1. DL manuals
  2. Yamaha
  3. Motorcycle
  4. r1 2008
  5. Service Manual

Yamaha r1 2008 Service Manual

Other manuals for r1 2008: Owner's Manual

Summary of r1 2008

  • Page 1

    2007 motorcycle service manual model : yzfr1w 4c8281972000 *4c8281972000*.

  • Page 2

    Eas20040 yzfr1w service manual ©2006 by yamaha motor co., ltd. First edition, october 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3

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

  • Page 4

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

  • Page 5

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

  • Page 6: General Information

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

  • Page 7: Identification

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

  • Page 8: Features

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

  • Page 9: Features

    Features 1-3 eas4c81010 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm 2 , 46.1 psi). Accordingly, when the energizing signal from the ecu energizes th...

  • Page 10: Features

    Features 1-4 eas4c81011 ycc-t (yamaha chip controlled throttle) ycc-i (yamaha chip controlled intake) mechanism characteristics yamaha developed the ycc-t and ycc-i system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, ...

  • Page 11: Features

    Features 1-5 aims and advantages of using ycc-i system • improvement of the engine power characteristics the high power design in all ranges is now provided by having both two features of the short intake function to ensure the power at the high speed revolution of engine, and the long intake functi...

  • Page 12: Features

    Features 1-6 ycc-t/ycc-i system outline 1. Throttle position sensor (for throttle cable pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. Ecu (engine control unit) 5. Etv main cpu (32 bit) 6. Etv sub cpu (16 bit) 7. Fi cpu (32 bit) 8. Throttle servo motor driver 9....

  • Page 13: Features

    Features 1-7 ycc-t/ycc-i control outline 1. Throttle position sensor (for throttle cable pulley) 2. Throttle position sensor (for throttle valves) 3. Crankshaft position sensor 4. Speed sensor 5. Coolant temperature sensor 6. Neutral switch 7. Atmospheric pressure sensor 8. Accelerator position (two...

  • Page 14: Features

    Features 1-8 eas4c81024 instrument functions multi-function meter unit warning ewa4c81008 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a t...

  • Page 15: Features

    Features 1-9 4. Push the “reset” button to set the min- utes. 5. Push the “select” button and then release it to start the clock. Odometer, tripmeter, and stopwatch modes push the “select” button to switch the dis- play between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” an...

  • Page 16: Features

    Features 1-10 air intake temperature display the air intake temperature display indicates the temperature of the air drawn into the air fil- ter case. Push the “reset” button to switch the coolant temperature display to the air intake temperature display. Note: • even if the air intake temperature i...

  • Page 17: Features

    Features 1-11 this mode cycles through five control func- tions, allowing you to make the following set- tings in the order listed below. Display brightness: • this function allows you to adjust the bright- ness of the displays and tachometer to suit the outside lighting conditions. • shift timing i...

  • Page 18: Important Information

    Important information 1-12 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to "special tools" on page 1-15. 3. When disasse...

  • Page 19: Important Information

    Important information 1-13 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if...

  • Page 20: Checking The Connections

    Checking the connections 1-14 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect severa...

  • Page 21: Special Tools

    Special tools 1-15 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers...

  • Page 22: Special Tools

    Special tools 1-16 steering nut wrench 90890-01403 spanner wrench yu-33975 3-28, 4-61 damper rod holder 90890-01423 damping rod holder ym-01423 4-53, 4-54 oil filter wrench 90890-01426 yu-38411 3-12 rod holder 90890-01434 damper rod holder double ended ym-01434 4-52, 4-57 rod puller 90890-01437 univ...

  • Page 23: Special Tools

    Special tools 1-17 rod puller attachment (m12) 90890-01435 universal damping rod bleeding tool set ym-a8703 4-56, 4-57 fork spring compressor 90890-01441 ym-01441 4-52, 4-57 fork seal driver 90890-01442 adjustable fork seal driver (36–46 mm) ym-01442 4-55 vacuum gauge 90890-03094 carburetor synchron...

  • Page 24: Special Tools

    Special tools 1-18 extension 90890-04136 3-10 valve spring compressor 90890-04019 ym-04019 5-23, 5-29 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym-04108 5-23, 5-29 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-11 mechanical ...

  • Page 25: Special Tools

    Special tools 1-19 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-25 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-25 valve guide installer (ø4.5) 90890-04117 valve guide installer (4.5 mm) ym-04117 5-25 valve guide reamer (ø5) 90890...

  • Page 26: Special Tools

    Special tools 1-20 pivot shaft wrench adapter 90890-01476 5-7 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-14, 5-41, 8- 83, 8-84, 8-85, 8-88, 8-89, 8- 90, 8-91, 8-92, 8-93, 8-94, 8- 95, 8-96, 8-97, 8-97, 8-98, 8- 99, 8-100 oil pressure adapter h 90890-03139 3-13 valve lapper 90890-041...

  • Page 27: Special Tools

    Special tools 1-21 ring nut wrench 90890-01507 ym-01507 4-68, 4-70 damper rod holder (22 mm) 90890-01365 4-69, 4-70 tool name/tool no. Illustration reference pages.

  • Page 28: Specifications

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

  • Page 29: General Specifications

    General specifications 2-1 eas20280 general specifications model model 4c86 dimensions overall length 2060 mm (81.1 in) overall width 720 mm (28.3 in) overall height 1110 mm (43.7 in) seat height 835 mm (32.9 in) wheelbase 1415 mm (55.7 in) ground clearance 135 mm (5.31 in) minimum turning radius 34...

  • Page 30: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 998.0 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) compression ratio 12.70 :1 standard compression pressure (at sea lev...

  • Page 31: Engine Specifications

    Engine specifications 2-3 cylinder head volume 14.00–14.80 cm³ (0.85–0.90 cu.In) warpage limit 0.10 mm (0.0039 in) camshaft 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...

  • Page 32: Engine Specifications

    Engine specifications 2-4 valve face width b (intake) 1.200–2.480 mm (0.0472–0.0976 in) valve face width b (exhaust) 1.625–2.900 mm (0.0640–0.1142 in) valve seat width c (intake) 0.90–1.10 mm (0.0354–0.0433 in) valve seat width c (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) valve margin thickness d (in...

  • Page 33: Engine Specifications

    Engine specifications 2-5 installed compression spring force (intake) 171–197 n (38.44–44.29 lbf) (17.44–20.09 kgf) at 35.50 mm (1.398 in) installed compression spring force (exhaust) 202–232 n (45.41–52.15 lbf) (20.60–23.66 kgf) at 33.00 mm (1.299 in) spring tilt (intake) 2.5 °/1.7 mm spring tilt (...

  • Page 34: Engine Specifications

    Engine specifications 2-6 oil ring dimensions (b × t) 1.50 × 2.25 mm (0.06 × 0.09 in) end gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) connecting rod oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green crankshaft width a 55.20–56....

  • Page 35: Engine Specifications

    Engine specifications 2-7 shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.100 mm (0.0039 in) shift fork thickness 5.80–5.88 mm (0.2283–0.2315 in) air filter air filter element oil-coated paper element fuel pump pump type electrical model/manufact...

  • Page 36: Chassis Specifications

    Chassis specifications 2-8 eas20300 chassis specifications chassis frame type diamond caster angle 24.00 ° trail 102.0 mm (4.02 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel...

  • Page 37: Chassis Specifications

    Chassis specifications 2-9 caliper cylinder inside diameter 24.05 mm × 3 (0.95 in × 3) recommended fluid dot 4 rear brake type single disc brake operation right foot operation brake pedal free play 4.3–9.3 mm (0.17–0.37 in) rear disc brake disc outside diameter × thickness 220.0 × 5.0 mm (8.66 × 0.2...

  • Page 38: Electrical Specifications

    Electrical specifications 2-10 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition timing (b.T.D.C.) 5.0 °/1050 r/min engine control unit model/manufacturer tbdf43/denso ignition coil model/manufacturer f6t568...

  • Page 39: Electrical Specifications

    Electrical specifications 2-11 electric starting system system type constant mesh starter motor model/manufacturer 5vy/yamaha power output 0.90 kw armature coil resistance 0.0090–0.0110 Ω brush overall length 10.8 mm (0.43 in) limit 7.19 mm (0.28 in) brush spring force 5.28–7.92 n (19.01–28.51 oz) (...

  • Page 40: Tightening Torques

    Tightening torques 2-12 eas20320 tightening torques eas20330 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each cha...

  • Page 41: Tightening Torques

    Tightening torques 2-13 eas20340 engine tightening torques item threa d size q’ty tightening torque remarks spark plugs m10 4 13 nm (1.3 m·kg, 9.4 ft·lb) cylinder head nut (2pieces) m10 2 see note cylinder head nut (8pieces) m10 8 see note cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft...

  • Page 42: Tightening Torques

    Tightening torques 2-14 exhaust pipe and muffler bolt m8 2 20 nm (2.0 m·kg, 14 ft·lb) exhaust pipe and exup valve bolt m6 5 12 nm (1.2 m·kg, 8.7 ft·lb) exhaust valve pipe bracket bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) exup pulley and shaft arm nut m6 1 6.5 nm (0.65 m·kg, 4.7 ft·lb) exup valve pulley c...

  • Page 43: Tightening Torques

    Tightening torques 2-15 note: • cylinder head nut (2 pieces) 1. First, tighten the bolts to 10 nm (1.0 m·kg, 7.2 ft·lb) with a torque wrench following the tighten- ing order. 2. Second, tighten the bolts to 25 nm (2.5 m·kg, 18 ft·lb) with a torque wrench following the tight- ening order. 3. Third, t...

  • Page 44: Tightening Torques

    Tightening torques 2-16 3. Final, tighten the bolts to 40 nm (4.0 m·kg, 29 ft·lb) with a torque wrench following the tighten- ing order. • crankcase bolt (main journal) 1. First, tighten the bolts to approximately 20 nm (2.0 m·kg, 14 ft·lb) with a torque wrench follow- ing the tightening order. 2. L...

  • Page 45: Tightening Torques

    Tightening torques 2-17 eas20350 chassis tightening torques item threa d size q’ty tightening torque remarks upper bracket pinch bolt m8 2 26 nm (2.6 m·kg, 19 ft·lb) steering stem nut m28 1 113 nm (11.3 m·kg, 82 ft·lb) handlebar pinch bolt m8 2 17 nm (1.7m·kg, 12 ft·lb) handlebar bolt m6 2 13 nm (1....

