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Yamaha Raptor 700R 2009 Service Manual - Throttle Body

Summary of Raptor 700R 2009

  • Page 1

    2009 service manual yfm70ry 1s3-28197-e2.

  • Page 2

    Eas20040 yfm70ry service manual ©2008 by yamaha motor co., ltd. First edition, june 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Important

    Eas20071 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on y...

  • Page 4: How to Use This Manual

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

  • Page 5: Symbols

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 17 18 lt new bf s t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Spec...

  • Page 7: Table of Contents

    Eas20110 table of contents general information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 electrical system 8 troubleshooting 9.

  • Page 9: General Information

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

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the left side of the frame. Eas20150 model label the model label “1” is affixed to the air filter case cover. This information will be needed to order spare parts. ...

  • Page 11: Features

    Features 1-2 eas20170 features eas1s3l001 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor s...

  • Page 12: Features

    Features 1-3 eas1s3l002 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/cm², 46.1 psi). Accordingly, when the energizing signal from the ecu energizes the ...

  • Page 13: Features

    Features 1-4 eas1s3l003 self-adjusting parking brake mechanism usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt “5” to achieve the proper clearance between the brake caliper piston “7” and the adjusting bolt. This adjust...

  • Page 14: Features

    Features 1-5 eas1s3l004 parking brake operation when the parking brake is operated, the parking brake cable turns the parking brake arm “1”. The ro- tation of the parking brake arm is changed to axial thrust in the parking brake shaft “2” and the adjusting bolt “3” is pushed against the adjusting bo...

  • Page 15: Features

    Features 1-6 when the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston “1” and the nut “2” are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the bra...

  • Page 16: Features

    Features 1-7 eas1s3l005 instrument functions multi-function display the multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total distance traveled) • two tripmeters (which show the distance trav- eled since they were l...

  • Page 17: Important Information

    Important information 1-8 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-11. 3. When disassem...

  • Page 18: Important Information

    Important information 1-9 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals “2”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, i...

  • Page 19: Checking The Connections

    Checking the connections 1-10 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 20: Special Tools

    Special tools 1-11 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 21: Special Tools

    Special tools 1-12 steering nut wrench 90890-01443 spanner wrench yu-33975 3-29, 3-32 ring nut wrench 90890-01268 spanner wrench yu-01268 3-32 axle nut wrench (46 mm) 90890-01498 rear axle nut wrench 46 mm ym-37134 4-14, 4-15 damper rod holder (30 mm) 90890-01327 ym-01327 4-46 ball joint remover 908...

  • Page 22: Special Tools

    Special tools 1-13 weight 90890-01084 yu-01083-3 5-15 valve spring compressor 90890-04019 ym-04019 5-20, 5-25 valve spring compressor attachment 90890-01243 valve spring compressor adapter (26 mm) ym-01253-1 5-20, 5-25 valve guide remover (ø6) 90890-04064 valve guide remover (6.0 mm) ym-04064-a 5-21...

  • Page 23: Special Tools

    Special tools 1-14 piston pin puller set 90890-01304 piston pin puller yu-01304 5-27 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-33, 5-35 flywheel puller 90890-01404 ym-01404 5-33 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-35, 5-60 universal clutch holder 90890-04086 y...

  • Page 24: Special Tools

    Special tools 1-15 crankcase separating tool 90890-01135 crankcase separator yu-01135-b 5-63 crankshaft installer pot 90890-01274 installing pot yu-90058 5-63 crankshaft installer bolt 90890-01275 bolt yu-90060 5-63 adapter (m16) 90890-04130 adapter #13 ym-04059 5-63 spacer (crankshaft installer) 90...

  • Page 25: Special Tools

    Special tools 1-16 spacer 90890-01309 pot spacer yu-90059 5-63 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-2 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-2 mechanical seal installer 90890-04132 water pump seal installer ym-33221-a 6-7...

  • Page 26: Special Tools

    Special tools 1-17 fuel pressure adapter 90890-03176 ym-03176 7-7 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-8 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-68 tool name/tool no. Illustration reference pages.

  • Page 27: Specifications

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

  • Page 28: General Specifications

    General specifications 2-1 eas29110 general specifications model model 1s3r, 1s3x (for cdn) 1s3v, 1s3y (for europe) 1s3l, 1s3w (for oceania) dimensions overall length 1845 mm (72.6 in) overall width 1170 mm (46.1 in) overall height 1130 mm (44.5 in) seat height 815 mm (32.1 in) wheelbase 1280 mm (50...

  • Page 29: Engine Specifications

    Engine specifications 2-2 eas29120 engine specifications engine engine type liquid-cooled 4-stroke, sohc displacement 686.0 cm³ cylinder arrangement forward-inclined single cylinder bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in) compression ratio 9.20 :1 standard compression pressure (at sea level) ...

  • Page 30: Engine Specifications

    Engine specifications 2-3 from low to full level 0.15 l (0.16 us qt, 0.13 imp.Qt) radiator cap opening pressure 93.3–122.7 kpa (0.9–1.2 kgf/cm², 13.3–17.4 psi) thermostat model/manufacturer 5vk1/nippon thermostat valve opening temperature 69–73 °c (156–163 °f) valve full open temperature 85 °c (185 ...

  • Page 31: Engine Specifications

    Engine specifications 2-4 timing chain model/number of links 98xrh2010/126 tensioning system automatic rocker arm/rocker arm shaft rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) rocker-arm-to-rocker-arm-shaft clear...

  • Page 32: Engine Specifications

    Engine specifications 2-5 valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) limit 6.050 mm (0.2382 in) valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) limit 6.050 mm (0.2382 in) valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in...

  • Page 33: Engine Specifications

    Engine specifications 2-6 piston piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) limit 0.13 mm (0.0051 in) diameter d 101.955–101.970 mm (4.0140–4.0146 in) height h 10.0 mm (0.39 in) offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 23.004–23.015 ...

  • Page 34: Engine Specifications

    Engine specifications 2-7 end gap (installed) 0.20–0.70 mm (0.01–0.03 in) crankshaft width a 74.95–75.00 mm (2.951–2.953 in) runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.350–0.650 mm (0.0138–0.0256 in) limit 1.00 mm (0.040 in) big end radial clearance e 0.010–0.025 mm (0.0004–0.001...

  • Page 35: Engine Specifications

    Engine specifications 2-8 4th 25/22 (1.136) 5th 22/24 (0.917) reverse gear 24/13 × 29/12 (4.462) main axle runout limit 0.08 mm (0.0031 in) drive axle runout limit 0.08 mm (0.0031 in) shifting mechanism shift mechanism type shift drum and guide bar shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in...

  • Page 36: Chassis Specifications

    Chassis specifications 2-9 eas29130 chassis specifications chassis frame type aluminum die-cast and steel tube frame caster angle 5.0° camber angle -1.0° kingpin angle 14.8° kingpin offset 2.8 mm (0.11 in) trail 21.0 mm (0.83 in) tread rear (std) 900.0 mm (35.43 in) tread front (std) 940.0 mm (37.01...

  • Page 37: Chassis Specifications

    Chassis specifications 2-10 front brake type dual disc brake operation right hand operation front disc brake disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) brake disc thickness limit 3.0 mm (0.12 in) brake disc deflection limit 0.15 mm (0.006 in) brake pad lining thickness (inner)...

  • Page 38: Chassis Specifications

    Chassis specifications 2-11 compression damping setting (for fast compression damping) minimum 4 standard 2 maximum 0 compression damping setting (for slow compression damping) minimum 20 standard 10 maximum 1 rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas...

  • Page 39: Electrical Specifications

    Electrical specifications 2-12 eas29140 electrical specifications voltage system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 9.0°/1600 r/min engine control unit model/manufacturer tbdf18/denso fuel injection sensor crankshaft position s...

  • Page 40: Electrical Specifications

    Electrical specifications 2-13 bulb voltage, wattage × quantity headlight 12 v, 30.0/30.0 w × 2 tail/brake light led indicator light neutral indicator light led fuel level warning light led reverse indicator light led coolant temperature warning light led engine trouble warning light led electric st...

  • Page 41: Electrical Specifications

    Electrical specifications 2-14 ignition fuse 10.0 a fuel injection system fuse 10.0 a spare fuse 20.0 a spare fuse 15.0 a spare fuse 10.0 a.

  • Page 42: Tightening Torques

    Tightening torques 2-15 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 43: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks cylinder head stud bolt (exhaust pipe) m8 4 15 nm (1.5 m·kg, 11 ft·lb) cylinder head bolt m9 4 35 nm (3.5 m·kg, 25 ft·lb) cylinder head bolt m9 2 38 nm (3.8 m·kg, 27 ft·lb) cylinder head bolt m...

  • Page 44: Tightening Torques

    Tightening torques 2-17 engine oil drain bolt (oil tank) m8 1 19 nm (1.9 m·kg, 13 ft·lb) oil baffle plate 1 bolt m5 2 4 nm (0.4 m·kg, 2.9 ft·lb) oil baffle plate 2 bolt m6 2 10 nm (1 m·kg, 7.2 ft·lb) oil pump bolt m6 1 10 nm (1 m·kg, 7.2 ft·lb) oil pump housing 2 screw m6 1 7 nm (0.7 m·kg, 5.1 ft·lb...

  • Page 45: Tightening Torques

    Tightening torques 2-18 tip temporarily tighten the cylinder bolts to 15 nm (1.5 m·kg, 11 ft·lb), and then tighten them to 50 nm (5.0 m·kg, 36 ft·lb). Clutch spring bolt m6 6 8 nm (0.8 m·kg, 5.8 ft·lb) clutch boss nut m20 1 95 nm (9.5 m·kg, 68 ft·lb) stake clutch cover bolt m6 14 10 nm (1 m·kg, 7.2 ...

  • Page 46: Tightening Torques

    Tightening torques 2-19 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine upper bracket bolt m8 2 33 nm (3.3 m·kg, 24 ft·lb) engine mounting nut (upper) m10 1 40 nm (4 m·kg, 29 ft·lb) engine lower bracket bolt m8 4 41 nm (4.1 m·kg, 30 ft·lb) engine mounting n...

