main) 7 fuse (fuel injection system) 8 starter relay 9 starter motor 0 starting circuit cut-off relay a sidestand switch b fuel pump c ecu d ignition coil e spark plug f fuel injector ...

  • Page 438

    Yzf-r1p/yzf-r1pc wiring diagram dark green green gray black blue brown chocolate color code orange pink red sky blue black/white black/yellow blue/black blue/red blue/white blue/yellow brown/blue brown/red brown/white green/red green/white green/yellow white yellow black/green black/blue black/red g...

  • Page 439

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A..