  • Page 46: Tightening Torques

    Tightening torques 2-18 note: • lower ring nut 1. First, tighten the lower ring nut approximately 52 nm (5.2 m·kg, 38 ft·lb) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut 18 nm (1.8 m·kg, 13 ft·lb). Connecting arm nut (connecting arm and frame) m10 ...

  • Page 47: Tightening Torques

    Tightening torques 2-19 • engine mounting adjust bolt and engine mount self locking nut refer to "installing the engine" on page 5-7. • front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 nm (9.1 m·kg, 65.8 ft·lb...

  • Page 48

    Lubrication points and lubricant types 2-20 eas20360 lubrication points and lubricant types eas20370 engine eas20380 chassis lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts crankshaft journals camshaft lobes camshaft journal...

  • Page 49

    Lubrication points and lubricant types 2-21 brake lever pivoting point and metal-to-metal moving parts clutch lever pivoting point and metal-to-metal moving parts engine mount bolts (rear upper and lower) relay arm, connecting rod and rear shock absorber collar pivot shaft swingarm pivot bearing swi...

  • Page 50

    Lubrication points and lubricant types 2-22.

  • Page 51

    Lubrication system chart and diagrams 2-23 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 52

    Lubrication system chart and diagrams 2-24 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. Ac magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.Ac magneto axle 13.Piston cooler 14.Chain tensioner 15.Intake camsh...

  • Page 53

    Lubrication system chart and diagrams 2-25 eas20410 lubrication diagrams.

  • Page 54

    Lubrication system chart and diagrams 2-26 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch.

  • Page 55

    Lubrication system chart and diagrams 2-27.

  • Page 56

    Lubrication system chart and diagrams 2-28 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump.

  • Page 57

    Lubrication system chart and diagrams 2-29.

  • Page 58

    Lubrication system chart and diagrams 2-30 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler.

  • Page 59

    Lubrication system chart and diagrams 2-31 a-a a a.

  • Page 60

    Lubrication system chart and diagrams 2-32 1. Main axle 2. Oil delivery pipe 3. Drive axle.

  • Page 61

    Lubrication system chart and diagrams 2-33.

  • Page 62

    Lubrication system chart and diagrams 2-34 1. Cylinder head 2. Crankshaft.

  • Page 63: Cooling System Diagrams

    Cooling system diagrams 2-35 eas20420 cooling system diagrams.

  • Page 64: Cooling System Diagrams

    Cooling system diagrams 2-36 1. Water pump 2. Radiator 3. Radiator fan.

  • Page 65: Cooling System Diagrams

    Cooling system diagrams 2-37.

  • Page 66: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat.

  • Page 67: Cable Routing

    Cable routing 2-39 eas20430 cable routing.

  • Page 68: Cable Routing

    Cable routing 2-40 1. Ground lead 2. Meter lead 3. Headlight stay 4. Right headlight lead (high beam) 5. Right auxiliary light lead 6. Intake air temperature sensor coupler 7. Headlight lead 8. Left auxiliary light lead 9. Left headlight lead (high beam) 10.Right console panel 11.Right intake air du...

  • Page 69: Cable Routing

    Cable routing 2-41.

  • Page 70: Cable Routing

    Cable routing 2-42 1. Right handlebar switch lead 2. Clutch cable 3. Main switch lead 4. Left handlebar switch lead 5. Horn lead 6. Horn 7. Throttle cables 8. Brake hose 9. Throttle cable (return side) 10.Throttle cable (pull side) a. Route the clutch cable so as to get along the front side of the m...

  • Page 71: Cable Routing

    Cable routing 2-43.

  • Page 72: Cable Routing

    Cable routing 2-44 1. Wire harness 2. Crankshaft position sensor lead 3. Bracket 4. Ignition coil lead 5. Right handlebar switch lead 6. Radiator fan motor lead 7. Heat protector 8. Right radiator fan motor lead 9. Coolant reservoir tank 10.Coolant reservoir drain hose 11.Hose clamp 12.O 2 sensor le...

  • Page 73: Cable Routing

    Cable routing 2-45.

  • Page 74: Cable Routing

    Cable routing 2-46 1. Left radiator fan motor lead 2. Heat protector 3. Immobilizer lead 4. Left handlebar switch lead 5. Main switch lead 6. Bracket 7. Exup servo motor lead 8. Cover 9. Fuel tank drain hose and fuel tank breather hose 10.Water pipe 11.Sidestand switch lead 12.Oil level switch lead ...

  • Page 75: Cable Routing

    Cable routing 2-47.

  • Page 76: Cable Routing

    Cable routing 2-48 1. Throttle cables 2. Rectifier/regulator 3. Rectifier/regulator lead 4. Right air outlet grille 5. Air induction system solenoid hose 6. Intake funnel servo motor lead 7. O 2 sensor lead 8. Rear brake light switch lead 9. Crankshaft position sensor lead 10.Engine ground lead 11.B...

  • Page 77: Cable Routing

    Cable routing 2-49.

  • Page 78: Cable Routing

    Cable routing 2-50 1. Starter relay lead 2. Starter motor lead 3. Battery positive lead 4. Lean angle sensor 5. Turn signal relay 6. Main fuse 7. Turn signal light/license plate light lead 8. Tail/brake light lead 9. Tail/brake light bracket 10.Lower tail cover 11.Seat lock cable 12.Anti safety alar...

  • Page 79: Cable Routing

    Cable routing 2-51.

  • Page 80: Cable Routing

    Cable routing 2-52 1. Fuel tank 2. O-ring 3. Fuel hose 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Air filter stay 7. Clip 8. Fuel tank bracket 9. Fuel hose clamp 10.Fuel pump assembly a. Install the lip of o-ring facing upward. B. Install the part pointing the white paint part of the hose...

  • Page 81: Cable Routing

    Cable routing 2-53.

  • Page 82

    Periodic checks and adjustments periodic maintenance .........................................................................3-1 introduction ....................................................................................3-1 periodic maintenance chart for the emission control system..............

  • Page 83

    Lubricating the sidestand......................................................... 3-35 lubricating the rear suspension .......................................... 3-35 electrical system.............................................................................. 3-36 checking and charging the batte...

  • Page 84: Periodic Maintenance

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

  • Page 85: Periodic Maintenance

    Periodic maintenance 3-2 6 * wheels • check runout and for damage. • replace if necessary. √ √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. √ √ √ √ √ 8 * wheel bearings • check bearings for smooth operation. • replace if ne...

  • Page 86: Periodic Maintenance

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

  • Page 87: Engine

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

  • Page 88: Engine

    Engine 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • camshafts note: • refer to "camshafts" on page 5-9. • when removing the timing...

  • Page 89: Engine

    Engine 3-6 note: • the thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. • since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. C....

  • Page 90: Engine

    Engine 3-7 eas20570 synchronizing the throttle bodies note: prior to synchronizing the throttle bodies, the valve clearance should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. Note: place the vehicle on a suitable stand. 2. Remove: • rider ...

  • Page 91: Engine

    Engine 3-8 note: • if more than one throttle body has a bypass air screw with a white paint mark, use the one with the lowest vacuum pressure as the standard. • after each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. • if an air scre...

  • Page 92: Engine

    Engine 3-9 2. Adjust: • throttle cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Loosen the locknut “1”. B. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. C. Tighten the locknut “1”. Warning ewa4c81006 after adjusting the...

  • Page 93: Engine

    Engine 3-10 10. Install: • radiator upper bolts • radiator lower bolt refer to "radiator" on page 6-1. 11. Install: • side cowlings • lower cowlings refer to "general chassis" on page 4- 1. Eas20710 measuring the compression pres- sure the following procedure applies to all of the cylinders. Note: i...

  • Page 94: Engine

    Engine 3-11 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: • spark plugs • ignition coils 8. Connect: • ignition coils eas20730 checking the engine oil level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Start the engine, w...

  • Page 95: Engine

    Engine 3-12 5. Drain: • engine oil (completely from the crankcase) 6. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” of the new oil f...

  • Page 96: Engine

    Engine 3-13 13. Check: • engine oil level refer to "checking the engine oil level" on page 3-11. Eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark ”a” → add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several ...

  • Page 97: Engine

    Engine 3-14 eas20870 adjusting the clutch cable free play 1. Check: • clutch cable free play “a” out of specification → adjust. 2. Adjust: • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjusting bolt “1” in direction “b” or “c” until the specified clutch cable fr...

  • Page 98: Engine

    Engine 3-15 4. Install: • air filter element note: install a new air filter element by fitting the pro- jections 1 on the element into the slots in the air filter case. Caution: eca4c81021 • make sure that the air filter element is properly seated in the air filter case. • pay attention to handling ...

  • Page 99: Engine

    Engine 3-16 note: before removing the fuel hoses, place a few rags in the area under where it will be remov- ing. Caution: eca14940 make sure the fuel tank breather hose is routed correctly. 3. Install: • fuel tank • fuel tank side covers refer to "fuel tank" on page 7-1. • rider seat refer to "gene...

  • Page 100: Engine

    Engine 3-17 note: when installing the exup cables, make sure they are parallel and not twisted. • upper cable: white metal section “12” • lower cable: black metal section “13” eas21100 adjusting the exup cables 1. Remove: • lower cowlings refer to "general chassis" on page 4- 1. 2. Remove: • exup va...

  • Page 101: Engine

    Engine 3-18 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • exup valve pulley cover 7. Install: • lower cowlings refer to "general chassis" on page 4- 1. Eas28360 checking the exup servo motor 1. Check: • exup servo motor operation out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check...

  • Page 102: Engine

    Engine 3-19 eas21120 checking the cooling system 1. Remove: • lower cowlings • side cowling refer to "general chassis" on page 4- 1. 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 103: Engine

    Engine 3-20 7. Drain: • coolant (from the engine and radiator) 8. Check: • copper washer “1” (coolant drain bolt “2”) 9. Install: • coolant drain bolt (with the copper washer) 10. Connect: • coolant reservoir hose 11. Install: • coolant reservoir 12. Fill: • cooling system (with the specified amount...

  • Page 104: Engine

    Engine 3-21 15. Install: • coolant reservoir cap 16. Start the engine, warm it up for several minutes, and then stop it. 17. Check: • coolant level refer to "checking the coolant level" on page 3-18. Note: before checking the coolant level, wait a few minutes until the coolant has settled. 18. Insta...

  • Page 105: Chassis

    Chassis 3-22 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) note: while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. Warning ewa13060...

  • Page 106: Chassis

    Chassis 3-23 warning ewa13050 a soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. Caution: eca13...