  • Page 47: Tightening Torques

    Tightening torques 2-20 pitman arm and tie-rod ball joint nut m10 2 25 nm (2.5 m·kg, 18 ft·lb) bearing retainer nut m42 1 65 nm (6.5 m·kg, 47 ft·lb) fuel pump nut m6 6 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank bolt m6 4 7 nm (0.7 m·kg, 5.1 ft·lb) front wheel hub nut m10 8 45 nm (4.5 m·kg, 32 ft·lb) front...

  • Page 48: Tightening Torques

    Tightening torques 2-21 tip 1. Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers. 2. Tighten the rear axle nuts 200 nm (20.0 m·kg, 145 ft·lb). 3. Loosen the rear axle nuts completely. 4. Retighten the rear...

  • Page 49: 2-22

    Lubrication points and lubricant types 2-22 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins timing chain sprocket inner surface connecting rod big end thrust surface piston pin piston surface valve stems, valv...

  • Page 50: 2-23

    Lubrication system chart and diagrams 2-23 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 10 7 6 5 4 3 1 2 17 3 13 16 15 3 14 11 12 18 8 20 19 21 9.

  • Page 51: 2-24

    Lubrication system chart and diagrams 2-24 1. Oil strainer 2. Oil pump 3. Right crankcase 4. Left crankcase 5. Ac magneto cover 6. Oil tank inlet hose 7. To oil tank 8. Main axle 9. Drive axle 10. Counter axle 11. From oil tank 12. Oil tank outlet hose joint 13. Clutch cover 14. Oil filter element 1...

  • Page 52: 2-25

    Lubrication system chart and diagrams 2-25 eas20410 lubrication diagrams 1 4 3 1 2 3 4.

  • Page 53: 2-26

    Lubrication system chart and diagrams 2-26 1. Oil tank breather hose 2. Oil tank outlet hose 3. Oil tank inlet hose 4. Oil tank.

  • Page 54: 2-27

    Lubrication system chart and diagrams 2-27 2 3 a-a a a 2 1.

  • Page 55: 2-28

    Lubrication system chart and diagrams 2-28 1. Oil delivery pipe 2. Oil filter 3. Oil pump.

  • Page 56: 2-29

    Lubrication system chart and diagrams 2-29 1 2 3 4 5 6 7.

  • Page 57: 2-30

    Lubrication system chart and diagrams 2-30 1. Oil filter 2. Oil pump driven gear 3. Oil pump rotor 1 4. Oil pump rotor 2 5. Oil tank outlet hose joint 6. Main axle 7. Counter axle.

  • Page 58: 2-31

    Lubrication system chart and diagrams 2-31 a a a-a 4 1 2 3 1 a.

  • Page 59: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil strainer 2. Oil pump rotor 2 3. Oil pump rotor 1 4. Oil pump driven gear a. To oil tank.

  • Page 60: 2-33

    Lubrication system chart and diagrams 2-33 2 1.

  • Page 61: 2-34

    Lubrication system chart and diagrams 2-34 1. Balancer 1 2. Crankshaft.

  • Page 62: Cooling System Diagrams

    Cooling system diagrams 2-35 eas20420 cooling system diagrams b b a a a-a b-b 2 3 4 5 6 7 1 a b c d d e f g h i.

  • Page 63: Cooling System Diagrams

    Cooling system diagrams 2-36 1. Thermostat cover 2. Fast idle plunger outlet hose 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Water pump breather hose 7. Water pump a. Install the radiator inlet hose onto the thermostat cover pipe, making sure that it contacts the cover and its yel...

  • Page 64: Cooling System Diagrams

    Cooling system diagrams 2-37 b a c-c d-d c c a d d b 6 7 1 2 3 4 5 6 1 6 2 6 3 4 a b c d e.

  • Page 65: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Radiator 2. Radiator fan motor breather hose 3. Fuel tank shield 4. Coolant reservoir breather hose 5. Coolant reservoir 6. Coolant reservoir hose 7. Drain hose a. Pass the radiator fan motor breather hose through the guide. B. Install the coolant reservoir hose onto ...

  • Page 66: Cooling System Diagrams

    Cooling system diagrams 2-39 a b b 4 1 1 2 2 3 a b-b a a b.

  • Page 67: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Water pump outlet hose 2. Water pump 3. Water pump breather hose 4. Water jacket inlet housing a. From radiator b. Install the water pump outlet hose onto the water jacket inlet housing, making sure to align the yellow paint mark on the hose with the projection on the...

  • Page 68: Cable Routing

    Cable routing 2-41 eas20430 cable routing a b 1 2 7 3 4 5 6 1 3 4 5 7 6 14 15 16 17 18 2 8 9 10 11 12 13 c d e f g h i j k l m n o.

  • Page 69: Cable Routing

    Cable routing 2-42 1. Handlebar switch lead 2. Clutch switch lead 3. Parking brake cable 4. Clutch cable 5. Front brake hose 6. Front brake light switch lead 7. Throttle cable 8. Meter assembly lead 9. Radiator fan motor breather hose 10. Wire harness 11. Coolant reservoir breather hose 12. Headligh...

  • Page 70: Cable Routing

    Cable routing 2-43 a d b c c e e b e-e b-b c-c a d a b c 1 2 3 4 d e 5 6 7 7 f g h i j k l 8 9 10 11 12 13 m n o p q 14 15 16 17 18 19 5 5 6 6 25 3 23 s t 4 24 20 20 21 22 u v 9 12 12 13 13 13 14 15 w 14 14 26 27 r.

  • Page 71: Cable Routing

    Cable routing 2-44 1. Headlight lead (left) 2. Radiator 3. Coolant reservoir hose 4. Radiator fan motor breather hose 5. Wire harness 6. Throttle cable 7. Fuel hose 8. Lean angle sensor lead 9. Negative battery lead 10. Battery box 11. Starter motor lead 12. Speed sensor lead 13. Rear brake light sw...

  • Page 72: Cable Routing

    Cable routing 2-45 a a a-a 1 2 3 4 5 6 a 7 8 9 10 11 12 13 12 13 c d e f g h b.

  • Page 73: Cable Routing

    Cable routing 2-46 1. Starter relay lead 2. Relay unit 3. Fuse box lead 4. Radiator fan motor relay 5. Headlight relay 6. Tail/brake light 7. Tail/brake light lead 8. Fuse box 9. Relay unit lead 10. Ecu (engine control unit) 11. Ecu lead 12. Wire harness 13. Starter motor lead a. Make sure that ther...

  • Page 74: Cable Routing

    Cable routing 2-47 b b a b-b a-a 8 9 10 11 a a 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 b c 21 22 d e f 23 24 25 g h i j 26 27 28 29 30 28 k 13 18 18.

  • Page 75: Cable Routing

    Cable routing 2-48 1. Parking brake cable 2. Radiator fan motor coupler 3. Ignition coil leads 4. Headlight lead (right) 5. Rectifier/regulator lead 6. Reverse control cable 7. Throttle cable 8. Handlebar switch lead 9. Clutch switch lead 10. Main switch lead 11. Front brake light switch lead 12. Co...

  • Page 76: Cable Routing

    Cable routing 2-49 a-a a a 1 2 3 4 5 6 7 8 a 9 10 11 5 4 12.

  • Page 77: Cable Routing

    Cable routing 2-50 1. Radiator fan motor relay 2. Headlight relay 3. Fuse box 4. Relay unit 5. Relay unit lead 6. Starter motor lead 7. Starter relay lead 8. Starter relay 9. Fuse box lead 10. Headlight relay lead 11. Radiator fan motor relay lead 12. Tail/brake light lead a. Route the starter motor...

  • Page 78: Cable Routing

    Cable routing 2-51 e e e-e a b c d f f d c b a a b c 1 2 3 d 4 5 6 7 e f 8 9 9 10 11 g 12 13 13 13 13 14 14 14 14 15 16 17 18 h i j k l.

  • Page 79: Cable Routing

    Cable routing 2-52 1. Throttle position sensor lead 2. Fast idle plunger outlet hose 3. Fuel injector lead 4. Intake air pressure sensor 5. Coolant temperature sensor lead 6. Spark plug lead 7. Rectifier/regulator 8. Headlight lead (right) 9. Reverse control cable 10. Ignition coil lead (red) 11. Ig...

  • Page 80: Cable Routing

    Cable routing 2-53.

  • Page 81

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

  • Page 82

    Chassis ....................................................................................................... 3-21 adjusting the front disc brake ................................................ 3-21 adjusting the rear disc brake .................................................. 3-21 checking the...

  • 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 long- er service life and re...

  • Page 85: Periodic Maintenance

    Periodic maintenance 3-2 ebu23070 tip • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. 4 * rear brake • check operation and correct if necessary. • check fluid...

  • Page 86: Periodic Maintenance

    Periodic maintenance 3-3 • every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • replace the brake hoses every four years and if cracked or damaged..

  • Page 87: Engine

    Engine 3-4 eas20472 engine eas20520 adjusting the valve clearance the following procedure applies to all of the valves. Tip • 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 cent...

  • Page 88: Engine

    Engine 3-5 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1”. B. Insert a thickness gauge “2” between the end of the adjusting screw and the valve tip. C. Turn the adjusting screw “3” with the ta...

  • Page 89: Engine

    Engine 3-6 • front fender • seat refer to “general chassis” on page 4-1. Eas20620 adjusting the engine idling speed 1. Start the engine and let it warm up for several minutes. 2. Install: • digital tachometer (onto the spark plug lead) 3. Check: • engine idling speed out of specification → adjust. 4...

  • Page 90: Engine

    Engine 3-7 6. Press the “select” or “reset” buttons to change the co adjustment volume “1”. Tip • to decrease the co adjustment volume, press the “reset” button. • to increase the co adjustment volume, press the “select” button. 7. Press and release the “reset” and “se- lect” buttons to execute the ...

  • Page 91: Engine

    Engine 3-8 warning ewa1s3l001 after adjusting the throttle lever free play, start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas29170 adjusting the speed limiter the sp...

  • Page 92: Engine

    Engine 3-9 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap “a” (with a wire thickness gauge) out of specification → regap. 7. Install: • spark plug tip before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug ca...

  • Page 93: Engine

    Engine 3-10 eas20710 measuring the compression pressure tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” on page 3-4. 2. Start the engine, warm it up for several min- ut...

  • Page 94: Engine

    Engine 3-11 eas20750 checking the engine oil level 1. Place the vehicle on a level surface. 2. Start the engine, warm it up until the engine oil has reached a normal temperature of 60 °c (140 °f), let it continue to idle for ten sec- onds, and then turn the engine off. Tip to achieve the proper engi...