  • Page 107: Chassis

    Chassis 3-24 eas21260 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake pad wear indicators “a” almost touch the brake disc → replace the brake pads as a set. Refer to "rear brake" on page 4-33. Eas21280 checking the f...

  • Page 108: Chassis

    Chassis 3-25 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adjusting nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21360 bleeding the hydrauli...

  • Page 109: Chassis

    Chassis 3-26 g. Loosen the bleed screw. Note: loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. H. Tighten the bleed screw and then release the brake lever or brake pedal. I. Repeat steps (e) to (h) until al...

  • Page 110: Chassis

    Chassis 3-27 note: to maintain the proper wheel alignment, adjust both sides evenly. D. Tighten both locknuts to specification. E. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting parts. If t...

  • Page 111: Chassis

    Chassis 3-28 c. Loosen the lower ring nut “4” completely, then tighten it to specification. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower b...

  • Page 112: Chassis

    Chassis 3-29 e. Repeat the above procedure on the oppo- site handlebar. F. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. G. Reinstall the upper bracket and measure the steeri...

  • Page 113: Chassis

    Chassis 3-30 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rebound damping caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression d...

  • Page 114: Chassis

    Chassis 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21610 adjusting the rear shock absorber assembly warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Spring preload caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • spri...

  • Page 115: Chassis

    Chassis 3-32 compression damping (fast compression damping) caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping (fast compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 116: Chassis

    Chassis 3-33 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the antic...

  • Page 117: Chassis

    Chassis 3-34 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given if a tir...

  • Page 118: Chassis

    Chassis 3-35 eas21710 lubricating the pedal lubricate the pivoting point and metal-to-metal moving parts of the pedal. Eas21720 lubricating the sidestand lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Eas21740 lubricating the rear suspension lubricate the pivoting poi...

  • Page 119: Electrical System

    Electrical system 3-36 eas21750 electrical system eas21760 checking and charging the battery refer to "electrical components" on page 8-77. Eas21770 checking the fuses refer to "electrical components" on page 8-77. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 120: Electrical System

    Electrical system 3-37 • headlight bulb coupler (high beam) 11. Install: • intake air duct panel refer to "general chassis" on page 4- 1. Eas21810 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Remove: front cowling inner panels refer to "general chassis"...

  • Page 121: Chassis

    Chassis general chassis....................................................................................4-1 checking the intake funnel........................................................4-5 checking the intake funnel........................................................4-5 checking the inta...

  • Page 122

    Handlebars ........................................................................................... 4-45 removing the handlebar ........................................................... 4-47 checking the handlebars ......................................................... 4-47 installing the ha...

  • Page 123: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 rider seat 2 passenger seat 1 3 battery negative lead 1 4 battery positive lead 1 5 ecu (engine control unit) 1 6 ecu lead coupler 1 disconnect. 7 ecu cover 1 8 battery band 1 9 batter...

  • Page 124: General Chassis

    General chassis 4-2 removing the front cowling and side cowlings order job/parts to remove q’ty remarks 1 side cowling inner panel 2 2 side cowling 2 3 front turn signal light lead coupler 2 disconnect. 4 lower cowling 2 5 lower cowling front cover 1 6 intake air duct panel 2 7 intake air temperatur...

  • Page 125: General Chassis

    General chassis 4-3 removing the rear fender order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Passenger seat refer to "general chassis" on page 4-1. Muffler refer to "engine removal" on page 5-1. 1 upper tail cover 1 2 tail/brake light lead coupler 1 disconne...

  • Page 126: General Chassis

    General chassis 4-4 removing the air filter case order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. 1 air filter case cover 1 2 air filter 1 3 intake funnel servo motor rod assembly 1 4 intake funnel joint 2 5 intake ...

  • Page 127: General Chassis

    General chassis 4-5 eas4c81025 checking the intake funnel 1. Check: • intake funnel cracks/damage → replace. • intake funnel seal rubber “1” cracks/damage → replace. • intake funnel rods damage/scratches → replace. Eas4c81026 checking the intake funnel 1. Install: • intake funnel rod • intake funnel...

  • Page 128: General Chassis

    General chassis 4-6 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “34”. Refer to "fuel injection system" on page 8-29. B. Set the engine stop switch to “ ”. C. Check that the intake funnel operate smoothly strokes from the upper position to the ...

  • Page 129: General Chassis

    General chassis 4-7 eas21840 removing the cover 1. Remove: • tail cover • rear fender note: to remove the quick fastener, push its center with a screwdriver, then pull the fastener out. Eas21850 installing the cover 1. Install: • rear fender • tail cover note: to install the quick fastener, push its...

  • Page 130: Front Wheel

    Front wheel 4-8 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 reflector 2 2 reflector bracket 2 3 left brake hose holder 1 4 right brake hose holder 1 5 left front brake caliper 1 6 right front brake caliper 1 7 front wheel axle pinch bolt 4 8...

  • Page 131: Front Wheel

    Front wheel 4-9 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal (left and right) 2 2 wheel bearing (left and right) 1 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 132: Front Wheel

    Front wheel 4-10 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • ...

  • Page 133: Front Wheel

    Front wheel 4-11 c. Remove the wheel bearings “3” with a gen- eral bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: eca14130 do not contact the wheel bearing inner race “4” or balls “5”. Contact should be made only with the outer race “6”....

  • Page 134: Front Wheel

    Front wheel 4-12 note: start with the lightest weight. B. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 135: Front Wheel

    Front wheel 4-13 warning ewa13490 make sure the brake cable is routed prop- erly. Note: make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs..

  • Page 136: Rear Wheel

    Rear wheel 4-14 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks 1 rear brake caliper 1 2 locknut (left and right) 2 loosen. 3 adjusting bolt (left and right) 2 loosen. 4 rear wheel axle nut 1 5 washer 1 6 rear wheel axle 1 7 left adjusting block 1 8 right adjusting...

  • Page 137: Rear Wheel

    Rear wheel 4-15 removing the brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sprocket 1 3 collar 2 4 dust cover 2 5 oil seal 1 6 bearing 1 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 rear wheel 1 for installation, reverse the ...

  • Page 138: Rear Wheel

    Rear wheel 4-16 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 139: Rear Wheel

    Rear wheel 4-17 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper “1” note: ...

  • Page 140: Rear Wheel

    Rear wheel 4-18 eas22110 checking the rear wheel drive hub 1. Check: • rear wheel drive hub “1” cracks/damage → replace. • rear wheel drive hub dampers “2” damage/wear → replace. Eas22120 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → re...

  • Page 141: Rear Wheel

    Rear wheel 4-19 warning ewa13500 make sure the brake hose is routed prop- erly. Rear wheel axle nut 150 nm (15.0 m·kg, 108 ft·lb) rear brake caliper bolt (front side) 27 nm (2.7 m·kg, 20 ft·lb) rear brake caliper bolt (rear side) 22 nm (2.2 m·kg, 16 ft·lb).

  • Page 142: Front Brake

    Front brake 4-20 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks 1 brake hose holder 1 2 front brake caliper 1 3 brake pad clip 4 4 brake pad pin 2 5 brake pad spring 2 6 brake pad 4 7 bleed screw 1 for installation, reverse the removal proce- dure..

  • Page 143: Front Brake

    Front brake 4-21 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-25. 1 stopper 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid reservoir diaphragm 1 5 ...

  • Page 144: Front Brake

    Front brake 4-22 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 bleed screw 1 3 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 145: Front Brake

    Front brake 4-23 removing the front brake calipers order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-25. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 146: Front Brake

    Front brake 4-24 disassembling the front brake calipers order job/parts to remove q’ty remarks 1 brake pad clip 4 2 brake pad pin 2 3 brake pad spring 2 4 brake pad 4 5 brake caliper piston 6 6 brake caliper piston seal 12 7 bleed screw 1 for assembly, reverse the disassembly pro- cedure..

  • Page 147: Front Brake

    Front brake 4-25 eas22220 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...

  • Page 148: Front Brake

    Front brake 4-26 d. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. ...

  • Page 149: Front Brake

    Front brake 4-27 note: always install new brake pads and a new brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake caliper pist...

  • Page 150: Front Brake

    Front brake 4-28 eas22360 disassembling the front brake calipers the following procedure applies to both of the brake calipers. 1. Remove: • brake caliper pistons “1” • brake caliper piston seals “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the right side brake caliper pistons with a piece of wood “...

  • Page 151: Front Brake

    Front brake 4-29 • whenever a brake caliper is disassem- bled, replace the brake caliper piston seals. Eas22450 installing the front brake cali- pers the following procedure applies to both of the brake calipers. 1. Install: • brake pads • brake pad springs • brake pad pins 2. Install: • brake calip...

  • Page 152: Front Brake

    Front brake 4-30 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-25. Eas22490 removing the front brake master cylinder note: before removing the front brake master cylin- der, drain the brake fluid from the e...

  • Page 153: Front Brake

    Front brake 4-31 eas22520 assembling the front brake mas- ter cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components. 1. Instal: • brake master cylinder kit eas...

  • Page 154: Front Brake

    Front brake 4-32 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful che...

  • Page 155: Rear Brake

    Rear brake 4-33 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad shim 4 5 brake pad 2 6 bleed screw 1 7 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 156: Rear Brake

    Rear brake 4-34 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-25. 1 footrest plate 1 2 brake fluid reservoir cap 1 3 rear brake fluid reservoir diaphragm holder 1 4 rear brake fluid reservoir...

  • Page 157: Rear Brake

    Rear brake 4-35 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 hose joint 1 3 bush 1 4 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 158: Rear Brake

    Rear brake 4-36 removing the rear brake calipers order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-25. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 159: Rear Brake

    Rear brake 4-37 disassembling the rear brake calipers order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad 2 4 brake pad shim 4 5 brake pad spring 1 6 brake caliper piston 1 7 brake caliper piston seal 2 8 bleed screw 1 for assembly, reverse the disassembly pro- cedure...

  • Page 160: Rear Brake

    Rear brake 4-38 eas22560 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the enti...

  • Page 161: Rear Brake

    Rear brake 4-39 3. Measure: • brake pad wear limit “a” out of specification → replace the brake pads as a set. 4. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring note: always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 162: Rear Brake

    Rear brake 4-40 eas22590 removing 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 “3” • brake caliper “4” note: put the end of the brake hose into a container and pu...

  • Page 163: Rear Brake

    Rear brake 4-41 warning ewa13610 whenever a brake caliper is disassembled, replace the brake caliper piston seals. 2. Check: • brake caliper bracket “1” cracks/damage → replace. Eas22650 assembling the rear brake caliper warning ewa13620 • before installation, all internal brake com- ponents should ...

  • Page 164: Rear Brake

    Rear brake 4-42 • when refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Caution: eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up an...

  • Page 165: Rear Brake

    Rear brake 4-43 4. Check: • brake hoses “1” cracks/damage/wear → replace. Eas22730 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake ...

  • Page 166: Rear Brake

    Rear brake 4-44 • when refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Caution: eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up an...

  • Page 167: Handlebars

    Handlebars 4-45 eas22850 handlebars removing the handlebars order job/parts to remove q’ty remarks front cowling refer to "general chassis" on page 4-1. Side cowling refer to "general chassis" on page 4-1. 1 grip end 2 2 handlebar grip 1 3 clutch switch connector 2 disconnect. 4 left handlebar switc...

  • Page 168: Handlebars

    Handlebars 4-46 18 upper bracket bolt 2 loosen. 19 upper bracket pinch bolt 2 loosen. 20 steering stem nut 1 loosen. 21 upper bracket 1 22 left handlebar 1 23 right handlebar 1 for installation, reverse the removal proce- dure. Removing the handlebars order job/parts to remove q’ty remarks.

  • Page 169: Handlebars

    Handlebars 4-47 eas22870 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the handlebar grip, and gradually ...

  • Page 170: Handlebars

    Handlebars 4-48 4. Install: • throttle grip • throttle cable housing “1” • throttle cables note: align the projection “a” on the throttle cable housing with the hole “b” in the right handlebar. 5. Install: • clutch lever holder “1” note: align the slit on the clutch lever holder with the punch mark ...

  • Page 171: Handlebars

    Handlebars 4-49.

  • Page 172: Front Fork

    Front fork 4-50 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-8. Front brake caliper refer to "front brake" on page 4-20. Side cowling refer to "general chassis" on page 4-1. 1 front fender 1 2 handlebar pinch bol...

  • Page 173: Front Fork

    Front fork 4-51 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 damper adjusting rod 1 4 damper adjusting rod locknut 1 5 washer 1 6 spacer 1 7 fork spring 1 8 dust seal 1 9 oil seal clip 1 10 oil seal 1 11 washer 1 12 damper rod assembly bolt 1 13 ...

  • Page 174: Front Fork

    Front fork 4-52 eas22970 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 175: Front Fork

    Front fork 4-53 3. Remove: • dust seal • oil seal clip “1” (with a flat-head screwdriver) • oil seal • washer 4. Remove: • damper rod assembly bolt • damper rod assembly note: while holding the damper rod with the damper rod holder “1”, loosen the damper rod assem- bly bolt. Eas23010 checking the fr...

  • Page 176: Front Fork

    Front fork 4-54 4. Check: • cap bolt o-ring “1” damage/wear → replace. Eas23040 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13660 • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dl...

  • Page 177: Front Fork

    Front fork 4-55 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” caution: eca14220 make sure the numbered side of the oil seal faces up. Note: • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the inner tu...

  • Page 178: Front Fork

    Front fork 4-56 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) caution: eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling the front fork leg, do not allow any f...

  • Page 179: Front Fork

    Front fork 4-57 a. Remove the rod puller attachment. B. Install the nut. C. Install the fork spring and spacer. Note: install the spring with the smaller pitch “a” fac- ing up “a”. D. Reinstall the rod puller attachment e. Press down in the spacer with the fork spring compressor “1” f. Pull up the r...

  • Page 180: Front Fork

    Front fork 4-58 warning ewa4c81003 • the fork spring is compressed. • always use a new cap bolt o-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg temporarily tighten the upper an...

  • Page 181: Steering Head

    Steering head 4-59 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front cowling refer to "general chassis" on page 4-1. Side cowling refer to "general chassis" on page 4-1. Front wheel refer to "front wheel" on page 4-8. Front fork legs refer to "front brake...

  • Page 182: Steering Head

    Steering head 4-60 17 bearing cover 1 18 bearing inner race 2 19 upper bearing 1 20 lower bearing 1 21 dust seal 1 22 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks.

  • Page 183: Steering Head

    Steering head 4-61 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut “1” (with the steering nut wrench “2”) warning ewa13730 securely support the lower ...

  • Page 184: Steering Head

    Steering head 4-62 • bearing races 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to "checking and adjusting the steering head" on page 3-27. 3. Install: • upper bracket • steering stem nut note: temporarily tighten the steering stem nut. 4. Install...

  • Page 185: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-...

  • Page 186: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-64 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held respo...

  • Page 187: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-65 • dust seals damage/wear → replace. • bolts bends/damage/wear → replace. Eas23260 checking the connecting arm and relay arm 1. Check: • connecting arm “1” • relay arm “2” damage/wear → replace. 2. Check: • bearings • oil seals damage/pitting → replace. 3. Check: • c...

  • Page 188: Swingarm

    Swingarm 4-66 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to "rear wheel" on page 4-14. Rear shock absorber assembly refer to "rear shock absorber assembly" on page 4-63. Drive sprocket refer to "engine removal" on page 5-1. 1 right footrest bracke...

  • Page 189: Swingarm

    Swingarm 4-67 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks.

  • Page 190: Swingarm

    Swingarm 4-68 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • relay arm-to-swingarm bolt “...

  • Page 191: Swingarm

    Swingarm 4-69 note: loosen the swingarm pivot shaft with the damper rod holder (22 mm) “2”. Eas23360 checking the swingarm 1. Check: • swingarm bends/cracks/damage → replace. 2. Check: • pivot shaft roll the pivot shaft on a flat surface. Bends → replace. Warning ewa13770 do not attempt to straighte...

  • Page 192: Swingarm

    Swingarm 4-70 3. Install: • pivot shaft “1” note: tighten the pivot shaft with the damper rod holder (22 mm) “2”. 4. Install: • pivot shaft ring nut “1” note: • lubricate the pivot ring nut threads and mat- ing surfaces with lithium-soap-based grease. • tighten the pivot shaft ring nut with the ring...

  • Page 193: Chain Drive

    Chain drive 4-71 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks swingarm refer to "swingarm" on page 4-66. 1 drive chain guard 1 2 drive chain 1 for installation, reverse the removal proce- dure..

  • Page 194: Chain Drive

    Chain drive 4-72 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain (with the ...

  • Page 195: Chain Drive

    Chain drive 4-73 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • o-rings “1” damage → replace the drive chain. • drive chain rollers “2” damage/wear → replace the drive chain. • drive chain side plates “3” damage/wear/cracks → replace the drive chain. 5. Lubricate: • drive chain 6. Check: • drive sprocke...

  • Page 196: Chain Drive

    Chain drive 4-74 caution: eca14300 never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life. 3. Adjust: • drive chain slack refer to "adjusting the drive chain slack" on page 3-26 caution: eca13550 a drive chain that is too tight will ove...

  • Page 197: Chain Drive

    Chain drive 4-75.

  • Page 198: Engine

    Engine engine removal ......................................................................................5-1 installing the engine ....................................................................5-7 camshafts........................................................................................

  • Page 199

    Checking the clutch plates..................................................... 5-48 checking the clutch springs .................................................. 5-49 checking the clutch housing ................................................. 5-49 checking the clutch boss ..........................

  • Page 200

    Checking the transmission ...................................................... 5-90 installing the transmission..................................................... 5-91.

  • Page 201: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks lower cowlings refer to "general chassis" on page 4-1. Drive chain loosen. Refer to "adjusting the drive chain slack" on page 3-26. 1 locknut 2 2 shift rod 1 3 sift arm 1 4 drive sprocket co...

  • Page 202: Engine Removal

    Engine removal 5-2 removing the exhaust pipe order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Passenger seat refer to "general chassis" on page 4-1. Side cowlings refer to "general chassis" on page 4-1. Lower cowlings refer to "general chassis" on page 4-1. 1...

  • Page 203: Engine Removal

    Engine removal 5-3 for installation, reverse the removal proce- dure. Removing the exhaust pipe order job/parts to remove q’ty remarks.

  • Page 204: Engine Removal

    Engine removal 5-4 disassembling the exhaust valve pipe order job/parts to remove q’ty remarks 1 washer 1 2 pulley 1 3 collar 1 4 plate 1 5 spring 1 6 exup pulley bracket 1 7 housing 1 8 gasket 1 9 collar 1 10 shaft arm 1 11 exhaust valve pipe 1 for assembly, reverse the disassembly pro- cedure..

  • Page 205: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Throttle body refer to "throttle bodies" on page 7-4. Engine oil drain. Refer to "changing the engine oil" o...

  • Page 206: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks 1 engine mounting bolt (front right side) 1 2 engine mount collar (outer) 1 3 engine mount collar (center) 1 4 engine mount collar (inner) 1 5 engine mounting bolt (front left side) 1 6 locknut 1 7 engine mounting bolt (re...

  • Page 207: Engine Removal

    Engine removal 5-7 eas23720 installing the engine 1. Install: • engine mounting adjust bolts (temporary tighten) 2. Install: • engine 3. Install: • engine mounting bolt (rear lower side) “1” • engine mounting bolt (rear upper side) “2” • locknuts note: lubricate the lower and upper engine mount- ing...

  • Page 208: Engine Removal

    Engine removal 5-8 note: first tighten the lower locknut, and then tighten the upper locknut. 8. Tighten: • left front engine mounting bolt “1” 9. Tighten: • right front engine mounting bolt “1” upper locknut 51 nm (5.1 m·kg, 37 ft·lb) lower locknut 51 nm (5.1 m·kg, 37 ft·lb) engine mounting bolt (f...

  • Page 209: Camshafts

    Camshafts 5-9 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank refer to "fuel tank" on page 7-1. Side cowlings refer to "general chassis" on page 4-1. Lower cowlings refer to "general chassis" on page 4-1. Throttle body refer to "throttle bodies" o...

  • Page 210: Camshafts

    Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to "crankshaft position sen- sor" on page 5-37. 1 camshaft sprocket bolt 4 loosen. 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 intake camshaft cap 3 5 dowel pin 6 6 exhaust camsha...

  • Page 211: Camshafts

    Camshafts 5-11 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to "crankshaft position sen- sor" on page 5-37. 2. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. B. When pi...

  • Page 212: Camshafts

    Camshafts 5-12 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out of specification → replace. 4. Me...

  • Page 213: Camshafts

    Camshafts 5-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. Eas23870 checking the timing chain and cam- shaft sprocket 1. Check: • timing chai...