  • Page 95: Engine

    Engine 3-12 eas20800 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler bolt “1” • dipstick “2” 4. Remove: • engine oil drain bolt (oil tank) “1” (along with the gas...

  • Page 96: Engine

    Engine 3-13 11.Fill: • oil tank • crankcase (with the specified amount of the recom- mended engine oil) 12.Install: • dipstick • engine oil filler bolt 13.Start the engine, warm it up for several min- utes, and then turn it off. 14.Check: • engine (for engine oil leaks) 15.Check: • engine oil level ...

  • Page 97: Engine

    Engine 3-14 tip if the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ engine side a. Loosen the locknut “4”. B. Turn ...

  • Page 98: Engine

    Engine 3-15 warning ewa13020 never use low flash point solvents, such as gasoline, to clean the air filter element. Such solvents may cause a fire or an explosion. Tip after cleaning, gently squeeze the air filter ele- ment to remove the excess solvent. Notice eca13430 do not twist the air filter el...

  • Page 99: Engine

    Engine 3-16 notice eca13450 make sure the crankcase breather hose is routed correctly. Eas21080 checking the exhaust system the following procedure applies to all of the ex- haust pipes and gaskets. 1. Check: • exhaust pipe “1” • muffler “2” • muffler protector “3” • exhaust pipe protector “4” crack...

  • Page 100: Engine

    Engine 3-17 d. Insert the tailpipe into the muffler and align the bolt holes. E. Insert the bolt and tighten it. F. Remove the purging bolt “3”. G. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of the muffler w...

  • Page 101: Engine

    Engine 3-18 3. Install: • front fender • seat refer to “general chassis” on page 4-1. Eas21130 changing the coolant 1. Remove: • coolant reservoir cap “1” 2. Disconnect: • coolant reservoir hose “2” 3. Drain: • coolant (from the coolant reservoir) 4. Connect: • coolant reservoir hose 5. Remove: • ra...

  • Page 102: Engine

    Engine 3-19 7. Drain: • coolant (from the engine and radiator) 8. Check: • coolant drain bolt “1” damage → replace. 9. Install: • copper washer “2” • coolant drain bolt 10.Remove: • air bleed bolt “1” 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes f...

  • Page 103: Engine

    Engine 3-20 15.Install: • coolant reservoir cap 16.Start the engine, warm it up for several min- utes, and then stop it. 17.Check: • coolant level refer to “checking the coolant lev- el” on page 3-17. Tip before checking the coolant level, wait a few minutes until the coolant has settled. A.

  • Page 104: Chassis

    Chassis 3-21 eas29360 chassis eas21170 adjusting the front disc brake 1. Adjust: • brake lever position “a” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the brake lever forward, loos- en the locknut “1”. B. While pushing the brake lever forward, turn the adjusting bolt “2” in d...

  • Page 105: Chassis

    Chassis 3-22 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 chemica...

  • Page 106: Chassis

    Chassis 3-23 3. Check: • brake hose clamp loose → tighten the clamp bolt. 4. Apply the front brake several times. 5. Check: • brake hose brake fluid leakage → replace the damaged hose. Refer to “front brakes” on page 4-17. 6. Install: • front fender • fuel tank top panel • seat refer to “general cha...

  • Page 107: Chassis

    Chassis 3-24 eas21330 adjusting the rear brake light switch tip the rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: • rear brake light operation timin...

  • Page 108: Chassis

    Chassis 3-25 i. Repeat steps (e) to (h) until all of the air bub- bles have disappeared from the brake fluid in the plastic hose. J. Tighten the bleed screw to specification. K. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid le...

  • Page 109: Chassis

    Chassis 3-26 d. Tighten the locknut. E. Slide the boots to their original positions. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21390 adjusting the drive chain slack tip measure the drive chain slack halfway between the drive axle and the rear axle. Notice eca13550 a drive chain that is to...

  • Page 110: Chassis

    Chassis 3-27 eas29280 checking the steering system 1. Place the vehicle on a level surface. 2. Check: • steering assembly bushings move the handlebar up and down, and back and forth. Excessive play → replace the steering stem bushings. 3. Check: • tie-rod ends free play → replace the tie-rod end. ▼▼...

  • Page 111: Chassis

    Chassis 3-28 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • toe-in warning ewa14910 • be sure that both tie-rods are turned the same amount. If not, the vehicle will drift right or left even though the handlebar is positioned straight. This may lead to mis- handling and an accident. ...

  • Page 112: Chassis

    Chassis 3-29 refer to “front arms and front shock absorber assemblies” on page 4-49. 3. Check: • operation pump the front shock absorber assembly up and down several times. Unsmooth operation → replace front shock absorber assembly. Refer to “front arms and front shock absorber assemblies” on page 4...

  • Page 113: Chassis

    Chassis 3-30 tip always tighten the locknut against the adjusting ring, then torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rebound damping force ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Tip...

  • Page 114: Chassis

    Chassis 3-31 notice eca1s3l003 do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Adjust: • compression damping force (slow compres- sion damping) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 115: Chassis

    Chassis 3-32 b. Loosen the locknut “2” with the ring nut wrench “1”. C. Turn the adjusting ring “3” in direction “a” or “b”. Notice eca1s3l002 never attempt to turn the adjusting ring be- yond the maximum or minimum setting. Tip • be sure to remove all dirt and mud from around the locknut and adjust...

  • Page 116: Chassis

    Chassis 3-33 notice eca1s3l003 do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. Tip make sure that the position indicator marks “c” are aligned when the shock absorber is set to the standard setting. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 117: Chassis

    Chassis 3-34 notice eca1s3l003 do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. Tip make sure that the position indicator marks “c” are aligned when the shock absorber is set to the standard setting. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 118: Chassis

    Chassis 3-35 maximum loading limit warning ewa14970 be extra careful of the vehicle balance and stability when towing a trailer. 1. Measure: • tire pressure out of specification → adjust. Tip • the low-pressure tire gauge “1” is included as standard equipment. • in order to insure an accurate readin...

  • Page 119: Chassis

    Chassis 3-36 warning ewa13270 damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: • outer cable damage → replace. 2. Check: • cable operation rough movement → lubricate. Tip hold the cable e...

  • Page 120: Electrical System

    Electrical system 3-37 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-55. Eas21770 checking the fuses refer to “electrical components” on page 8-55. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 121: Electrical System

    Electrical system 3-38 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1 a b.

  • Page 122: Electrical System

    Electrical system 3-39.

  • Page 123: Chassis

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

  • Page 124

    Rear brake ............................................................................................... 4-28 introduction ..................................................................................... 4-34 checking the rear brake disc.................................................... 4-3...

  • Page 125

    Swingarm................................................................................................... 4-59 removing the swingarm................................................................ 4-61 checking the swingarm ................................................................ 4-61 inst...

  • Page 126: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat, front panel, foot protectors and engine skid plate order job/parts to remove q’ty remarks 1 seat 1 tip pull back the seat lock lever, than pull up on the rear of the seat. 2 front panel 1 3 left foot protector 1 4 right foot protector 1...

  • Page 127: General Chassis

    General chassis 4-2 removing the headlights and front fender order job/parts to remove q’ty remarks seat/front panel refer to “removing the seat, front panel, foot protectors and engine skid plate”. 1 headlight coupler 2 disconnect. 2 left headlight 1 3 right headlight 1 4 fuel tank top panel 1 5 me...

  • Page 128: General Chassis

    General chassis 4-3 removing the rear fender order job/parts to remove q’ty remarks seat/front panel refer to “removing the seat, front panel, foot protectors and engine skid plate”. Fuel tank top panel/front fender refer to “removing the headlights and front fender”. 1 air filter case cover 1 2 bat...

  • Page 129: General Chassis

    General chassis 4-4 12 air filter case 1 13 rear fender 1 for installation, reverse the removal proce- dure. Removing the rear fender order job/parts to remove q’ty remarks 2 (3) 3 4 3 13 8 12 5 6 10 11 7 9 (4) 1 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 7 nm (0.7 m • k...

  • Page 130: Front Wheels

    Front wheels 4-5 eas21870 front wheels removing the front wheels and brake discs order job/parts to remove q’ty remarks the following procedure applies to both of the front wheels. Place the vehicle on a level surface. 1 front wheel 1 2 brake disc guard (outer) 1 3 cotter pin 1 4 front wheel axle nu...

  • Page 131: Front Wheels

    Front wheels 4-6 eas21890 removing the front wheels 1. Place the vehicle on a level surface. 2. Elevate: • front wheels tip place the vehicle on a suitable stand so that the front wheels are elevated. 3. Remove: • front brake calipers tip do not apply the brake lever when removing the brake calipers...

  • Page 132: Front Wheels

    Front wheels 4-7 2. Check: • wheel bearings wheel hub play/wheel turns roughly → re- place. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean wheel hub exterior. B. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing in- ner race. Use a soft metal drift punch a...

  • Page 133: Front Wheels

    Front wheels 4-8 2. Check: • brake disc refer to “checking the front brake discs” on page 4-22. Eas29420 installing the front wheels the following procedure applies to both of the front wheels. 1. Install: • brake disc guard (outer) “1” tip install the brake disc guard (outer) with the punched burrs...

  • Page 134: Rear Wheels

    Rear wheels 4-9 eas22020 rear wheels removing the rear wheels order job/parts to remove q’ty remarks the following procedure applies to both of the rear wheels. Place the vehicle on a level surface. 1 rear wheel 2 2 cotter pin 2 3 rear wheel axle nut 2 4 rear wheel hub 2 for installation, reverse th...

  • Page 135: Rear Wheels

    Rear wheels 4-10 eas1s3l014 removing the rear wheels 1. Place the vehicle on a level surface. 2. Elevate: • rear wheels tip place the vehicle on a suitable stand so that the rear wheels are elevated. Eas29430 checking the rear wheels the following procedure applies to both of the rear wheels. 1. Che...

  • Page 136: Rear Wheels

    Rear wheels 4-11 eas29460 installing the rear wheels the following procedure applies to both of the rear wheels. 1. Install: • wheel tip the arrow mark “1” on the tire must point in the direction of rotation “a” of the wheel. 2. Tighten: • wheel nut t r . . Wheel nut 45 nm (4.5 m·kgf, 32 ft·lbf).

  • Page 137: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-12 eas29470 rear axle and rear axle hub removing the rear axle and rear axle hub order job/parts to remove q’ty remarks rear wheels/rear wheel hubs refer to “rear wheels” on page 4-9. 1 set bolt 2 2 rear axle ring nut 1 3 conical spring washer 1 4 rear axle pinch bolt 4...

  • Page 138: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-13 12 spacer 1 13 rear axle hub 1 14 oil seal 2 15 bearing 2 16 bearing 2 17 spacer 1 for installation, reverse the removal proce- dure. Removing the rear axle and rear axle hub order job/parts to remove q’ty remarks 16 16 1 1 2 3 7 5 6 4 (4) (4) 11 10 12 17 15 15 14 14...

  • Page 139: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-14 eas29490 removing the rear axle 1. Place the vehicle on a level surface. 2. Remove: • rear axle ring nut set bolts “1” 3. Loosen: • rear axle ring nut “2” tip • apply the brake pedal so that the rear axle does not turn when loosening the nut. • use the axle nut wrenc...

  • Page 140: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-15 eas29510 checking the rear wheel sprocket 1. Check: • rear wheel sprocket refer to “chain drive” on page 4-63. Eas1s3l015 checking the rear brake disc 1. Check: • brake disc refer to “checking the rear brake disc” on page 4-34. Eas29520 installing the rear wheel spro...

  • Page 141: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-16 4. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-26. 2 2 1.

  • Page 142: Front Brakes

    Front brakes 4-17 eas22210 front brakes removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Front wheel refer to “front wheels” on page 4-5. 1 brake caliper bolt 2 2 brake pad retaining bolt 2 3 brake pad/pad shim ...

  • Page 143: Front Brakes

    Front brakes 4-18 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm 1 3 front brake light switch connector 2 disconnect. 4 front brake light switch 1 5 brake lever 1 6 union bolt 1 7 copp...

  • Page 144: Front Brakes

    Front brakes 4-19 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 145: Front Brakes

    Front brakes 4-20 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Front wheel refer to “front wheels” on page 4-5. 1 union bolt 1 2 copper washer 2 3 brake hose 1 disconnect. 4 brake pad ...

  • Page 146: Front Brakes

    Front brakes 4-21 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake caliper retaining bolt 2 2 brake pad/pad shim 2/1 3 brake pad spring 1 4 brake caliper bracket 1 5 brake caliper piston 2 6 bra...

  • Page 147: Front Brakes

    Front brakes 4-22 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, th...

  • Page 148: Front Brakes

    Front brakes 4-23 e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • front whe...

  • Page 149: Front Brakes

    Front brakes 4-24 tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake caliper pistons • brake caliper dust seals “1” • brake caliper piston seals “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake...

  • Page 150: Front Brakes

    Front brakes 4-25 1. Install: • caliper piston seals “1” • dust seals “2” 2. Install: • brake caliper pistons “1” 3. Install: • brake pads refer to “replacing the front brake pads” on page 4-23. Eas22440 installing the front brake calipers the following procedure applies to both of the brake caliper...

  • Page 151: Front Brakes

    Front brakes 4-26 4. Check: • brake fluid level below the minimum level mark → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-21. 5. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydr...

  • Page 152: Front Brakes

    Front brakes 4-27 2. Install: • copper washers • brake hose • union bolt warning ewa13530 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-41. Tip • while holding the brake hose, tighten the union bolt as shown. • turn the handlebar to the...

  • Page 153: Rear Brake

    Rear brake 4-28 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 brake caliper bolt 2 2 brake pad retaining bolt 2 3 brake pad/insulator/pad shim 2/1/1 4 brake pad spring 1 for installation, reverse the removal proce- dure. Lt 3 4 2 t r . . 17 nm (1.7 m • kg,...

  • Page 154: Rear Brake

    Rear brake 4-29 removing the rear brake master cylinder order job/parts to remove q’ty remarks right foot protector refer to “general chassis” on page 4-1. Brake fluid drain. 1 brake fluid reservoir hose cover 1 2 brake fluid reservoir cap 1 3 brake fluid reservoir diaphragm holder 1 4 brake fluid r...

  • Page 155: Rear Brake

    Rear brake 4-30 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 hose joint 1 2 brake master cylinder kit 1 3 brake master cylinder 1 for assembly, reverse the disassembly pro- cedure..

  • Page 156: Rear Brake

    Rear brake 4-31 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. 1 parking brake cable 1 disconnect. 2 union bolt 1 3 copper washer 2 4 brake hose 1 disconnect. 5 brake caliper bolt 2 6 brake caliper assembly 1 for installation, reverse the removal proce- dur...

  • Page 157: Rear Brake

    Rear brake 4-32 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 adjusting bolt 1 2 locknut 1 3 parking brake arm 1 4 parking brake shaft 1 5 rubber boot 1 6 parking brake bracket mounting bolt 2 7 parking brake case bracket 1 8 parking brake case 1 9 gasket 1 10 brake p...

  • Page 158: Rear Brake

    Rear brake 4-33 17 bleed screw 1 for assembly, reverse the disassembly pro- cedure. Disassembling the rear brake caliper order job/parts to remove q’ty remarks.

  • Page 159: Rear Brake

    Rear brake 4-34 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 160: Rear Brake

    Rear brake 4-35 • brake pad spring tip always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loose...

  • Page 161: Rear Brake

    Rear brake 4-36 eas22630 disassembling the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake caliper piston “1” • dust seal “2” • brake caliper piston seal “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tur...

  • Page 162: Rear Brake

    Rear brake 4-37 2. Install: • brake caliper piston “1” turn the brake caliper piston clockwise until section “a” of the brake caliper piston is level with the surface of the brake caliper body. Tip align an end “b” of the groove in the brake cali- per piston with the punch mark “c” on the brake cali...

  • Page 163: Rear Brake

    Rear brake 4-38 2. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) 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 ...

  • Page 164: Rear Brake

    Rear brake 4-39 eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder “1” damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear...

  • Page 165: Rear Brake

    Rear brake 4-40 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...

  • Page 166: Handlebar

    Handlebar 4-41 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 handlebar cover 1 2 plastic band 4 3 front brake light switch connector 2 4 brake master cylinder/holder 1/1 5 throttle lever assembly/holder 1/1 6 spacer 1 7 clutch switch 1 8 parking brake lever 1 9 c...

  • Page 167: Handlebar

    Handlebar 4-42 eas1s3l016 removing the clutch switch 1. Remove: • clutch switch “1” tip push the fastener when removing the clutch switch out of the clutch lever holder. Eas22860 removing the handlebar 1. Place the vehicle on a level surface. 2. Remove: • handlebar grips “1” tip blow compressed air ...

  • Page 168: Handlebar

    Handlebar 4-43 3. Install: • handlebar grip “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe off grease or oil on the handlebar sur- face “a” with a lacquer thinner. B. Apply a thin coat of rubber adhesive onto the left and right ends of the handlebar. C. Install the handlebar grips to ...

  • Page 169: Handlebar

    Handlebar 4-44 7. Install: • clutch cable 8. Connect: • clutch switch coupler tip lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 9. Adjust: • clutch cable free play refer to “adjusting the clutch lever free play” on page 3-13. 10.Adjust: • throttle lever free pl...

  • Page 170: Steering Stem

    Steering stem 4-45 eas29540 steering stem removing the steering stem order job/parts to remove q’ty remarks front fender/fuel tank refer to “general chassis” on page 4-1. 1 pitman arm 1 2 lock washer 1 3 steering stem bushing 2 4 spacer 2 5 oil seal 2 6 steering stem 1 7 oil seal 1 8 oil seal 1 9 be...

  • Page 171: Steering Stem

    Steering stem 4-46 eas29550 removing the bearing retainer 1. Remove: • bearing retainer eas29560 checking the steering stem 1. Check: • steering stem “1” bends → replace. Warning ewa15030 do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals “1” • stee...

  • Page 172: 4-47

    Tie-rods and steering knuckles 4-47 eas29660 tie-rods and steering knuckles removing the tie-rods and steering knuckles order job/parts to remove q’ty remarks the following procedure applies to both of the tie-rods and steering knuckles. Front wheel/brake disc refer to “front wheels” on page 4-5. Fr...

  • Page 173: 4-48

    Tie-rods and steering knuckles 4-48 eas29670 removing the steering knuckles the following procedure applies to both of the steering knuckles. 1. Remove: • steering knuckle “1” tip use a general puller to separate the ball joints “2” from the steering knuckle “1”. Eas29680 checking the tie-rods the f...

  • Page 174: 4-49

    Front arms and front shock absorber assemblies 4-49 eas29710 front arms and front shock absorber assemblies removing the front arms and front shock absorber assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the front upper arms, front lower arms, and front ...

  • Page 175: 4-50

    Front arms and front shock absorber assemblies 4-50 11 bushing 6 12 circlip 1 13 rubber boot/boot retaining ring 1/1 14 ball joint 1 for installation, reverse the removal proce- dure. Removing the front arms and front shock absorber assemblies order job/parts to remove q’ty remarks 6 4 5 8 11 2 2 11...

  • Page 176: 4-51

    Front arms and front shock absorber assemblies 4-51 eas1s3l017 handling the front shock absorber assemblies warning ewa1s3l012 these front shock absorber assemblies con- tain highly compressed nitrogen gas. Before handling the front shock absorber assem- blies, read and make sure you understand the ...

  • Page 177: 4-52

    Front arms and front shock absorber assemblies 4-52 eas29760 checking the front shock absorber assemblies the following procedure applies to both of the front shock absorber assemblies. 1. Check: • front shock absorber assembly oil leaks → replace the front shock absorber assembly. • front shock abs...

  • Page 178: 4-53

    Front arms and front shock absorber assemblies 4-53 d. Hold the body “4” in place while turning in the long bolt “5” to remove the ball joint “10” from the front lower arm “11”. E. Remove the ball joint remover/installer. F. Attach the assembled ball joint remover/in- staller, new ball joint (with r...

  • Page 179: 4-54

    Front arms and front shock absorber assemblies 4-54 d. Install the new cotter pins. E. Tighten the front upper and lower arm nuts to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Upper steering knuckle nut 25 nm (2.5 m·kg, 18 ft·lb) lower steering knuckle nut 25 nm (2.5 m·...