  • Page 214: Camshafts

    Camshafts 5-14 note: squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod. 2. Check: • timing chain tensioner housing • timing chain tensioner rod • timing chain tensioner spring damage/wear → replace. 3. Install: • timing chain te...

  • Page 215: Camshafts

    Camshafts 5-15 eas24000 installing the camshafts 1. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When position #1 is at tdc, align the “t” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲...

  • Page 216: Camshafts

    Camshafts 5-16 caution: eca4c81004 • lubricate the camshaft cap bolts with the engine oil. • the camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. • do not turn the crankshaft when installing the camshaft to avoid damage or improper...

  • Page 217: Camshafts

    Camshafts 5-17 11. Measure: • valve clearance out of specification → adjust. Refer to "adjusting the valve clearance" on page 3-4. 12. Install: • pickup coil rotor cover "crankshaft position sensor" on page 5-37..

  • Page 218: Cylinder Head

    Cylinder head 5-18 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to "engine removal" on page 5-1. Intake camshaft refer to "camshafts" on page 5-9. Exhaust camshaft refer to "camshafts" on page 5-9. 1 cylinder head 1 2 cylinder head gasket 1 3 ...

  • Page 219: Cylinder Head

    Cylinder head 5-19 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to "removing the camshafts" on page 5-11. 2. 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 t...

  • Page 220: Cylinder Head

    Cylinder head 5-20 2. Install: • gasket “1” • dowel pins 3. Install: • cylinder head note: pass the timing chain through the timing chain cavity. 4. Tighten: • cylinder head nuts “1” – “10” • cylinder head nuts “7” “10” • cylinder head bolts “11” “12” note: • first, tighten the nuts “1” – “10” to ap...

  • Page 221: Valves and Valve Springs

    Valves and valve springs 5-21 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to "cylinder head" on page 5-18. 1 intake valve lifter 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve upper spring seat 8 5...

  • Page 222: Valves and Valve Springs

    Valves and valve springs 5-22 for installation, reverse the removal proce- dure. Removing the valves and valve springs order job/parts to remove q’ty remarks.

  • Page 223: Valves and Valve Springs

    Valves and valve springs 5-23 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve l...

  • Page 224: Valves and Valve Springs

    Valves and valve springs 5-24 • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212°f) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 225: Valves and Valve Springs

    Valves and valve springs 5-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Mea...

  • Page 226: Valves and Valve Springs

    Valves and valve springs 5-26 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impression. D. Measure the valve seat width. N...

  • Page 227: Valves and Valve Springs

    Valves and valve springs 5-27 e. Apply a fine lapping compound to the valve face and repeat the above steps. F. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Inst...

  • Page 228: Valves and Valve Springs

    Valves and valve springs 5-28 eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head. Eas24340 installing the valves the following procedure applies to all of the valves ...

  • Page 229: Valves and Valve Springs

    Valves and valve springs 5-29 5. To secure the valve cotters “1” onto the valve stem, lightly tap the valve tip with a soft-face hammer. Caution: eca13800 hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • valve pad “1” • valve lifter “2” (with the recommended lubrica...

  • Page 230: Generator

    Generator 5-30 eas24480 generator removing the generator order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Passenger seat refer to "general chassis" on page 4-1. Side cowlings refer to "general chassis" on page 4-1. Lower cowlings refer to "general chassis" on...

  • Page 231: Generator

    Generator 5-31 12 stator coil assembly lead holder 1 13 idler gear 1 14 idler gear shaft 1 15 washer 1 16 bearing 1 for installation, reverse the removal proce- dure. Removing the generator order job/parts to remove q’ty remarks.

  • Page 232: Generator

    Generator 5-32 eas24490 removing the generator 1. Remove: • plug • generator rotor cover “1” note: • while pushing generator rotor, remove the generator rotor cover. • loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. • after all of the bolts are fully loosened, remove th...

  • Page 233: Generator

    Generator 5-33 note: • first tighten the m8 bolts and then tighten the m6 bolts. • tighten the generator rotor cover bolts in stages and in a crisscross pattern..

  • Page 234: Starter Clutch

    Starter clutch 5-34 eas24550 starter clutch removing the starter clutch order job/parts to remove q’ty remarks 1 generator rotor 1 2 damper 3 3 driven gear 1 4 washer 1 5 starter clutch drive gear 1 6 collar 1 7 washer 1 8 spacer 1 9 o-ring 1 for assembly, reverse the removal proce- dure..

  • Page 235: Starter Clutch

    Starter clutch 5-35 eas24560 removing the starter clutch 1. Remove: • spacer “1” • o-ring “2” • washer “3” 2. Remove: • starter clutch drive gear “1” • collar “2” • washer “3” 3. Remove: • driven gear “1” • dampers “2” • generator rotor “3” eas4c81007 checking the damper 1. Check: • dampers “1” dama...

  • Page 236: Starter Clutch

    Starter clutch 5-36 b. When turning the starter clutch drive gear clockwise “a”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch drive gear counterclockwise “b”, it should turn freely,...

  • Page 237: Crankshaft Position Sensor

    Crankshaft position sensor 5-37 eas24520 crankshaft position sensor removing the crankshaft position sensor order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Side cowlings refer to "general chassis" on page 4-1. Lower cowlings refer to "general chassis" on pag...

  • Page 238: Crankshaft Position Sensor

    Crankshaft position sensor 5-38 eas24530 removing the crankshaft position sensor 1. Disconnect: • crankshaft position sensor lead coupler 2. Remove: • crankshaft position sensor • o-ring • pickup coil rotor cover “1” note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross patte...

  • Page 239: Electric Starter

    Electric starter 5-39 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Throttle body refer to "throttle bo...

  • Page 240: Electric Starter

    Electric starter 5-40 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 lock washer 1 4 washer 1 5 starter motor yoke 1 6 armature assembly 1 7 gasket 2 8 brush holder 1 9 rear cover 1 for assembly, reverse the removal proce- dure..

  • Page 241: Electric Starter

    Electric starter 5-41 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 1000 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measure...

  • Page 242: Electric Starter

    Electric starter 5-42 7. Check: • gear teeth damage/wear → replace the starter motor. Eas24800 assembling the starter motor 1. Install: • brush holder • armature ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull both the brush spring and the brush outside and hook the brush spring to the groove portion at the ...

  • Page 243: Electric Starter

    Electric starter 5-43 eas24810 installing the starter motor 1. Install: • starter motor “1” • starter motor bolts “2” 2. Connect: • starter motor lead “3” starter motor bolt 10 nm (1.0 m·kg, 7.2 ft·lb) starter motor lead bolt 7 nm (0.7 m·kg, 5.1 ft·lb).

  • Page 244: Clutch

    Clutch 5-44 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to "general chassis" on page 4-1. Bottom cowlings refer to "general chassis" on page 4-1. Engine oil drain. Refer to "changing the engine oil" on page 3-11. 1 cover 1 2 clutch cable ...

  • Page 245: Clutch

    Clutch 5-45 removing the push lever shaft order job/parts to remove q’ty remarks 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 proce- dure..

  • Page 246: Clutch

    Clutch 5-46 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 1 3 push rod 1 4 bearing 1 5 friction plate 1 1 6 clutch plate 1 1 7 friction plate 2 7 8 clutch plate 2 1 9 clutch plate 3 6 10 friction plate 3 1 11 clutch damper spring 1 12 clutch dam...

  • Page 247: Clutch

    Clutch 5-47 eas25080 removing the clutch 1. Remove: • clutch cover “1” • gasket note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compression springs • pressure pl...

  • Page 248: Clutch

    Clutch 5-48 • springs • pressure plate 2 • conical spring washer • thrust plate 2 eas25100 checking the friction plates the following procedure applies to all of the friction plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness...

  • Page 249: Clutch

    Clutch 5-49 clutch plate “2” note: when adjusting the clutch assembly width [by replacing the clutch plate(s)], be sure to replace the clutch plate “1” fast. After replacing the clutch plate “1”, if specifica- tions cannot be met, replace the clutch plate “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas25140...

  • Page 250: Clutch

    Clutch 5-50 eas4c81005 checking the pressur plate 2 1. Check: • pressure plate 2 cracks / damage → replace. Eas25170 checking the pressure plate 1 1. Check: • pressure plate “1” cracks/damage → replace. • bearing “2” damage/wear → replace. Eas4c81006 checking the push lever shaft and push rod 1. Che...

  • Page 251: Clutch

    Clutch 5-51 3. Install: • spring “1” • clutch boss nut “2” note: • put the spring detent “a” into the groove of the pressure plate 2. Assemble so that each spring detent “a” is positioned in a different groove. • while holding the clutch boss “3” with the clutch holding tool “4”, tighten the clutch ...

  • Page 252: Clutch

    Clutch 5-52 note: assemble the friction plates and clutch plates according to the installation order. 7. Install: • friction plate 1 “1” note: install the last friction plate shifting half phase with the ø2 punch mark “2”. 8. Install: • bearing • pull rod • pressure plate 1 “1” 9. Install: • clutch ...

  • Page 253: Clutch

    Clutch 5-53 12. Tighten: • clutch cover bolts “1” • clutch cover bolt “2” note: tighten the clutch cover bolts in a stages and in a crisscross pattern. 13. Adjust: • clutch cable free play refer to "adjusting the clutch cable free play" on page 3-14. Clutch cover bolt 12 nm (1.2 m·kg, 8.7 ft·lb) clu...

  • Page 254: Shift Shaft

    Shift shaft 5-54 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks shift arm refer to "engine removal" on page 5-1 clutch assembly refer to "clutch" on page 5-44. 1 circlip 1 2 washer 1 3 shift shaft 1 4 collar 1 5 shift shaft spring 1 6 washer 1 ...

  • Page 255: Shift Shaft

    Shift shaft 5-55 eas4c81008 removing the shift shaft 1. Remove: • clutch assembly refer to "clutch" on page 5-44 2. Remove: • shift arm • shift rod refer to "engine removal" on page 5-1 3. Remove: • circlip “1” • washer “2” (left side of the engine) 4. Remove • shift shaft “1” • shift shaft spring “...

  • Page 256: Shift Shaft

    Shift shaft 5-56 • stopper lever spring “3” 2. Install: • washer • collar • shift shaft spring “1” • shift shaft “2” note: • mesh the stopper lever with the shift drum segment assembly. • lubricate the oil seal lips with lithium soap base grease. • install the end of the shift shaft spring onto the ...

  • Page 257: Oil Pump

    Oil pump 5-57 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks side cowlings refer to "general chassis" on page 4-1. Lower cowlings refer to "general chassis" on page 4-1. Engine oil drain. Refer to "changing the engine oil" on page 3-11. Exup cables refer t...

  • Page 258: Oil Pump

    Oil pump 5-58 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 11 relief valve assembly 1 12 oil/water pump assembly drive chain guide 1 13 collar 1 14 oil/water pump assembly drive sprocket 1 15 washer 1 16 oil/water pump assembly drive chain 1 17 dowel pin 1 18 oil/water pump assembly 1 for in...

  • Page 259: Oil Pump

    Oil pump 5-59 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil/water pump driven sprocket 1 2 collar 1 3 oil pump housing 1 4 bearing 1 5 pin 2 6 oil pump outer rotor 1 7 oil pump inner rotor 1 8 pin 1 for assembly, reverse the disassembly pro- cedure..

  • Page 260: Oil Pump

    Oil pump 5-60 eas24930 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. Eas4c81012 checking the sprocket and chain ...

  • Page 261: Oil Pump

    Oil pump 5-61 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas24970 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). Eas24980 checking th...

  • Page 262: Oil Pump

    Oil pump 5-62 • o-ring “2” damage/wear → replace. • oil nozzle passage obstruction → blow out with compressed air. Eas25010 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” • ...

  • Page 263: Oil Pump

    Oil pump 5-63 note: install the oil/water pump assembly drive chain “1” onto the oil/water pump assembly drive sprocket “2”. Caution: eca4c81007 after installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 3. Install: • oil/water pump as...

  • Page 264: Oil Pump

    Oil pump 5-64 • engine oil drain bolt warning ewa12820 always use new copper washers. Note: • tighten the oil pan bolts in stages and in a crisscross pattern. • lubricate the oil level switch o-ring with engine oil. Engine oil drain bolt 43 nm (4.3 m·kg, 31 ft·lb).

  • Page 265: Crankcase

    Crankcase 5-65 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks air filter case refer to "general chassis" on page 4-1. Throttle body assembly refer to "throttle bodies" on page 7-4. Engine refer to "engine removal" on page 5-1 cylinder head refer to "cylinder head"...

  • Page 266: Crankcase

    Crankcase 5-66 7 lower crankcase 1 8 dowel pin 3 9 damper 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 267: Crankcase

    Crankcase 5-67 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerica...

  • Page 268: Crankcase

    Crankcase 5-68 3. Install: • dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) caution: eca13980 before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when th...

  • Page 269: Crankshaft

    Crankshaft 5-69 eas25960 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to "crankcase" on page 5-65. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 piston pin 4 6 piston 4 7 connecting...

  • Page 270: Crankshaft

    Crankshaft 5-70 removing the crankshaft order job/parts to remove q’ty remarks lower crankcase refer to "crankcase" on page 5-65. Connecting rod and connecting rod caps refer to "removing the connecting rods and pistons" on page 5-71. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft ...

  • Page 271: Crankshaft

    Crankshaft 5-71 eas26030 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap “1” • big end bearings note: • identify the position of each big end bearing so that it can be reinstalled in its original plac...

  • Page 272: Crankshaft

    Crankshaft 5-72 note: identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Eas24390 checking the cylinder and piston 1. Check: • piston wall • cylinder wall vertical scratches → rebore or replace the cylinder, and replace the piston and ...

  • Page 273: Crankshaft

    Crankshaft 5-73 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s...

  • Page 274: Crankshaft

    Crankshaft 5-74 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas4c81015 checking the big end bearings 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼...

  • Page 275: Crankshaft

    Crankshaft 5-75 e. Tighten the connecting rod bolts. Note: install by carrying out the following procedures in order to assemble in the most suitable con- dition. Note: • first, tighten the bolts to 15 nm (1.5 m·kg, 11 ft·lb). • retighten the bolts to 29.4 nm (3.0 m·kg, 21 ft·lb). F. Replace the con...

  • Page 276: Crankshaft

    Crankshaft 5-76 p. After the installation, check that the section shown “a” is flush with each other by touch- ing the surface. • side machined face “a” warning ew2d1008 • when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a ...

  • Page 277: Crankshaft

    Crankshaft 5-77 eas26190 installing the connecting rod and piston the following procedure applies to all of the connecting rods and pistons. 1. Install: • top ring “1” • 2nd ring “2” • oil ring expander “4” • upper oil ring rail “3” • lower oil ring rail “5” note: be sure to install the piston rings...

  • Page 278: Crankshaft

    Crankshaft 5-78 7. Install: • cylinder gasket “2” 8. Install: • big end bearings (onto the connecting rods and connecting rod caps) note: • align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods and connecting rod caps. • be sure to reinstall each big end bea...

  • Page 279: Crankshaft

    Crankshaft 5-79 11. Install: • cylinder assembly “1” • connecting rod caps “2” note: • make sure that the “y” marks “a” on the con- necting rods face towards the left side of the crankshaft. • make sure that the characters on both the connecting rod and connecting rod cap are aligned. 12. Tighten: •...

  • Page 280: Crankshaft

    Crankshaft 5-80 • if they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the con- necting rod bolt. Caution: eca14680 • do not use a torque wrench to tighten the bolt to the specified angle. • tighten th...

  • Page 281: Crankshaft

    Crankshaft 5-81 d. Put a piece of plastigauge® “2” on each crankshaft journal. Note: do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bear- ings “1” into the lower crankcase and assemble the crankcase halves. Note: • align the projectio...

  • Page 282: Crankshaft

    Crankshaft 5-82 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • crankshaft journal bearings (j1–j5) note: • the numbers “a” stamped into the crank- shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “j1–j5” refer to th...

  • Page 283: Crankshaft

    Crankshaft 5-83 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 upper bearing in its original place. 3. Install: • crankshaft 4. Install: • crankcase (lower) refer to "crankcase" on p...

  • Page 284: Transmission

    Transmission 5-84 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase separate. Refer to "crankcase" on page 5-65. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 washer 1 6 shift fork guide bar r...

  • Page 285: Transmission

    Transmission 5-85 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 286: Transmission

    Transmission 5-86 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 287: Transmission

    Transmission 5-87 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 3rd wheel gear 1 8 collar 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 288: Transmission

    Transmission 5-88 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks.

  • Page 289: Transmission

    Transmission 5-89 eas26250 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Ins...

  • Page 290: Transmission

    Transmission 5-90 3. Check: • shift fork movement (along the shift fork guide bar) rough movement → replace the shift forks and shift fork guide bar as a set. Eas26270 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear → replace the shift drum assembly. • shift drum...

  • Page 291: Transmission

    Transmission 5-91 eas26350 installing the transmission 1. Install: • bearing “1” note: make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • oil pipe “2” 2. Install: • main axle assembly “1” • bearing housing “2” • shift fork “c” • shift d...

  • Page 292: Transmission

    Transmission 5-92 4. Check: • transmission rough movement → repair. Note: oil each gear, shaft, and bearing thoroughly..

  • Page 293: Transmission

    Transmission 5-93.

  • Page 294: Cooling System

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

  • Page 295: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Side cowling refer to "general chassis" on page 4-1. Coolant drain. Refer to "changing the coolant" on page 3-19. Fuel tank refer to "fuel tank" on page 7-1....

  • Page 296: Radiator

    Radiator 6-2 11 radiator fan motor 2 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to remove q’ty remarks.

  • Page 297: Radiator

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

  • Page 298: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-11. Coolant drain. Refer to "changing the coolant" on page 3-19. 1 oil cooler inlet hose 1 2 oil cooler bolt 1 loosen. 3 washer 1 disconnec...

  • Page 299: Oil Cooler

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

  • Page 300: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Coolant refer to "changing the coolant" on...

  • Page 301: Thermostat

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

  • Page 302: Thermostat

    Thermostat 6-8 note: if the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri- ous overheating or over cooling. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • thermostat housing cover “1” • thermostat housing “2” cracks/damage → replace. Eas26460 assembling the the...

  • Page 303: Water Pump

    Water pump 6-9 eas26500 water pump disassembling the water pump order job/parts to remove q’ty remarks oil/water pump assembly refer to "oil pump" on page 5-57. Oil pump rotor refer to "oil pump" on page 5-57. 1 water pump cover 1 2 o-ring 1 3 pin 2 4 impeller shaft (along with the impeller) 1 5 wat...

  • Page 304: Water Pump

    Water pump 6-10 eas26520 disassembling the water pump 1. Remove: • water pump seal “1” • water pump housing “2” note: tap out the bearing and oil seal from the out- side of the water pump housing. 2. Remove: • oil seal “1” • bearing “2” • water pump housing “3” note: tap out the bearing and oil seal...

  • Page 305: Water Pump

    Water pump 6-11 2. Install: • water pump seal “1” caution: eca14080 never lubricate the water pump seal sur- face with oil or grease. Note: • install the water pump seal with the special tools. • before installing the water pump seal, apply yamaha bond no. 1215 (three bond no. 1215®) “2” to the wate...

  • Page 306: Fuel System

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

  • Page 307: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Passenger seat refer to "general chassis" on page 4-1. 1 fuel tank side cover 2 2 fuel sender coupler 1 3 fuel pump coupler 1 4 fuel tank drain hose 1 5 f...

  • Page 308: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector cover • fuel hose • fuel sender coupler • fuel pump coupler • fuel tank drain hose • fuel tank breather hose • fuel tank side cover caution: eca4...

  • Page 309: Fuel Tank

    Fuel tank 7-3 eas4c81002 installing the fuel tank 1. Install: • fuel hose • fuel hose connector cover caution: eca14740 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly i...

  • Page 310: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. 1 sub-wire harness coupler 1 disconn...

  • Page 311: Throttle Bodies

    Throttle bodies 7-5 removing the injectors order job/parts to remove q’ty remarks 1 intake air pressure sensor coupler 1 disconnect. 2 cylinder #1-injector coupler 1 disconnect. 3 cylinder #2-injector coupler 1 disconnect. 4 cylinder #3-injector coupler 1 disconnect. 5 cylinder #4-injector coupler 1...

  • Page 312: Throttle Bodies

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

  • Page 313: Throttle Bodies

    Throttle bodies 7-7 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary tighten the throttle position sen- sor (for throttle valves). B. Check that the throttle valves are fully closed. C. Connect the throttle position sensor (for throttle valves), throttle position sensor (for throttle cable pulley) and th...

  • Page 314: Throttle Bodies

    Throttle bodies 7-8 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲.