  • Page 180: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-55 eas1s3l019 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rear wheels refer to “rear wheels” on page 4-9. 1 self-locking nut/bolt/spacer 1/1/1 2 self-locking nut/bolt/spacer 1/1/1 3 self-locking nut/bolt...

  • Page 181: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-56 15 bushing 4 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order job/parts to remove q’ty remarks ls ls ls ls new ls ls ls new ls ls 2 2 2 1 1 1 6 3 6 ls 7 5 3 12 12 12 8 9 7 4 4 10 10 8 12 11 13 15 15 15 14 15 new new ...

  • Page 182: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-57 eas1s3l045 handling the rear shock absorber assembly warning ewa1s3l016 this rear shock absorber assembly contains highly compressed nitrogen gas. Before handling the rear shock absorber assembly, read and make sure you understand the fol- lowing information. The ma...

  • Page 183: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-58 • gas cylinder damage/gas leaks → replace the rear shock absorber assembly. Eas1s3l021 installing the rear shock absorber assembly 1. Install: • bushing “1” (to connecting arm) tip apply lithium-soap-based grease on the bush- ings when installing. 2. Install: • bush...

  • Page 184: Swingarm

    Swingarm 4-59 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear axle hub refer to “rear axle and rear axle hub” on page 4-12. Rear shock absorber assembly refer to “rear shock absorber as- sembly” on page 4-55. 1 rear axle pinch bolt 4 2 dust seal 1 3 swingarm skid ...

  • Page 185: Swingarm

    Swingarm 4-60 12 bearing 2 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks 7 3 2 (4) 1 6 4 8 9 12 11 11 10 10 12 9 8 5 100 nm (10.0 m • kg, 72 ft • lb) t.R. 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 7 nm (0...

  • Page 186: Swingarm

    Swingarm 4-61 eas23350 removing the swingarm 1. Place the vehicle on a level surface. 2. Check: • swingarm side play • swingarm vertical movement ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the tightening torque of the pivot shaft nut. B. Check the swingarm side play “a” by moving the...

  • Page 187: Swingarm

    Swingarm 4-62 3. Install: • relay arm • rear shock absorber assembly refer to “rear shock absorber as- sembly” on page 4-55. 4. Install: • rear wheels refer to and “rear wheels” on page 4-9. 5. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-26 drive chain slack 25.0...

  • Page 188: Chain Drive

    Chain drive 4-63 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks swingarm refer to “swingarm” on page 4-59. 1 drive sprocket cover 1 2 drive chain guide 2 1 3 drive sprocket nut 1 4 lock washer 1 5 drive sprocket 1 6 drive chain 1 for installation, reverse the re...

  • Page 189: Chain Drive

    Chain drive 4-64 eas23441 checking the drive chain 1. Measure: • 15-link section of the drive chain out of specification → replace the drive chain. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the length “a” between the inner sides of the pins and the length “b” between the outer sid...

  • Page 190: Chain Drive

    Chain drive 4-65 4. Lubricate: • drive chain 5. Check: • drive sprocket • rear wheel sprocket more than 1/4 tooth “a” wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprock- ets as a set. Eas28800 installing the drive chain 1. Lubricate: • drive chain 2. Insta...

  • Page 191: Engine

    5 engine engine removal ........................................................................................ 5-1 installing the exhaust pipes and muffler ............................. 5-2 installing the engine....................................................................... 5-7 cylinder he...

  • Page 192

    Clutch ........................................................................................................ 5-40 removing the clutch ..................................................................... 5-44 removing the primary drive gear and balancer driven gear ..................................

  • Page 194: Engine Removal

    Engine removal 5-1 eas23711 engine removal removing the muffler and exhaust pipe order job/parts to remove q’ty remarks seat/fuel tank top panel refer to “general chassis” on page 4-1. 1 muffler 1 2 muffler protector 1 3 gasket 1 4 exhaust pipe 1 1 5 gasket 1 6 exhaust pipe 2 1 7 exhaust pipe protec...

  • Page 195: Engine Removal

    Engine removal 5-2 eas1s3l022 installing the exhaust pipes and muffler 1. Tighten: • exhaust pipe nuts “1”, “2”, and “3” tip tighten the exhaust pipe nuts in the order “1”, “2”, “3”. 2. Install: • gasket “1” (to muffler) tip install the gasket with the chamfer “a”, located on an inner rim of the gas...

  • Page 196: Engine Removal

    Engine removal 5-3 removing the oil tank order job/parts to remove q’ty remarks engine oil drain. Engine skid plate refer to “general chassis” on page 4-1. 1 shift pedal 1 2 oil tank inlet hose 1 3 oil tank outlet hose 1 4 oil tank breather hose 1 5 oil tank 1 for installation, reverse the removal p...

  • Page 197: Engine Removal

    Engine removal 5-4 disconnecting the leads, cables and hoses order job/parts to remove q’ty remarks coolant drain. Right foot protector/air filter case/battery/fuel tank refer to “general chassis” on page 4-1. Rear brake light switch/right footrest refer to “rear brake” on page 4-28. Radiator inlet ...

  • Page 198: Engine Removal

    Engine removal 5-5 11 sub-wire harness 1 12 ground lead 1 13 clutch cable 1 14 parking brake cable 1 15 reverse control cable 1 for installation, reverse the removal proce- dure. Disconnecting the leads, cables and hoses order job/parts to remove q’ty remarks.

  • Page 199: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks 1 engine upper bracket bolt 2 2 engine mounting bolt (upper)/nut 1/1 3 engine upper bracket 1 4 engine lower bracket bolt 4 5 engine mounting bolt (middle)/nut 1/1 6 engine lower bracket 2 7 engine mounting bolt (lower)/nu...

  • Page 200: Engine Removal

    Engine removal 5-7 eas23720 installing the engine notice eca1s3l015 install all of the bolts/nuts and then tighten them to full torque specifications. 1. Install: • swingarm • pivot shaft • washer • pivot shaft nut refer to “installing the swingarm” on page 4-61. Tip do not fully tighten the pivot s...

  • Page 201: Cylinder Head

    Cylinder head 5-8 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks throttle body refer to “throttle body” on page 7-4. Thermostat/coolant temperature sensor refer to “thermostat” on page 6-3. 1 engine upper bracket 1 2 spark plug 1 3 camshaft sprocket cover/o-...

  • Page 202: Cylinder Head

    Cylinder head 5-9 eas24130 removing the cylinder head 1. Align: • “i” mark “a” on the ac magneto rotor (with the stationary pointer “b” on the ac magneto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When the piston is at tdc on the compres- sio...

  • Page 203: Cylinder Head

    Cylinder head 5-10 3. Measure: • cylinder head warpage out of specification → resurface the cylinder head. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. B. Measure the warpage. C. If the limit is exceeded, resurface ...

  • Page 204: Cylinder Head

    Cylinder head 5-11 • timing chain tensioner rod damage/wear → replace the defective part(s). Eas24230 installing the cylinder head 1. Install: • cylinder head gasket • dowel pins 2. Install: • cylinder head • cylinder head bolts cylinder head bolts “1” length: 135 mm (5.31 in) cylinder head bolts “2...

  • Page 205: Cylinder Head

    Cylinder head 5-12 notice eca1s3l016 do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. E. While holding the camshaft, temporarily tight- en the camshaft sprocket bolts. F. Remove the wire from the timing chain. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 206: Cylinder Head

    Cylinder head 5-13 notice eca13750 be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 8. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” on page 3-4..

  • Page 207: Camshaft

    Camshaft 5-14 eas23730 camshaft removing the rocker arms and camshaft order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-8. 1 camshaft retainer 1 2 rocker arm shaft 2 3 rocker arm 2 4 locknut/valve adjuster 4/4 5 camshaft 1 notice eca1s3l017 do not disassemble th...

  • Page 208: Camshaft

    Camshaft 5-15 eas23770 removing the rocker arms and camshaft 1. Loosen: • locknuts • valve clearance adjusting screws 2. Remove: • camshaft retainer “1” 3. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm tip remove the rocker arm shafts with the ...

  • Page 209: Camshaft

    Camshaft 5-16 eas1s3l025 checking the decompression system 1. Check: • decompression system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the decompression system with the camshaft sprocket installed on and the de- compressor lever pin installed in the cam- shaft. B. Check that the deco...

  • Page 210: Camshaft

    Camshaft 5-17 tip • apply engine oil to the bearing. • install the bearing so that the seal “a” is facing the camshaft. 2. Lubricate: • camshaft • decompressor lever pin • decompressor lever 3. Install: • decompressor lever pin “1” • decompressor lever “2” tip install the decompressor lever pin “1” ...

  • Page 211: Camshaft

    Camshaft 5-18 t r . . Camshaft retainer bolt 10 nm (1.0 m·kg, 7.2 ft·lb).

  • Page 212: Valves and Valve Springs

    Valves and valve springs 5-19 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-8. Rocker arms/rocker arm shafts/camshaft refer to “camshaft” on page 5-14. 1 valve cotter 8 2 valve spring re...

  • Page 213: Valves and Valve Springs

    Valves and valve springs 5-20 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve sealin...

  • Page 214: Valves and Valve Springs

    Valves and valve springs 5-21 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide remover “1...

  • Page 215: Valves and Valve Springs

    Valves and valve springs 5-22 • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness “a” out of specification → replace the valve. 6. Measure: • valve stem runout out of specification → replace the valve. Tip • whe...

  • Page 216: Valves and Valve Springs

    Valves and valve springs 5-23 tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice eca13790 do not let the lappi...

  • Page 217: Valves and Valve Springs

    Valves and valve springs 5-24 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24340 installing the valves the following procedure applies to all of the valves and ...

  • Page 218: Valves and Valve Springs

    Valves and valve springs 5-25 tip • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 4. Install: • valve cotters tip install the valve cotters by compressing the valve spring with the valve spring compressor “1” and the valve s...

  • Page 219: Cylinder and Piston

    Cylinder and piston 5-26 eas24350 cylinder and piston removing the cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-8. 1 timing chain guide (exhaust side) 1 2 water jacket joint 1 3 o-ring 1 4 cylinder 1 5 cylinder gasket 1 6 dowel pin 2 7 p...

  • Page 220: Cylinder and Piston

    Cylinder and piston 5-27 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” notice eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin cl...

  • Page 221: Cylinder and Piston

    Cylinder and piston 5-28 b. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clear...

  • Page 222: Cylinder and Piston

    Cylinder and piston 5-29 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Eas24440 checking the piston pin 1. Check: • piston pin...

  • Page 223: Cylinder and Piston

    Cylinder and piston 5-30 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” tip • apply engine oil onto the piston pin. • make sure the punch mark “a” on the piston points towards the exhaust side of the cylinder. • before installing the piston pin clips, cover the crankcase opening wi...

  • Page 224: 5-31

    Ac magneto and starter clutch 5-31 eas1s3l026 ac magneto and starter clutch removing the ac magneto and starter clutch order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-12. Front fender refer to “general chassis” on page 4-1. Oil tank inlet hose re...

  • Page 225: 5-32

    Ac magneto and starter clutch 5-32 11 starter idle gear shaft 1 12 ac magneto rotor 1 13 starter clutch 1 14 woodruff key 1 15 starter wheel gear 1 16 washer 1 for installation, reverse the removal proce- dure. Removing the ac magneto and starter clutch order job/parts to remove q’ty remarks lt lt e...

  • Page 226: 5-33

    Ac magneto and starter clutch 5-33 eas24490 removing the ac magneto rotor 1. Remove: • ac magneto cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • ac magneto rotor nut “1” • washer tip • ...

  • Page 227: 5-34

    Ac magneto and starter clutch 5-34 2. Check: • starter idle gear “1” • starter wheel gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter wheel gear contacting surfaces damage/pitting/wear → replace the defec- tive part(s). 4. Check: • starter clutch operation ▼▼▼...

  • Page 228: 5-35

    Ac magneto and starter clutch 5-35 2. Apply: • sealant “1” (onto the crankshaft position sensor/stator assembly lead grommet) 3. Install: • woodruff key • ac magneto rotor • washer • ac magneto rotor nut tip • clean the tapered portion of the crankshaft and the ac magneto rotor hub. • when installin...

  • Page 229: Electric Starter

    Electric starter 5-36 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks exhaust pipe refer to “engine removal” on page 5-1. 1 starter motor lead 1 disconnect. 2 parking brake cable 1 3 starter motor 1 for installation, reverse the removal proce- dure. T r . ...

  • Page 230: Electric Starter

    Electric starter 5-37 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 square ring 1 4 lock washer 1 5 shim 1 6 armature assembly 1 7 starter motor yoke 1 8 brush holder assembly 1 9 square ring 1 10 shim 1 11 starter motor rear cover ...

  • Page 231: Electric Starter

    Electric starter 5-38 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → cut the mica to the proper measurement...

  • Page 232: Electric Starter

    Electric starter 5-39 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bushing • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” tip align the tab “a” on the brush seat with the slot “b” in the start...

  • Page 233: Clutch

    Clutch 5-40 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Front fender refer to “general chassis” on page 4-1. Rear brake light switch/right foot rest/brake ped- al/spring refer to “rear brake” on page 4-28. Oil delivery pipe refer to “cylinder he...

  • Page 234: Clutch

    Clutch 5-41 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 1 2 pull lever 1 3 pull lever spring 1 4 circlip 1 5 pull lever shaft 1 6 oil seal 1 7 bearing 1 8 bearing 1 for installation, reverse the removal proce- dure. E 5 8 7 6 4 3 2 1 new new new ls.

  • Page 235: Clutch

    Clutch 5-42 removing the clutch order job/parts to remove q’ty remarks 1 clutch spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 7 6 clutch plate 7 7 conical spring washer 1 8 wire circlip 1 9 friction plate 2 1 10 clutch damper spring 1 11 clutch damper spring seat 1 12 clutc...

  • Page 236: Clutch

    Clutch 5-43 18 straight key 1 19 lock washer 1 20 water pump drive gear 1 21 primary drive gear 1 22 balancer drive gear 1 23 straight key 1 24 lock washer 1 25 balancer driven gear 2 1 26 straight key 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove...

  • Page 237: Clutch

    Clutch 5-44 eas25070 removing the clutch 1. Remove: • clutch cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the clutch boss nut staked point “a”. 3. Loosen: • clutch boss nut “1” tip w...

  • Page 238: Clutch

    Clutch 5-45 tip measure the friction plate at four places. Eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gau...

  • Page 239: Clutch

    Clutch 5-46 eas25170 checking the pressure plate 1. Check: • pressure plate cracks/damage → replace. Eas25200 checking the primary drive gears 1. Check: • primary drive gear “1” • primary driven gear “2” damage/wear → replace the primary drive gear and clutch housing as a set. Excessive noise during...

  • Page 240: Clutch

    Clutch 5-47 tip • align the punch mark “a” on the balancer drive gear with the punch mark “b” on the balancer driven gear 2. • align the punch mark “c” on the balancer drive gear with the punch mark “d” on the balancer driven gear 1. 2. Tighten: • balancer driven gear 2 nut “1” • primary drive gear ...

  • Page 241: Clutch

    Clutch 5-48 • while holding the clutch boss “1” with the uni- versal clutch holder “4”, tighten the clutch boss nut. • stake the clutch boss nut “3” at a cutout “b” in the main axle. 4. Install: • clutch springs tip tighten the clutch spring bolts in stages and in a crisscross pattern. 5. Install: •...

  • Page 242: Clutch

    Clutch 5-49 9. Adjust: • clutch cable length tip move the pull lever a notch until the cable length is within specification. 10.Adjust: • clutch lever free play refer to “adjusting the clutch lever free play” on page 3-13. B a 1 c.

  • Page 243: Oil Pump

    Oil pump 5-50 eas24911 oil pump removing the oil pump order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-40. 1 oil baffle plate 1 1 2 circlip 1 3 oil pump driven gear 1 4 oil baffle plate 2 1 5 oil pump 1 6 oil pump gasket 1 7 o-ring 2 for installation, reverse the rem...

  • Page 244: Oil Pump

    Oil pump 5-51 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing 1/oil seal 1/1 2 oil pump outer rotor 1 1 3 dowel pin 1 4 oil pump inner rotor 1 1 5 oil pump housing cover/oil seal 1/1 6 dowel pin 2 7 oil pump shaft 1 8 dowel pin 1 9 oil pump inner rotor 2 1 10 oil...

  • Page 245: Oil Pump

    Oil pump 5-52 eas24960 checking the oil pump 1. Check: • oil pump driven gear “1” • oil pump housing 1 “2” • oil pump housing cover “3” • oil pump housing 2 “4” cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-...

  • Page 246: Shift Shaft

    Shift shaft 5-53 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-40. 1 shift pedal 1 2 shift shaft 1 3 shift shaft spring 1 4 stopper lever/washer 1/1 5 stopper lever spring 1 6 roller 1 7 shift guide 1...

  • Page 247: Shift Shaft

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

  • Page 248: Shift Shaft

    Shift shaft 5-55 • shift guide “4” (to the pawl holder) 3. Install: • shift lever assembly “1” • shift guide “2” tip the shift lever assembly is installed at the same time as the shift guide. Eas25450 installing the shift shaft 1. Install: • stopper lever “1” • stopper lever spring “2” • shift shaft...

  • Page 249: Crankcase

    Crankcase 5-56 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine assembly refer to “engine removal” on page 5-1. Piston refer to “cylinder and piston” on page 5-26. Ac magneto refer to “ac magneto and starter clutch” on page 5-31. Balancer driven gears refer t...

  • Page 250: Crankcase

    Crankcase 5-57 8 circlip 1 9 right crankcase 1 10 left crankcase 1 11 dowel pin 2 12 dowel pin/o-ring 1/1 13 oil strainer 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 251: Crankcase

    Crankcase 5-58 removing the crankcase bearings order job/parts to remove q’ty remarks crankshaft refer to “crankshaft” on page 5-62. Transmission refer to “transmission” on page 5-65. 1 oil seal retainer 1 2 bearing retainer 1 3 bearing retainer 1 4 oil seal 4 5 bearing 10 for installation, reverse ...

  • Page 252: Crankcase

    Crankcase 5-59 eas1s3l036 separating the crankcase 1. Remove: • crankcase bolts tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • right crankcase • dowel pins • o-ring notice eca13900 tap on one...

  • Page 253: Crankcase

    Crankcase 5-60 eas25580 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air. Eas2...

  • Page 254: Crankcase

    Crankcase 5-61 5. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft ham- mer. Notice eca1s3l018 before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in bo...

  • Page 255: Crankshaft

    Crankshaft 5-62 eas25960 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-56. 1 balancer 1 1 2 balancer 2 1 3 crankshaft 1 for installation, reverse the removal proce- dure. 2 1 3.

  • Page 256: Crankshaft

    Crankshaft 5-63 eas1s3l038 removing the crankshaft 1. Remove: • crankshaft “1” tip • remove the crankshaft with the crankcase separating tool “2”. • make sure the crankcase separating tool is centered over the crankshaft. Eas1s3l039 checking the crankshaft 1. Measure: • crankshaft width a “a” out of...

  • Page 257: Crankshaft

    Crankshaft 5-64 notice eca1s3l019 apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier. Tip hold the connecting rod at top dead center (tdc) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaf...

  • Page 258: Transmission

    Transmission 5-65 eas26241 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-56. 1 spacer 1 2 circlip 1 3 washer 1 4 reverse wheel gear 2 1 5 spacer 1 6 counter axle assembly 1 7 shif...

  • Page 259: Transmission

    Transmission 5-66 disassembling the main axle order job/parts to remove q’ty remarks 1 circlip 1 2 2nd pinion gear 1 3 toothed lock washer 1 4 toothed washer retainer 1 5 4th pinion gear 1 6 toothed spacer 1 7 toothed washer 2 8 circlip 2 9 3rd pinion gear 1 10 5th pinion gear 1 11 main axle/1st pin...

  • Page 260: Transmission

    Transmission 5-67 disassembling the drive axle order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 reverse wheel gear 2 1 4 spacer 1 5 dog clutch 1 6 circlip 1 7 toothed washer 1 8 1st wheel gear 1 9 toothed spacer 1 10 5th wheel gear 1 11 toothed lock washer 1 12 toothed washer retainer...

  • Page 261: Transmission

    Transmission 5-68 18 circlip 1 19 toothed washer 1 20 2nd wheel gear 1 21 spacer 1 22 drive axle 1 for installation, reverse the removal proce- dure. Disassembling the drive axle order job/parts to remove q’ty remarks m m m 22 21 11 2 3 4 5 6 7 8 9 10 1 12 13 14 15 16 17 19 20 18 new new new new m m...