  • Page 315: Air Induction System

    Air induction system 7-9 eas27040 air induction system removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks 1 air cut-off valve coupler 1 disconnect. 2 air cut-off valve hose 1 1 disconnect. 3 air cut-off valve hose 2 1 disconnect. 4 air cut-off valve hose 3 1 dis...

  • Page 316: Air Induction System

    Air induction system 7-10 eas27060 checking the air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the r...

  • Page 317: Air Induction System

    Air induction system 7-11.

  • Page 318: Electrical System

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

  • Page 319

    Electrical components................................................................... 8-77 checking the switches............................................................... 8-81 checking the bulbs and bulb sockets................................. 8-84 checking the fuses...........................

  • Page 320: Ignition System

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

  • Page 321: Ignition System

    Ignition system 8-2 1. Main switch 4. Main fuse 8. Battery 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 19.Ecu (engine control unit) 20.Ignition coil #1 21.Ignition coil #2 22.Ignition coil #3 23.Ignition coil #4 24.Spark plug 35.Crankshaft position sensor 40.Lean angle se...

  • Page 322: Ignition System

    Ignition system 8-3 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 passenger seat 3 fuel tank 4 side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng →...

  • Page 323: Ignition System

    Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8 check the engine stop switch. Refer to "checking the switches" on page 8-81. Replace the right handlebar switch. 9 check the neutral switch. Refer to "checking the switches" on page 8-81. Replace the neutral ...

  • Page 324: Electric Starting System

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

  • Page 325: Electric Starting System

    Electric starting system 8-6 1. Main switch 4. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 58.Engine stop switch 59.Start switch 64.Clutch switch 79.Ignition fuse 88.Ground 89.Battery negative lead.

  • Page 326: Electric Starting System

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

  • Page 327: Electric Starting System

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

  • Page 328: Electric Starting System

    Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 passenger seat 3 fuel tank 4 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuses. (m...

  • Page 329: Electric Starting System

    Electric starting system 8-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8 check the engine stop switch. Refer to "checking the switches" on page 8-81. Replace the right handlebar switch. 9 check the neutral switch. Refer to "checking the switches" on page 8-81. Replace the neutral ...

  • Page 330: Charging System

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

  • Page 331: Charging System

    Charging system 8-12 2. Ac magneto 3. Rectifier/regulator 4. Main fuse 8. Battery 88.Ground 89.Battery negative lead.

  • Page 332: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuse. (main) refer to "checking the fuses" on page 8-...

  • Page 333: Charging System

    Charging system 8-14.

  • Page 334: Lighting System

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

  • Page 335: Lighting System

    Lighting system 8-16 1. Main switch 4. Main fuse 8. Battery 19.Ecu (engine control unit) 51.High beam indicator light 54.Meter light 62.Dimmer switch 71.Headlight 72.Auxiliary light 74.License plate light 76.Tail/brake light 77.Headlight relay (on/off) 78.Headlight relay (dimmer) 81.Headlight fuse 8...

  • Page 336: Lighting System

    Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 fuel tank 3 side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → o...

  • Page 337: Lighting System

    Lighting system 8-18 ng → ok ↓ ng → ok ↓ 8 check the headlight relay (dimmer). Refer to "checking the relays" on page 8-88. Replace the headlight relay. 9 check the entire lighting system’s wiring. Refer to "lighting system" on page 8-15. Properly connect or repair the lighting system’s wiring. This...

  • Page 338: Signaling System

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

  • Page 339: Signaling System

    Signaling system 8-20 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 15.Fuel pump 19.Ecu (engine control unit) 33.Speed sensor 43.Fuel level warning light 44.Oil level warning light 45.Neutral indicator light 46.Tacho meter 47...

  • Page 340: Signaling System

    Signaling system 8-21 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 passenger seat 3 fuel tank 4 side cowling ng → ok ↓ ng → ...

  • Page 341: Signaling System

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

  • Page 342: Signaling System

    Signaling system 8-23 ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ 3 check the turn signal relay. Refer to "checking the relays" on page...

  • Page 343: Signaling System

    Signaling system 8-24 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 2 check the entire signaling system’s wiring. Refer to "signaling system" on page 8-19. Properly connect or repair the signal- ing system’s wiring. This circuit is ok. 1 check the speed sensor. Refer to "checking t...

  • Page 344: Cooling System

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

  • Page 345: Cooling System

    Cooling system 8-26 eas27320 troubleshooting note: • before troubleshooting, remove the following part(s): 1 rider seat 2 passenger seat 3 fuel tank 4 side cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Main switch 4. Main fuse 8. Battery 19.Ecu (engine control unit) 36.Coola...

  • Page 346: Cooling System

    Cooling system 8-27 ng → ok ↓ 7 check the entire cooling system’s wiring. Refer to "cooling system" on page 8-25. Properly connect or repair the cooling system’s wiring. This circuit is ok..

  • Page 347: Cooling System

    Cooling system 8-28.

  • Page 348: Fuel Injection System

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

  • Page 349: Fuel Injection System

    Fuel injection system 8-30 1. Main switch 4. Main fuse 5. Backup fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 15.Fuel pump 16.Throttle position sensor (for throttle valves) 17.Throttle position sensor (for throttle cable pulley...

  • Page 350: Fuel Injection System

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

  • Page 351: Fuel Injection System

    Fuel injection system 8-32 eas27362 fail-safe actions (substitute characteristics operation control) if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc-...

  • Page 352: Fuel Injection System

    Fuel injection system 8-33 20 intake air pressure sensor atmospheric pressure sensor intake air pressure sensor-open or short circuit detected. Defective values are detected due to the internal malfunction of the intake air pressure sensor or the atmospheric pressure sensor. Able able 21 coolant tem...

  • Page 353: Fuel Injection System

    Fuel injection system 8-34 communication error with the meter 43 fuel system voltage (monitor voltage) the ecu is unable to monitor the battery voltage (an open circuit in the line to the ecu). Able able 44 error in writing the amount of co adjust- ment on eeprom error is detected while reading or w...

  • Page 354: Fuel Injection System

    Fuel injection system 8-35 eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the faulty system with the faul...

  • Page 355: Fuel Injection System

    Fuel injection system 8-36 eas27421 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “on”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch ...

  • Page 356: Fuel Injection System

    Fuel injection system 8-37 note: if the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “off” to cancel the diagnostic mode. Fault code table fault code no. Symptom probable cause of malfunction diagnostic code no. 11 no normal signals are re...

  • Page 357: Fuel Injection System

    Fuel injection system 8-38 20 when the main switch is turned to “on”, the atmo- spheric pressure sensor voltage and intake air pres- sure sensor voltage differ greatly. • atmospheric pressure sensor hose is clogged. • intake air pressure sensor hose is clogged, kinked, or pinched. • malfunction of t...

  • Page 358: Fuel Injection System

    Fuel injection system 8-39 41 lean angle sensor: open or short circuit detected. • open or short circuit in wire harness. • defective lean angle sensor. • malfunction in ecu. 08 42 no normal signals are received from the speed sensor. • open circuit in wire harness. • malfunction in speed sensor. • ...

  • Page 359: Fuel Injection System

    Fuel injection system 8-40 sensor operation table er-3 data from the ecu cannot be received correctly. • improper connection in wire harness. • malfunction in meter. • malfunction in ecu. — er-4 non-registered data has been received from the meter. • improper connection in wire harness. • malfunctio...

  • Page 360: Fuel Injection System

    Fuel injection system 8-41 09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, recharge the battery.) 13 throttle position sensor (for throttle valves) signal 2...

  • Page 361: Fuel Injection System

    Fuel injection system 8-42 actuator operation table 61 malfunction history code — • no history 00 • history exists 11-60 (fault detection code) • (if more than one code number is detected, the dis- play changes every two seconds to show all the detected code numbers. When all code numbers are shown,...

  • Page 362: Fuel Injection System

    Fuel injection system 8-43 31 cylinder-#2 ignition coil actuates the cylinder-#2 igni- tion coil five times at one-sec- ond intervals. Illuminates the engine trou- ble warning light. Check the spark five times. • connect an ignition checker. 32 cylinder-#3 ignition coil actuates the cylinder-#3 igni...

  • Page 363: Fuel Injection System

    Fuel injection system 8-44 eas27461 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfu...

  • Page 364: Fuel Injection System

    Fuel injection system 8-45 fault code no. 11 symptom no normal signals are received from the cylinder identifi- cation sensor when the engine is started or while the vehicle is being driven. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement meth...

  • Page 365: Fuel Injection System

    Fuel injection system 8-46 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor check for l...

  • Page 366: Fuel Injection System

    Fuel injection system 8-47 fault code no. 14 symptom intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code no. 03 intake air pressure sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 intake air pressure sensor ...

  • Page 367: Fuel Injection System

    Fuel injection system 8-48 fault code no. 17 symptom exup servo motor circuit: open or short circuit detected. Diagnostic code no. 53 exup servo motor orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness ...

  • Page 368: Fuel Injection System

    Fuel injection system 8-49 fault code no. 19 symptom open circuit is detected in the input line from the side- stand switch to the ecu. Diagnostic code no. 20 sidestand switch orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ec...

  • Page 369: Fuel Injection System

    Fuel injection system 8-50 fault code no. 21 symptom coolant temperature sensor: open or short circuit detected. Diagnostic code no. 06 coolant temperature sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • coolant temperature sensor couple...

  • Page 370: Fuel Injection System

    Fuel injection system 8-51 fault code no. 23 symptom atmospheric pressure sensor: open or short circuit detected. Diagnostic code no. 02 atmospheric pressure sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • atmospheric pressure sensor cou...

  • Page 371: Fuel Injection System

    Fuel injection system 8-52 fault code no. 30 symptom latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code no. 08 lean angle sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the ve...

  • Page 372: Fuel Injection System

    Fuel injection system 8-53 fault code no. 34 symptom open circuit detected in the primary lead of the cylinder- #2 ignition coil. Diagnostic code no. 31 cylinder-#2 ignition coil orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#2 ignit...

  • Page 373: Fuel Injection System

    Fuel injection system 8-54 fault code no. 35 symptom open circuit detected in the primary lead of the cylinder- #3 ignition coil. Diagnostic code no. 32 cylinder-#3 ignition coil orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#3 ignit...

  • Page 374: Fuel Injection System

    Fuel injection system 8-55 fault code no. 36 symptom open circuit detected in the primary lead of the cylinder- #4 ignition coil. Diagnostic code no. 33 cylinder-#4 ignition coil orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#4 ignit...

  • Page 375: Fuel Injection System

    Fuel injection system 8-56 fault code no. 39 symptom open circuit detected in injector. Diagnostic code no. 36 37 38 39 injector #1 injector #2 injector #3 injector #4 orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • injector coupler • main wire...