  • Page 262: Transmission

    Transmission 5-69 disassembling the counter axle order job/parts to remove q’ty remarks 1 circlip 2 2 washer 2 3 spacer 1 4 reverse wheel gear 1 1 5 counter axle 1 for installation, reverse the removal proce- dure. 5 4 3 2 1 2 1 new new m.

  • Page 263: Transmission

    Transmission 5-70 eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • shift fork pawl “2” bends/damage/scoring/wear → replace the shift fork. 2. Check: • shift fork guide bar roll the shift fork guide bar on a flat su...

  • Page 264: Transmission

    Transmission 5-71 3. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmission axle assemblies. 4. Check: • transmission gear movement rough movement → replace the defective part(s). 5. Check: • circlips bends/damage/looseness → rep...

  • Page 265: Transmission

    Transmission 5-72.

  • Page 266: Transmission

    Transmission 5-73.

  • Page 267: Cooling System

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

  • Page 268: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks front fender refer to “general chassis” on page 4-1. Coolant drain. 1 radiator fan motor coupler 1 disconnect. 2 coolant reservoir hose 1 3 radiator fan motor breather hose 1 disconnect. 4 radiator outlet hos...

  • Page 269: Radiator

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

  • Page 270: Thermostat

    Thermostat 6-3 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks front fender refer to “general chassis” on page 4-1. Coolant drain. 1 radiator inlet hose 1 2 thermostat cover 1 3 o-ring 1 4 thermostat 1 5 coolant temperature sensor 1 6 copper washer 1 for installati...

  • Page 271: Thermostat

    Thermostat 6-4 eas26450 checking the thermostat 1. Check: • thermostat “1” does not open at 69–73 °c (156.2–163.4 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer ...

  • Page 272: Water Pump

    Water pump 6-5 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant drain. 1 radiator outlet hose 1 disconnect. 2 water pump outlet hose 1 ...

  • Page 273: Water Pump

    Water pump 6-6 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump housing cover 1 2 gasket 1 3 circlip 1 4 impeller shaft gear 1 5 pin 1 6 washer 1 7 impeller shaft assembly 1 8 water pump seal 1 9 oil seal 1 10 bearing 1 11 water pump housing 1 for assembly, reverse th...

  • Page 274: Water Pump

    Water pump 6-7 eas26510 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 2. Remove: • bearing “1” • oil seal “2” tip remove the bearing and oil seal from the out- side of the water pump housing “3”. Eas26540 c...

  • Page 275: Water Pump

    Water pump 6-8 3. Measure: • impeller shaft tilt 3. Mechanical seal installer 4. Middle driven shaft bearing driver a. Push down impeller shaft tilt limit 0.15 mm (0.006 in) 1. Straightedge 2. Impeller 4 a 1 2 3 new.

  • Page 276: Water Pump

    Water pump 6-9.

  • Page 277: Fuel System

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

  • Page 278: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks seat/front panel/fuel tank top panel/front fender refer to “general chassis” on page 4-1. 1 fuel pump coupler 1 disconnect. 2 fuel hose connector holder 1 3 fuel hose 1 4 fuel tank 1 tip when installing th...

  • Page 279: 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 holder • fuel hose notice eca1s3l006 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although ...

  • Page 280: Fuel Tank

    Fuel tank 7-3 eas1s3l011 installing the fuel hose 1. Install: • fuel hose • fuel hose holder • fuel pump coupler notice eca1s3l007 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be p...

  • Page 281: Throttle Body

    Throttle body 7-4 eas26970 throttle body removing the throttle body order job/parts to remove q’ty remarks fuel tank shield refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-18. 1 fuel hose 1 disconnect. 2 fuel injector coupler 1 disconnect. 3 intake ai...

  • Page 282: Throttle Body

    Throttle body 7-5 13 air filter case joint clamp screw 1 loosen. 14 throttle body assembly 1 for installation, reverse the removal proce- dure. Removing the throttle body order job/parts to remove q’ty remarks 4 nm (0.4 m • kg, 2.9 ft • ib) t.R. 3 nm (0.3 m • kg, 2.2 ft • ib) t.R. 12 13 1 2 3 4 5 6 ...

  • Page 283: Throttle Body

    Throttle body 7-6 disassembling the throttle body order job/parts to remove q’ty remarks 1 throttle position sensor 1 2 fuel injection pipe 1 3 fuel injector 1 4 throttle body 1 notice eca1s3l008 the throttle body should not be disas- sembled. For assembly, reverse the disassembly pro- cedure. 3 2 4...

  • Page 284: Throttle Body

    Throttle body 7-7 eas26980 checking the injector 1. Check: • injector damage → replace. Eas26990 checking the throttle body 1. Check: • throttle body cracks/damage → replace the throttle body. 2. Check: • fuel passages obstructions → clean. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wash t...

  • Page 285: Throttle Body

    Throttle body 7-8 c. Measure the throttle position sensor voltage. D. Adjust the throttle position sensor angle so that the voltage is within the specified range. E. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “3”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 286: Throttle Body

    Throttle body 7-9.

  • Page 287: Electrical System

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

  • Page 288

    Electrical components...................................................................... 8-55 checking the switches ................................................................. 8-57 checking the bulbs and bulb sockets ................................... 8-60 checking the fuses .................

  • Page 290: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27100 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br r br /g br br br ...

  • Page 291: Ignition System

    Ignition system 8-2 1. Crankshaft position sensor 4. Main switch 6. Battery 7. Main fuse 21.Ecu (engine control unit) 22.Ignition coil 23.Spark plug 30.Lean angle sensor 36.Engine stop switch 45.Ignition fuse.

  • Page 292: Ignition System

    Ignition system 8-3 eas27130 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Fuel tank 4. Front panel 5. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓...

  • Page 293: Ignition System

    Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-57. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-57. The engine stop switch is faulty. Replace the left handlebar s...

  • Page 294: Electric Starting System

    Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br...

  • Page 295: Electric Starting System

    Electric starting system 8-6 4. Main switch 6. Battery 7. Main fuse 8. Starter relay 9. Starter motor 11.Starting circuit cut-off relay 32.Neutral switch 33.Clutch switch 36.Engine stop switch 37.Start switch 45.Ignition fuse.

  • Page 296: 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 297: Electric Starting System

    Electric starting system 8-8 1. Battery 2. Main fuse 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay 6. Clutch switch 7. Neutral switch 8. Start switch 9. Starter relay 10. Starter motor 11. Ignition fuse.

  • Page 298: Electric Starting System

    Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main ...

  • Page 299: Electric Starting System

    Electric starting system 8-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 9. Check the neutral switch. Refer to “checking the switches” on page 8-57. Replace the neutral switch. 10.Check the clutch switch. Refer to “checking the switches” on page 8-57. Replace the clutch switch. 11.Check the start switc...

  • Page 300: Charging System

    Charging system 8-11 eas27200 charging system eas27210 circuit diagram l b b r/l br l/y b/l g/w l/y w w w w w w l/y r/w r/w r/l r/l y/r b/l w w w r w w w b r w w w (gray) b b r y/r br r/l r/w on off off r br r br br r (black) r r r r r r b b b b b b l/w br r r l/w br r br/g br br br/r br/y br/l br/l...

  • Page 301: Charging System

    Charging system 8-12 2. Ac magneto 3. Rectifier/regulator 6. Battery 7. Main fuse.

  • Page 302: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the...

  • Page 303: Charging System

    Charging system 8-14.

  • Page 304: Lighting System

    Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram b l b b r/l br l/y b/l g/w l/y w w w w w w l/y r/w r/w r/l r/l y/r b/l w w w r w w w b r w w w (gray) b b r y/r br r/l r/w on off off r br r br br r (black) r r r r r r b b b b b b l/w br r r l/w br br r br/g br br br/r br/y br/l...

  • Page 305: Lighting System

    Lighting system 8-16 4. Main switch 6. Battery 7. Main fuse 35.Light switch 38.Headlight relay 39.Headlight 40.Tail/brake light 43.Headlight fuse.

  • Page 306: Lighting System

    Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight or taillight. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1....

  • Page 307: Lighting System

    Lighting system 8-18.

  • Page 308: Signaling System

    Signaling system 8-19 eas27270 signaling system eas27280 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br r br /g br br ...

  • Page 309: Signaling System

    Signaling system 8-20 4. Main switch 6. Battery 7. Main fuse 10.Relay unit 14.Multi-function meter 16.Fuel level warning light 17.Coolant temperature warning light 18.Reverse indicator light 19.Neutral indicator light 20.Reverse switch 21.Ecu (engine control unit) 26.Coolant temperature sensor 27.Sp...

  • Page 310: Signaling System

    Signaling system 8-21 eas27290 troubleshooting • any of the following fail to light: warning light, brake light or an indicator light. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ che...

  • Page 311: Signaling System

    Signaling system 8-22 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the reverse indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ 3. Check the entire signaling system wiring. Refer to “circu...

  • Page 312: Signaling System

    Signaling system 8-23 ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or repair the signaling system wiring. Repla...

  • Page 313: Signaling System

    Signaling system 8-24.

  • Page 314: Cooling System

    Cooling system 8-25 eas27300 cooling system eas27310 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br r br /g br br br /...

  • Page 315: Cooling System

    Cooling system 8-26 4. Main switch 6. Battery 7. Main fuse 21.Ecu (engine control unit) 26.Coolant temperature sensor 45.Ignition fuse 46.Radiator fan motor 47.Radiator fan motor relay 48.Circuit breaker (fan motor).

  • Page 316: Cooling System

    Cooling system 8-27 eas27320 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main...

  • Page 317: Cooling System

    Cooling system 8-28 ng → ok ↓ 8. Check the entire cooling system wiring. Refer to “circuit diagram” on page 8-25. Properly connect or repair the cooling sys- tem wiring. Replace the ecu..

  • Page 318: Fuel Injection System

    Fuel injection system 8-29 eas27330 fuel injection system eas27340 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br r br...

  • Page 319: Fuel Injection System

    Fuel injection system 8-30 1. Crankshaft position sensor 4. Main switch 5. Fuel injection system fuse 6. Battery 7. Main fuse 12.Fuel pump relay 14.Multi-function meter 15.Engine trouble warning light 19.Neutral indicator light 21.Ecu (engine control unit) 22.Ignition coil 23.Spark plug 24.Fuel inje...

  • Page 320: 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 en- gine under substitute ch...

  • Page 321: Fuel Injection System

    Fuel injection system 8-32 self-diagnostic function table fault code no. Item symptom able / un- able to start able / un- able to drive 12 crankshaft position sensor no normal signals are received from the crankshaft position sen- sor. Unable unable 13 intake air pressure sensor (open or short circu...

  • Page 322: Fuel Injection System

    Fuel injection system 8-33 communication error with the meter 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 ...

  • Page 323: Fuel Injection System

    Fuel injection system 8-34 setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “off”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch to “on”, and continue to...

  • Page 324: Fuel Injection System

    Fuel injection system 8-35 diagnostic code table fault code no. Symptom probable cause of malfunction diagnostic code no. 12 no normal signals are re- ceived from the crankshaft position sensor. • open or short circuit in wire harness. • defective crankshaft position sensor. • malfunction in cranksh...

  • Page 325: Fuel Injection System

    Fuel injection system 8-36 sensor operation table 43 power supply to the fuel in- jector and fuel pump is not normal. • open or short circuit in wire harness. • malfunction in ecu. D09 44 error is detected while reading or writing on ee- prom (co adjustment val- ue). • malfunction in ecu. (the co ad...

  • Page 326: Fuel Injection System

    Fuel injection system 8-37 actuator operation table • actuator operation set the engine stop switch to “off” and then to “run”. D08 lean angle sensor remove the lean angle sensor and incline it more than 65 degrees. • upright 0.4–1.4 • overturned 3.7–4.4 d09 fuel system voltage (battery voltage) app...

  • Page 327: Fuel Injection System

    Fuel injection system 8-38 eas27481 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 328: Fuel Injection System

    Fuel injection system 8-39 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor check for lo...

  • Page 329: Fuel Injection System

    Fuel injection system 8-40 fault code no. 13 symptom intake air pressure sensor: open or short circuit detected. Diagnostic code no. D03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor couple...

  • Page 330: Fuel Injection System

    Fuel injection system 8-41 fault code no. 14 symptom intake air pressure sensor: hose line malfunction (clogged or detached hose). Diagnostic code no. D03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 intake air pressure sensor ho...

  • Page 331: Fuel Injection System

    Fuel injection system 8-42 fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. D01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. • ...

  • Page 332: Fuel Injection System

    Fuel injection system 8-43 fault code no. 16 symptom stuck throttle position sensor detected. Diagnostic code no. D01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. • check the install...

  • Page 333: Fuel Injection System

    Fuel injection system 8-44 fault code no. 22 symptom intake air temperature sensor: open or short circuit de- tected. Diagnostic code no. D05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of intake air tem- ...

  • Page 334: Fuel Injection System

    Fuel injection system 8-45 fault code no. 33 symptom malfunction detected in the primary lead of the ignition coil. Diagnostic code no. D30 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • ignition coil connector (primary coil side)...

  • Page 335: Fuel Injection System

    Fuel injection system 8-46 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. D08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • main wire harness-ecu c...

  • Page 336: Fuel Injection System

    Fuel injection system 8-47 fault code no. 42 symptom a. No normal signals are received from the speed sensor. Diagnostic code no. A d07 speed sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • speed sensor coupler • main wire harness-ecu cou...

  • Page 337: Fuel Injection System

    Fuel injection system 8-48 fault code no. 42 symptom b. Open circuit is detected in the neutral switch. Diagnostic code no. B d21 neutral switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • neutral switch coupler • main wire harness-ecu coupl...

  • Page 338: Fuel Injection System

    Fuel injection system 8-49 fault code no. 43 symptom power supply to the fuel injector and fuel pump is not nor- mal. Diagnostic code no. D09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • relay unit coupler (fuel pump relay...

  • Page 339: Fuel Injection System

    Fuel injection system 8-50 fault code no. 46 symptom power supply to the fuel injection system is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness-ecu coupler • check the coupler for any pins ...

  • Page 340: Fuel Pump System

    Fuel pump system 8-51 eas27550 fuel pump system eas27560 circuit diagram b lb br /l br l /yb /l g /wl /y w ww w ww l /y r /w r /w r /l r /l y /r b /l w w w r w w w br w ww (gra y) b b r y /r br r /l r /w on off off r br rb r br r (bla ck) r r r r r r b b b b b b l /wb r r r l /w br br r br /g br br ...

  • Page 341: Fuel Pump System

    Fuel pump system 8-52 4. Main switch 5. Fuel injection system fuse 6. Battery 7. Main fuse 12.Fuel pump relay 21.Ecu (engine control unit) 31.Fuel pump 36.Engine stop switch 45.Ignition fuse.

  • Page 342: Fuel Pump System

    Fuel pump system 8-53 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and fuel injection sy...

  • Page 343: Fuel Pump System

    Fuel pump system 8-54.

  • Page 344: Electrical Components

    Electrical components 8-55 eas27972 electrical components 2 3.

  • Page 345: Electrical Components

    Electrical components 8-56 1. Main switch 2. Meter assembly 3. Front brake light switch 4. Clutch switch 5. Handlebar switch 6. Lean angle sensor 7. Battery 8. Starter relay 9. Main fuse 10. Circuit breaker (fan) 11. Fuse box 12. Radiator fan motor relay 13. Headlight relay 14. Relay unit 15. Tail/b...

  • Page 346: Electrical Components

    Electrical components 8-57 eas27980 checking the switches off y/r l y l y y/r br l/b r/b b off l/b b br r/b off on r br r br b b b b 1 2 3 4 5 6 10 7 8 9.

  • Page 347: Electrical Components

    Electrical components 8-58 1. Light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Front brake light switch 6. Clutch switch 7. Fuse 8. Reverse switch 9. Neutral switch 10. Rear brake light switch.

  • Page 348: Electrical Components

    Electrical components 8-59 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. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes ...

  • Page 349: Electrical Components

    Electrical components 8-60 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or bo...

  • Page 350: Electrical Components

    Electrical components 8-61 tip 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 re- spectiv...

  • Page 351: Electrical Components

    Electrical components 8-62 eas28030 checking and charging the battery warning ewa13290 batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear when ...

  • Page 352: Electrical Components

    Electrical components 8-63 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Notice eca1s3l022 • do not use a high-rate battery charger since it forces a high-amperage current into the bat...

  • Page 353: Electrical Components

    Electrical components 8-64 tip set the charging voltage at 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be over-charged. C. Make sure that the current is higher than the standard charging current written on the bat- tery. Tip if the current is lowe...

  • Page 354: Electrical Components

    Electrical components 8-65 eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester ( Ω × 1) and battery (12 v) to the relay terminal ...

  • Page 355: Electrical Components

    Electrical components 8-66 second step: radiator fan motor relay eas28050 checking the diodes 1. Check: • relay unit (diode) out of specification → replace. Tip the pocket tester or the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ...

  • Page 356: Electrical Components

    Electrical components 8-67 b. Connect the pocket tester ( Ω × 1k) to the spark plug cap as shown. C. Measure the spark plug cap resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28090 checking the ignition coil 1. Check: • primary coil resistance out of specification → replace. ▼▼▼ ▼ ...

  • Page 357: Electrical Components

    Electrical components 8-68 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the spark plug. B. Connect the ignition checker “1” as shown. C. Turn the main switch to “on” and engine stop switch to “ ”. D. Measure the ignition spark gap “a”. E. Crank the engine b...

  • Page 358: Electrical Components

    Electrical components 8-69 c. Set the main switch to “on”. D. Tilt the lean angle sensor to 65°. E. Measure the lean angle sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28940 checking the starter motor operation 1. Check: • starter motor operation does not operate → p...

  • Page 359: Electrical Components

    Electrical components 8-70 b. Measure the stator coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28170 checking the rectifier/regulator 1. Check: • charging voltage out of specification → replace the rectifi- er/regulator. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Co...

  • Page 360: Electrical Components

    Electrical components 8-71 b. Measure the fuel sender current. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (...

  • Page 361: Electrical Components

    Electrical components 8-72 tip the radiator fan motor circuit breaker “1” is at- tached to the wire harness with white tape near the headlight relay “2”. 2. Check: • radiator fan motor circuit breaker resistance out of specification → replace the radiator fan motor circuit breaker. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 362: Electrical Components

    Electrical components 8-73 e. Measure the coolant temperature sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor maximum resistance o...

  • Page 363: Electrical Components

    Electrical components 8-74 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the in- take air temperature sensor terminal as shown. B. Measure the intake air temperature sensor resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ intake air tempera...

  • Page 364: Electrical Components

    Electrical components 8-75.

  • Page 365: Troubleshooting

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

  • Page 366: Troubleshooting

    Troubleshooting 9-1 eas28451 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ad...

  • Page 367: Troubleshooting

    Troubleshooting 9-2 • improper throttle cable free play • flooded throttle body electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator • ...

  • Page 368: Troubleshooting

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

  • Page 369: Troubleshooting

    Troubleshooting 9-4 eas28710 faulty lighting or signaling system headlight does not come on • wrong headlight bulb • too many electrical accessories • hard charging • incorrect connection • improperly grounded circuit • poor contacts (main or light switch) • burnt-out headlight bulb headlight bulb b...

  • Page 370: Wiring Diagram

    Eas28740 wiring diagram yfm70ry 2009 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Main switch 5. Fuel injection system fuse 6. Battery 7. Main fuse 8. Starter relay 9. Starter motor 10. Relay unit 11. Starting circuit cut-off relay 12. Fuel pump relay 13. Meter assembly 14. ...

  • Page 372

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

  • Page 373

    Yfm70ry 2009 wiring diagram yfm70ry 2009 schÉma de cblage b l b b r/l br l/y b/l g/w l/y w w w w w w l/y r/w r/w r/l r/l y/r b/l w w w r w w w b r w w w (gray) b b r y/r br r/l r/w on off off r br r br br r (black) r r r r r r b b b b b b l/w br r r l/w br br r br/g br br br/r br/y br/l br/l br/y br...

  • Page 374

    Yfm70ry 2009 wiring diagram yfm70ry 2009 schÉma de cblage (gray) on off off (black) (black) (black) (black) (dark green) (black) (black) b a b (black) (black) (black) (black) (black) a (black) (gray) (black) (gray) (gray) (gray) wire harness sub-wire harness a (black) (black) wire harness front brak...