  • Page 376: Fuel Injection System

    Fuel injection system 8-57 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. 08 lean angle sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • main wire harness ecu c...

  • Page 377: Fuel Injection System

    Fuel injection system 8-58 fault code no. 42 symptom ano normal signals are received from the speed sensor. Bopen circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch orde r item/components and probable cause check or maintenance job reinstatement meth...

  • Page 378: Fuel Injection System

    Fuel injection system 8-59 fault code no. 43 symptom power supply to the injectors and fuel pump is not nor- mal. Diagnostic code no. 09 fuel system voltage (battery voltage) orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • relay unit coupler (f...

  • Page 379: Fuel Injection System

    Fuel injection system 8-60 fault code no. 46 symptom power supply is not normal. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement method 1 malfunction in rectifier/regulator • replace if defective. Refer to "charging sys- tem" on page 8-11. Sta...

  • Page 380: Fuel Injection System

    Fuel injection system 8-61 fault code no. 59 symptom throttle position sensor (for throttle cable pulley): open or short circuit detected. Throttle position sensor (for throttle cable pulley): cou- pler connection is loose. Diagnostic code no. 14 15 throttle position sensor (for throttle cable pulle...

  • Page 381: Fuel Injection System

    Fuel injection system 8-62 fault code no. 60 symptom throttle servo motor: open or short circuit detected. Defective throttle servo motor. Malfunction in ecu (servo motor driving system). Diagnostic code no. 01 13 throttle position sensor (for throttle valves) signal 1 throttle position sensor (for ...

  • Page 382: Fuel Injection System

    Fuel injection system 8-63 fault code no. Er-2 symptom no signals are received from the ecu within the specified duration. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness...

  • Page 383: Fuel Injection System

    Fuel injection system 8-64 fault code no. Er-4 symptom non-registered data has been received from the meter. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembl...

  • Page 384: Fuel Pump System

    Fuel pump system 8-65 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 385: Fuel Pump System

    Fuel pump system 8-66 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 15.Fuel pump 19.Ecu (engine control unit) 48.Multi-function meter 58.Engine stop switch 79.Ignition fuse 88.Ground 89.Battery negative lead.

  • Page 386: Fuel Pump System

    Fuel pump system 8-67 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1 rider seat 2 passenger seat 3 fuel tank 4 side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuses. (main, ignition and...

  • Page 387: Fuel Pump System

    Fuel pump system 8-68 ng → ok ↓ 7 check the entire fuel pump sys- tem’s wiring. Refer to "fuel pump system" on page 8-65. Properly connect or repair the fuel pump system’s wiring. Replace the ecu..

  • Page 388: Immobilizer System

    Immobilizer system 8-69 eas27640 immobilizer system eas27650 circuit diagram.

  • Page 389: Immobilizer System

    Immobilizer system 8-70 1. Main switch 4. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Battery 19.Ecu (engine control unit) 42.Immobilizer system indicator light 48.Multi-function meter 79.Ignition fuse 88.Ground 89.Battery negative lead.

  • Page 390: Immobilizer System

    Immobilizer system 8-71 eas27671 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 391: Immobilizer System

    Immobilizer system 8-72 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with ...

  • Page 392: Immobilizer System

    Immobilizer system 8-73 standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a standard key that h...

  • Page 393: Immobilizer System

    Immobilizer system 8-74 voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost standard key.To re-regist...

  • Page 394: Immobilizer System

    Immobilizer system 8-75 ng → ok ↓ eas27721 self-diagnosis fault code indication when a system failure occurs, the error code number is indicated in the lcd display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code. 4 check ...

  • Page 395: Immobilizer System

    Immobilizer system 8-76 immobilizer system indicator light fault code indication digit of 10 : cycles of 1 sec. On and 1.5 sec. Off. Digit of 1 : cycles of 0.5 sec. On and 0.5 sec. Off. Example: fault code 52 54 immobilizer unit codes transmitted between the ecu and the immobilizer unit do not match...

  • Page 396: Electrical Components

    Electrical components 8-77 eas27970 electrical components.

  • Page 397: Electrical Components

    Electrical components 8-78 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Fuel injection system fuse 6. Starter relay 7. Battery 8. Main fuse 9. Neutral switch 10.Rear brake light switch 11.Exup servo motor 12.Sidestand switch 13.O 2 sensor 14.Speed sensor 15.Oil ...

  • Page 398: Electrical Components

    Electrical components 8-79.

  • Page 399: Electrical Components

    Electrical components 8-80 1. Air temperature sensor 2. Atmospheric pressure sensor 3. Fuel pump 4. Coolant temperature sensor 5. Starting circuit cut-off relay 6. Turn signal relay 7. Ecu (engine control unit) 8. Lean angle sensor 9. Crankshaft position sensor 10.Intake air pressure sensor 11.Throt...

  • Page 400: Electrical Components

    Electrical components 8-81 eas27980 checking the switches.

  • Page 401: Electrical Components

    Electrical components 8-82 1. Main switch 2. Horn switch 3. Dimmer switch 4. Turn signal switch 5. Clutch switch 6. Sidestand switch 7. Engine stop switch 8. Front brake light switch 9. Start switch 10.Oil level switch 11.Neutral switch 12.Rear brake light switch.

  • Page 402: Electrical Components

    Electrical components 8-83 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 403: Electrical Components

    Electrical components 8-84 eas27990 checking the bulbs and bulb sock- ets check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. N...

  • Page 404: Electrical Components

    Electrical components 8-85 note: check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. B. Connect the pocket tester probes to the respective leads of the bulb...

  • Page 405: Electrical Components

    Electrical components 8-86 • avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: external • skin — wash with water. • eyes — flush with water for 15 minutes and get immediate medical attention. Internal • drink large quanti...

  • Page 406: Electrical Components

    Electrical components 8-87 • do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. • if it is impossible to regulate the charging current on the battery charger, be careful not to overcharge...

  • Page 407: Electrical Components

    Electrical components 8-88 c. Make sure that the current is higher than the standard charging current written on the battery. Note: if the current is lower than the standard charg- ing current written on the battery, this type of battery charger cannot charge the mf battery. A variable voltage charg...

  • Page 408: Electrical Components

    Electrical components 8-89 relay unit (fuel pump relay) headlight relay (on/off) headlight relay (dimmer) radiator fan motor relay eas4c81019 checking the turn signal relay 1. Check: • turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal r...

  • Page 409: Electrical Components

    Electrical components 8-90 b. Turn the main switch to “on”. C. Measure the turn signal relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • turn signal relay output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the turn si...

  • Page 410: Electrical Components

    Electrical components 8-91 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continu- ity. ▲▲▲▲▲▲...

  • Page 411: Electrical Components

    Electrical components 8-92 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil from the spark plug. B. Connect the ignition checker/dynamic spark tester “2” as shown. C. Set the main switch to “on”. D. Measure the ignition spark gap “a”. E. Crank the engine by pushing the starter switch a...

  • Page 412: Electrical Components

    Electrical components 8-93 c. When turn the lean angle sensor to 65 °. D. Measure the lean angle sensor out put volt- age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4c81020 checking the starter motor opera- tion 1. Check: • starter motor operation does not operate → perform the electric starting system trou...

  • Page 413: Electrical Components

    Electrical components 8-94 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. B. Connect the pocket tester (ac 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run at approxi- mately 5000 r/min. D. Measure the charging vo...

  • Page 414: Electrical Components

    Electrical components 8-95 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the oil level switch terminal as shown. B. Measure the pickup coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28230 checking the fuel sender 1. Disconnect: • fuel pump coupler • fuel sender couple...

  • Page 415: Electrical Components

    Electrical components 8-96 b. Set the main switch to “on”. C. Elevate the rear wheel and slowly rotate it. D. Measure the voltage (dc 5 v) of white/yel- low and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 v 4.8v to 0.6 v to 4.8 v. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 416: Electrical Components

    Electrical components 8-97 d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. E. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4c81022 checking the throttle position...

  • Page 417: Electrical Components

    Electrical components 8-98 b. Measure the throttle position sensor (for throttle valves) maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • throttle position sensor (for throttle valves) note: when installing the throttle position sensor (for throttle valves), adjust its angle properly...

  • Page 418: Electrical Components

    Electrical components 8-99 eas28390 checking the cylinder identifica- tion sensor 1. Check: • cylinder identification sensor output volt- age out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the cylinder identification sensor coupler (wire harn...

  • Page 419: Electrical Components

    Electrical components 8-100 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. B. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • intake air temperature sensor intake air pr...

  • Page 420: Electrical Components

    Electrical components 8-101.

  • Page 421: Troubleshooting

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

  • Page 422: Troubleshooting

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

  • Page 423: Troubleshooting

    Troubleshooting 9-2 electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator 3. Ignition coil(s) • broken or shorted primary or secondar...

  • Page 424: Troubleshooting

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

  • Page 425: Troubleshooting

    Troubleshooting 9-4 7. Wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose wheel axle • excessive wheel runout 8. Frame • bent frame • damaged steering head pipe • improperly installed bearing race eas28710 faulty lighting or signaling sys- tem headlight ...

  • Page 426

    Eas28740 wiring diagram yzfr1w 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Main fuse 5. Backup fuse 6. Immobilizer unit 7. Etv fuse 8. Battery 9. Fuel injection system fuse 10. Starter relay 11. Starter motor 12. Starting circuit cut-off relay 13. Neutral switch 14. Sidestand switch 15. F...

  • Page 427

    Lg r/b o o c gy/r gy/r c r/b r/b b/l c o/g o/g c l p/w b/l gy/g gy/g c br/r br/r c w/b w/b c r/b r/b d g/b g/b d l/b l/b d o/b o/b d r/l r/l d p/w p/w d g/w g/w d r/b gy/g r/b o/g r/b o r/b gy/r w l/y b/l w/b l b/l r/b r/b r/l r/l r/l b/l g/w br/r br br/r r/w g/b r/l l/b r/l c b/l b/l r/b r/l l l d ...

  • Page 428

    C y/l off run free push r n l hi lo off on on off c wire harness e wire harness rear turn signal light lead coupler a wire harness wire harness sub-wire harness 2 sub-wire harness 1 wire harness d b headlight sub-wire harness headlight sub-wire harness 6 2 3 1 5 79 82 80 81 83 85 78 87 86 84 77 75 6...

  • Page 429

    Yamaha motor canada ltd. 480 gordon baker road toronto, on m2h 3b4.